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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority from Provisional Application No. 62/056,144 filed Sep. 26, 2014, the contents of which are hereby incorporated by reference.
FIELD
[0002] The present subject matter relates generally to methods and apparatuses for treating an organic feed. More specifically, the present invention relates to methods for treating a cumene and alpha-methylstyrene stream using a caustic wash column having an integrated water wash section.
BACKGROUND
[0003] The present subject matter relates to the preparation of a cumene feed for a cumene oxidation process. More specifically, it relates to a process and apparatus for the preparation of a cumene feed for cumene oxidation from a fresh cumene and alpha-methylstyrene stream. It is important that the caustic wash column is stable. It is also important that caustic does not carry over from the caustic wash column which deactivates the downstream alpha-methylstyrene hydrogenation catalyst. Currently, downstream equipment is used to remove caustic that is carried over from the caustic wash column. For example, a caustic settler may be used after a caustic wash column to ensure the caustic is thoroughly removed from the feed before it enters a downstream unit. However, it would be preferable to improve the caustic wash column itself so that it may be stable and limit the caustic carry over without the need for additional equipment.
[0004] Accordingly, it is desirable to develop methods and apparatuses for a process for removing organic acids using an integrated caustic wash column. Furthermore, other desirable features and characteristics of the methods and apparatuses will become apparent from the subsequent detailed description and the appended claims, taken in conjunction with the accompanying drawing and this background.
SUMMARY
[0005] Methods and apparatuses for producing hydrocarbons are provided. In an exemplary embodiment, a method includes treating an organic feed using a caustic wash column having an integrated water wash section.
[0006] In one approach, a process for treating an organic feed includes a process for treating an organic feed by introducing a feed stream from a feed tank containing at least one organic acid compound into a caustic wash section of a caustic wash column. Then an aqueous caustic scrubbing solution is introduced into the caustic wash column. A water stream is also introduced to a water wash section of the caustic wash column. Contacting of the feed through an aqueous caustic scrubbing solution removes the organic acid from the feed. The process removes spent aqueous caustic and organic acid solution from the caustic wash column. The process also removes an organic product from the water wash section of the caustic wash column having a reduced level of organic acid relative to the feed stream.
[0007] In another approach, the apparatus for treating an organic feed includes a caustic wash column having a lower portion, an intermediate portion, and an upper portion. In one example, the line for introducing the feed from a feed tank containing at least one organic acid compound enters the caustic wash column in the intermediate portion of the caustic wash column. A line for introducing an aqueous caustic scrubbing solution is also connected to the caustic wash column. In one example, the line for introducing an aqueous caustic scrubbing solution may enter the caustic wash column in the intermediate portion of the caustic wash column. A line for introducing a water stream into the water wash section of the caustic wash column is connected to the column. In one example, the line for introducing the water stream into the column may enter the column in the upper portion of the column. The column may include jetting trays within the column for contacting of the feed through an aqueous caustic scrubbing solution to remove the organic acid from the feed. A line for removing spent aqueous caustic and organic acid solution from the caustic wash column is connected to the bottom of the column. A line for removing an organic product from the water wash section of the caustic wash column wherein the organic product has a reduced level of organic acid relative to the feed stream is connected the top of the column.
[0008] An advantage of the methods and apparatuses for the continuous preparation of a cumene feed is that it provides a more stable system.
[0009] Another advantage of the methods and apparatuses for the continuous preparation of a cumene feed is that it limits caustic carry over.
[0010] Another advantage of the methods and apparatuses for the continuous preparation of a cumene feed is that it consolidates the amount of units needed to restrict caustic carry over.
[0011] A further advantage of the methods and apparatuses for the continuous preparation of a cumene feed is that the feed tank accounts for any upsets from upstream vessels.
[0012] Yet another advantage of the methods and apparatuses for the continuous preparation of a cumene feed is that the caustic supplied for the process does not have to be diluted, but can be directly used in the caustic wash column.
[0013] Additional objects, advantages and novel features of the examples will be set forth in part in the description which follows, and in part will become apparent to those skilled in the art upon examination of the following description and the accompanying drawing or may be learned by production or operation of the examples. The objects and advantages of the concepts may be realized and attained by means of the methodologies, instrumentalities and combinations particularly pointed out in the appended claims.
BRIEF DESCRIPTION OF THE DRAWING
[0014] The FIGURE depicts one or more implementations in accord with the present concepts, by way of example only, not by way of limitations. In the FIGURE, like reference numerals refer to the same or similar elements.
[0015] The FIGURE is an illustration of a process for treating an organic feed using a caustic wash column having an integrated water wash section.
DETAILED DESCRIPTION
[0016] The following detailed description is merely exemplary in nature and is not intended to limit the application and uses of the embodiment described. Furthermore, there is no intention to be bound by any theory presented in the preceding background or the following detailed description.
[0017] The further description of the process of this invention is presented with reference to the attached FIGURE. The FIGURE is a simplified flow diagram of a preferred embodiment of this invention and is not intended as an undue limitation on the generally broad scope of the description provided herein and the appended claims. Certain hardware such as valves, pumps, compressors, heat exchangers, instrumentation and controls, have been omitted as not essential to a clear understanding of the invention. The use and application of this hardware is well within the skill of the art.
[0018] The overall process to which this invention pertains concerns the oxidation of a secondary alkylbenzene, for example, isopropylbenzene (cumene) isobutylbenzene, isoamylbenzene, 1-methyl-4-isopropylbenzene, p-diisopropylbenzene, p-diisobutylbenzene, 1-isopropyl-4-isobutylbenzene, cyclohexyl benzene, and the like, to form the corresponding hydroperoxide, i.e., isopropylbenzene hydroperoxide, isobutylbenzene hydroperoxide, isoamylbenzene hydroperoxide, 1-methyl-4-isopropylbenzene hydroperoxide, p-diisopropylbenzene hydroperoxide, p-diisobutylbenzene hydroperoxide, 1-isobutyl-4-isopropylbenzene dihydroperoxide, cyclohexylbenzene hydroperoxide, and the like. The present invention is particularly directed to a process for the preparation of a cumene feed for cumene oxidation from a fresh cumene stream and a recycle cumene stream containing trace quantities of at least one organic acid compound. The organic acid compound is selected from the group consisting of formic acid, acetic acid, benzoic acid, propionic acid, butyric acid and phenol.
[0019] The various embodiments described herein relate to methods and apparatuses for treating an organic feed using a caustic wash column having an integrated water wash section. In accordance with the present invention, the vertical, countercurrent contacting zone is preferably contained in a vessel such as a column 30 , which has packing, trays or other convenient means to provide countercurrent liquid-liquid extraction. In one example, jetting trays may provide contacting of the organic phase through an aqueous caustic scrubbing solution to remove the organic acid from the organic phase. The contacting zone is preferably operated at a pressure from about atmospheric (0 kPa gauge) to about 150 psig (1035 kPa gauge) and a temperature from about 41° F. (5° C.) to about 140° F. (60° C.). However, other operating temperatures and pressures may be used in the practice of the present process, but preferably so long as the liquid phase is maintained.
[0020] Turning to the FIGURE, a feed tank 10 supplies a feed 20 to the caustic wash column 30 . In the example shown in the FIGURE, the feed tank 10 ensures that the caustic sufficiently contacts the hydrocarbon mixture because it acts as a place holder for the feed 20 , instead of allowing the feed 20 to flow directly from the upstream unit to the caustic wash column 30 . The feed 20 in the example shown in the FIGURE includes cumene, alpha-methylstyrene, and phenol. However, it is contemplated that the feed may contain other hydrocarbon mixtures. For example, it is contemplated that the feed may contain acetone, organic acids, benzene, hydroxyacetone, 2-MBF, acetaldehyde, propionaldehyde, and heavy alkyphenols.
[0021] The caustic wash column 30 comprises a lower portion 40 , an intermediate portion 50 , and an upper portion 60 . The feed 20 enters the caustic wash column 30 in the intermediate portion 50 . The caustic solution 80 enters the caustic wash column 30 in the intermediate portion 50 of the caustic wash column 30 . However, it is contemplated that the feed 20 and caustic solution 80 may enter the caustic wash column 30 at other portions of the column 30 .
[0022] The aqueous caustic solution which is introduced into the caustic/hydrocarbon contacting zone preferably contains from about 1 to about 20 wt % caustic. While various caustic solutions that are known in the art for treating a cumene feed may be used, the preferred caustic solution is an aqueous sodium hydroxide solution. Make-up caustic solutions may have concentrations from about 5 to about 50 wt % caustic. In the example shown in the FIGURE, the sodium hydroxide may comprise 45 wt % of the caustic solution. The concentration of the aqueous caustic solution used is related to the amount of organic acid that is being removed from the feed 20 .
[0023] A water stream 70 enters the caustic wash column 30 in the upper portion 60 of the column 30 . A mesh blanket 100 may also be located in the upper portion 60 of the caustic wash column 30 . As the organic feed 20 moves up the caustic wash column 30 the organic acid in the organic feed 20 becomes entrained with the caustic 80 and then is contacted with the water stream 70 . Within the column 30 , an acid base reaction occurs. The caustic reacts with the phenol to make water and sodium phenate. The organic feed passes through the mesh blanket 100 once before it reaches the top of the column 30 . The mesh blanket coalesces any small amounts of water or caustic, therefore minimizing the amount of water exiting the top of the column 30 . Once the organic feed reaches the top of the column 30 , a clean, mainly caustic free organic phase exits the top of the column 30 in the product stream 90 .
[0024] A portion of the product stream 90 may be recycled back to the feed 20 via line 110 . The recycled product 110 may be admixed with the feed 20 before entering the caustic wash column 30 , or the recycled product feed 110 and the feed 20 may enter the caustic wash column 30 at distinct inlets.
[0025] A second product stream 120 exits from the bottom of the column 30 . The second product stream 120 comprises water, caustic, and sodium phenate.
[0026] It should be noted that various changes and modifications to the presently preferred embodiments described herein will be apparent to those skilled in the art. Such changes and modifications may be made without departing from the spirit and scope of the present invention and without diminishing its attendant advantages.
SPECIFIC EMBODIMENTS
[0027] While the following is described in conjunction with specific embodiments, it will be understood that this description is intended to illustrate and not limit the scope of the preceding description and the appended claims.
[0028] A first embodiment of the invention is a process for treating an organic feed comprising introducing a feed stream from a feed tank containing at least one organic acid compound into a caustic wash section of a caustic wash column; introducing an aqueous caustic scrubbing solution into the caustic wash column; introducing a water stream into the water wash section of the caustic wash column; contacting of the feed through an aqueous caustic scrubbing solution to remove the organic acid from the feed; removing spent aqueous caustic and organic acid solution from the caustic wash column; and removing an organic product from the water wash section of the caustic wash column having a reduced level of organic acid relative to the feed stream. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the first embodiment in this paragraph, wherein the organic feed comprises cumene and alpha-methylstyrene. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the first embodiment in this paragraph, wherein the organic acid compound is phenol. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the first embodiment in this paragraph, wherein the process removes 1-25 wt % of phenol. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the first embodiment in this paragraph, wherein the aqueous caustic scrubbing solution contains sodium hydroxide. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the first embodiment in this paragraph, wherein the aqueous scrubbing solution contains 40-50 wt % of sodium hydroxide. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the first embodiment in this paragraph, wherein the organic product is a mixture comprising of 75-90 wt % cumene and alphamethylstyrene. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the first embodiment in this paragraph, wherein the caustic wash column is operated at a pressure from about 0.1 to 3.0 kg/cm2(g) and a temperature from about 30 to 60° C. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the first embodiment in this paragraph, further comprising coalescing of any water and aqueous caustic scrubbing solution using a mesh blanket. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the first embodiment in this paragraph, wherein jetting trays provide contacting of the organic phase through an aqueous caustic scrubbing solution to remove the organic acid from the organic phase.
[0029] A second embodiment of the invention is a process for treating an organic feed comprising introducing a feed stream comprising cumene and alphamethylstyrene from a feed tank into a caustic wash column having a caustic wash section and a water wash section; introducing a scrubbing solution comprising 45 wt % sodium hydroxide into the caustic wash column; introducing a water stream into a water wash section of the caustic wash column; contacting of the feed through an aqueous caustic scrubbing solution to remove the organic acid from the feed; removing water, sodium hydroxide, and sodium phenate from the lower portion of the caustic wash column; and removing 10-25 wt % phenol from the feed. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the second embodiment in this paragraph, wherein the caustic wash column is operated at a pressure from about 0.1 to 3.0 kg/cm2(g) and a temperature from about 30 to 60° C. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the second embodiment in this paragraph, further comprising coalescing of any water and aqueous caustic scrubbing solution using a mesh blanket. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the second embodiment in this paragraph, wherein jetting trays provide contacting of the organic phase through an aqueous caustic scrubbing solution to remove the organic acid from the organic phase.
[0030] Without further elaboration, it is believed that using the preceding description that one skilled in the art can utilize the present invention to its fullest extent and easily ascertain the essential characteristics of this invention, without departing from the spirit and scope thereof, to make various changes and modifications of the invention and to adapt it to various usages and conditions. The preceding preferred specific embodiments are, therefore, to be construed as merely illustrative, and not limiting the remainder of the disclosure in any way whatsoever, and that it is intended to cover various modifications and equivalent arrangements included within the scope of the appended claims.
[0031] In the foregoing, all temperatures are set forth in degrees Celsius and, all parts and percentages are by weight, unless otherwise indicated.
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The present subject matter relates to methods and apparatuses for the continuous preparation of a cumene feed for a cumene oxidation process. More specifically, the subject matter relates to a process for passing a cumene alpha-methylstyrene stream through a caustic wash column having an integrated water wash section for the removal of organic acids.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention concerns to an automatic switching circuit of recording mode for image recording/reproducing apparatus, and more particularly to an automatic switching circuit of recording mode which, in the case of monitoring camera for recording intermittently, when motion is detected, recording mode is not only automatically switched for continued recording of pictorial images but the detection of motion is performed in oblique direction of screen.
2. Description of Prior Art
Generally, monitoring camera is widely used in various fields like those for recording situations by using in combination with video casette which can tele-record continuously images on a monitor for a long time, and for coupling image sensors to a monitor in order for video to operate automatically in accordance with the screen variations including the entry of people, and simultaneously for giving off warning sounds.
In U. S. Pat. No. 4,614,966 entitled, "Electronic still camera for generating long time exposure by adding results of multiple short time exposure", in order to prevent detection error of movement magnitude by short time exposure, a technique is introduced to prevent the detection error of movement magnitude by generating long time exposure added by data of short time exposure.
Also, U. S. Pat. No. 4,458,266, entitled "Video movement Detector" discloses a technique of detecting exact movement by dividing TV screen display into detection domain of matrix style and by integrating video signals from said domains and by detecting movement magnitude by way of comparing integrated result with previously-stored values.
However, in the conventional technical constitution as explained in the foregoing, in order to detect movement magnitude, it is inevitable to use memory, and for detection of movement magnitude by storing pixels, it has become necessary to use large capacity of memory.
Even in the case of using 1H(horizontal) retardation element CCD, the drawback of necessitating the use of large capacity of retardation element has existed for comparison between the fields.
Accordingly, it is the object of the present invention to provide automatic switching circuit of recording mode wherein, in the case of monitoring camera, intermittent recording is performed during normal times, and if movement is detected during the performance of intermittant recording, movement against 1 line of oblique direction on the screen is detected by utilizing 1H retardation element, and once movement is detected, continued recording is performed so that retardation element can be saved and simultaneously recording media can be effectively utilized.
SUMMARY OF THE INVENTION
In accordance with aspects of the present invention, there are provided various means, comprising:
pickup means for converting optical information against objects to electrical signals;
signal processing means for separating the electrical image signals of pickup means into composite image signals and luminance signals;
movement detecting means for detecting the difference between the previous field and current field against the pixel of oblique direction by receiving luminance signal from signal processing means;
comparative means for comparing movement magnitude outputted from movement detecting means with the reference value;
mode control means for switching the recording mode according to the compared value of comparative means; and
recording means for recording output signal of pickup means according to the mode switched by mode control means.
BRIEF DESCRIPTION OF THE DRAWINGS
For fuller understanding of the nature and objects of the invention, reference should be made to the following detailed description taken in connection with the accompanying drawings in which:
FIG. 1 is a block diagram of automatic switching circuit of recording mode in accordance with the present invention;
FIG. 2 is a detailed circuit drawing as shown in FIG. 1;
FIG. 3A-3E are waveform drawings of movement as shown in FIG. 2; and
FIG. 4 is a pixel drawing of screen detected from movement detecting means adopted in FIG. 1.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 is a block diagram of automatic switching circuit of recording mode in accordance with the present invention.
According to FIG. 1, pickup means 10 converts the optical information against the object into electrical signal.
Signal processing means 20 separates the electrical signals of pickup means 10 into composite image signal and luminance signal.
Movement detecting means 30 detects the difference between the previous field and present field against the pixel of oblique direction by receiving the luminance signal from signal processing means 20.
Movement discriminating means 40 compares the reference values and the movement magnitude outputted from movement detecting means 30.
Mode control means 50 switches recording mode by way of comparative values of movement discriminating means 40.
Recording apparatus 60 records the output signal of signal processing means 20 according to the mode switched by mode control means 50.
FIG. 2 is a detailed circuit diagram as shown in FIG. 1.
According to FIG. 2, signal processing means 20 includes:
a preprocessor 21 for extracting the genuine image signal out of the signals from pickup means 10;
a Y/C (luminance/chrominance signal) separator 22 for separating luminance signal from chrominance signal;
a luminance/color difference signal separator 23 for generating luminance signal and color difference signal by dint of luminace signal and chrominance signal;
an encoder 24 for generating composite image signal by way of luminance signal and color difference signal.
Movement detecting means 30 includes:
a clock generator 31 for generating pulses during scanning period of diagonal pixel on one sceen;
a first switch 32 for inputting luminance signal from signal processing means 20 by being switched by pulses outputted from said clock generator 31;
a delayer 33 for delaying the diagonal pixel of 1 horizontal line inputted by said first switch 32 until the diagonal pixel of next horizontal line is inputted; and
an operational amplifier 34 which is a difference signal amplification means for outputting by amplification the difference between the diagonal pixel delayed by said delayer 33 and the currently-inputted diagonal pixel.
Movement discriminating means 40 includes;
first & second comparators 41, 42 which are comparative means for comparing the movement signal outputted from movement detecting means 30 with reference level; and
a first gate 43 for outputting movement discriminating signal by way of the output of said first & second comparators 41, 42 when movement signal is above the reference level.
Recording mode control means 50 includes:
an intermittent tele-recording timer 53 for generating tele-recording start signal in predetermined interval;
a second switch 51 for switching the input of movement discriminating signal outputted from movement discriminating means 40 according to the pulses generated from movement detecting means 30;
signal preservation means of T F/F(Toggle Flip/Flop) 52 for preserving movement discriminating signal to prevent movement discriminating signal from being changed within the switching period; and
a second gate 54 for controlling the tele-recording of recording apparatus in accordance with the outputs of said intermittent tele-recording timer 53 and T F/F(52)
With reference to the movement waveform drawings as shown in FIGS. 3A-3E and the pixel drawing of screen detected from movement detecting means 30 as shown in FIG. 4, above-mentioned construction is explained in detail as below.
The optical information against the objects incident from camera lens(not shown) extracts the charges photoelectric-converted from CCD (Charged Coupled Device) of pickup means 10.
In this location, pickup means 10 comprises CCD for converting optical information against the objects into electrical signal for accumulation and CCD driving circuit for reading out photoelectric charge accumulated for a time period corresponding to shutter speed by adding scanning pulse to each pixel of CCD.
Preprocessor 21 of signal processing means 20 performs CDS(Coefficient Double Sampling) in order to extract genuine image signal out of photoelectric-converted signals outputted from said pickup means 10.
Y/C separator 22 separates image signals outputted from said preprocessor 21 into luminance signal Y and chrominace signal C for outputting to luminance/color difference separator 23.
At this moment, luminance signal Y is also supplied to movement detecting means 30.
Said luminance/color difference separator 23 is composed of matrix and separates the output signal of Y/C separator 22 into luminance signal Y and color difference signals R-Y, B-Y.
Encoder 24 encodes said luminance signal Y and color difference signals R-Y, B-Y and outputs to recording apparatus 60 in composite image signals.
Meanwhile, the delayer 33 of movement detecting means 30 is short-circuited according to the clocks outputted from clock generator 31 and delays by 1 field the luminance signal Y of said Y/C separator 22 inputted through the first switch 32, which implies, delays by 1 vertical period.
At this point, delayer 33 is composed of 1H delaying element or a shift register, and in the case of using CCD delaying element, 1 horizontal line is 201.5 clocks and frequency is around 4 MHZ at driving clock of 1H CCD delaying element as illustrated in FIG. 3A.
At this moment, as the vertical perod, in the case of NTSC(National Television System Committee), is 525/2=262.5H, as depicted in FIG. 3B, the blanking period from vertical driving pulse of 1V=262.5H is assumed 61H as illustrated in FIG. 3C. And as illustrated in FIG. 3D, 1H CCD driving clock is counted in 202.5 clock period for generation of driving output, thus controlling the first switch 32, delayer 33, second switch of mode controller 50 and T F/F 52, then pixel on screen increasing per 1 clock during the increase of 1 horizontal line is selected.
Furthermore, at clock generator 31, as illustrated in FIG. 3E, vertical driving pulse having 1 vertical period 1V of 201.5 clocks is generated, and first switch 31, delayer 33, second switch 51 and T F/F are controlled.
Accordingly, in the final output outputted from the delayer 33, as depicted in FIG. 4, pixel of diagonal direction on the screen is delayed by 1 vertical period for outputting, and the output signal of said delayer 33 is adjusted in level by a variable resistor 35 for input into non-inversion terminal of operational amplifier.
In inversion terminal of said operational amplifier 34, the luminance signal Y of diagonal direction of screen against the current field outputted from Y/C separator 22 of signal processing means 20 is switched to signal period by the first switch 32 as illustrated in FIG. 3D and thereafter inputted.
Accordingly, in the operational amplifier 34, the difference signal between the pixel of diagonal direction delayed by delayer 33 and the pixel of diagonal direction against the current field, in other words, the signal in accordance with the movement magnitude is amplified for output.
The difference signal outputted from said operational amplifier 34 is inputted to movement discriminating means 40.
When the difference signal is inputted to movement discriminating means 40, the outputs of said operational amplifier 34 are compared with predetermined reference levels, ref 1, ref 2, by a source voltage Vcc and resistors R1, R2, R3 at first & second comparators 41, 42.
At the first gate 43, when the signal according to the movement magnitude outputted from said operational amplifer 34 lies in between reference levels, ref 1, ref 2, the logic signal of low state is outputted. When above the reference level, ref 1 or below reference level, ref 2, logic signal of high state is outputted.
In other words, the first comparator 41 discriminates whether or not difference signal is above the reference level, ref 1 when the luminance signal value of delayed diagonal direction of pixel is larger than the luminance signal value of diagonal direction against the current field and the second comparator 42 discriminates whether or not difference signal is above the reference level, ref 2 when the luminance signal value of pixel of diagonal direction against the current field is larger than the luminance signal value of pixel of delayed diagonal direction. And accordingly, when difference signal outputted from operational amplifier 34 of movement detecting means 30 is above the reference level, ref 1, the first comparator outputs logic signal of high state, and the second comparator outputs logic signal of low state.
When the difference signal outputted from operational amplifer 34 is below the reference level, ref 2, the first comparator 41 outputs logic signal of low state and the second comparator 42 outputs logic signal of high state. At this moment, the first gate 43 outputs logic signal of high state.
In this manner, when the variation degree of screen is above the reference value, the output of first gate 43 becomes logic signal of high state, and through the second switch 51 of mode controller 50 and T F/F 52 controlled by clock generator 31 of movement detecting means 30, is supplied to the second gate 54, causing the output of second gate 54 to become logic level of high state. The output signal of second gate 54 is applied to tele-recording control terminal REC of recording apparatus 60.
Accordingly, the recording apparatus 60 records continuously the output signal of said processing means 20.
When the variation degree of screen is below the reference value, in other words, when the output of said operational amplifier 34 is below predetermined reference value, as the output of operational amplifier 34 is smaller than the reference level, ref 1 and larger than the reference level, ref 2, logic level of signal in low state is outputted from the first gate 43 and inputted to the second gate 54.
At this point, the recording apparatus 60 tele-records or does not tele-record the composite image signal outputted from signal processing means 20 according to the output signal of intermittent tele-recording set-up timer 50 in mode controller 50.
At the second gate 54 of mode controller 50, the logic level signals of high and low states are outputted by set-up interval outputted from intermittent tele-recording time set-up timer 53, and recording apparatus 60 records periodically the composite image signal outputted from encoder 24 of signal processing means 20.
In other words, assuming that set-up interval is one minute, as logic level signals of high and low states are outputted in one minute period at intermittent tele-recording timer 53, one minute of high state and one minute of low state of logic level signals are applied to tele-recording control terminal REC of recording apparatus 60 through the second gate 54, causing the recording apparatus 60 to record composite image signal in every one minute period.
At this moment, as T F/F 52 is the same as the period of first & second switches 32, 51, in order to prevent the output of first gate 43 from changing within switching period, the first switch 32 maintains the output of first gate 43, namely, the compared value of the first & second comparators 41, 42, in every switching moment.
As from the foregoing, the automatic switching circuit of recording mode in accordance with the present invention, utilizing 1H delaying element, can simplify the circuit, perform continued filming only in case of necessity and obtain the effect of saving recording media by controlling intermittent/continued recording by virtue of detection of movement, namely, the detection of the difference of pixel between the previous field and current field in diagonal direction of screen, causing the lessened capacity of delaying element.
The foregoing description of the preferred embodiment has been presented for the purpose of illustration and description. Many modifications and variations are possible in light of above teaching, and specifically by the control of pulses generated from clock generator, one line of diagonal direction detected from movement detecting means can be moved from the right upper end of screen toward the left lower end in diagonal direction, or pixel signal from upper end to any lower vertical line, or pixel signal from left to right in any horizontal line can be detected, and it will be understood by one of ordinary skill in the art that various modification can be made, without departing from the spirit and scope of the invention. Accordingly, it is not intended that the invention be limited, except as by the appended claims.
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An automatic switching circuit of recording mode in an image recording and reproduction apparatus, and wherein, when the image recording apparatus is recording intermittently and movement is detected, the recording mode is automatically switched for continued recording of pictorial images. This results in the conservation of recording media and saves delaying element by performing the detection of movement in the diagonal direction of a screen.
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CROSS REFERENCE TO RELATED APPLICATION
This application is a non-provisional application, which incorporates by reference herein and claims priority of U.S. Provisional Application No. 61/583,568, filed Jan. 5, 2012.
BACKGROUND OF THE INVENTION
The reference numbers used in this section and throughout this disclosure refer to the documents set forth in the “References” section herein.
DNA polymerase activity is indispensable for genome replication and organism propagation across all biological domains (1-3). Since its initial characterization (4), the ability to harness DNA polymerase activity in vitro has become a fundamental tool in the field of molecular biology research (5). Above and beyond its established importance in research, in vitro measurement of DNA polymerase activity potentially offers numerous useful applications within the pharmaceutical and clinical setting. For instance, since bacterial DNA polymerase is actively being targeted for development of novel antimicrobial agents (6, 7), a rapid and sensitive assay capable of measuring DNA polymerase activity is desirable. Also, loss or gain of DNA polymerase activity is intimately involved in human disease. For example, emerging links between DNA polymerase activity and genetic aberrations are designating the enzyme as a target for anti-cancer therapies (8, 9). Deficiencies in DNA polymerase activity have also been linked to mitochondrial disorders (10). Furthermore, measurement of DNA polymerase activity has the potential to be used as a rapid and sensitive diagnostic tool, capable of detecting virtually any organism harboring active DNA polymerase within a given environmental or biological matrix where sterility is expected.
The most common method used to measure DNA polymerase activity in vitro depends upon incorporation of radiolabeled nucleotides (11). However, routine use of such DNA polymerase assays is undesirable due to the inherent risks and restrictions associated with radioisotopes. Consequently, over the past few decades numerous non-radioactive in vitro polymerase assays have been developed. Some rely upon the measurement of fluorescence generated by DNA polymerase-mediated release of single stranded binding protein (12) or binding of PICOGREEN dsDNA reagent to double stranded DNA (13,14). Other methods rely on microplate coupling and detection of fluorescently-labeled nucleotides (15). More recently, molecular beacon-based (16) and electrochemical-based (17) DNA polymerase assays have been developed. Despite successfully averting the use of radioactivity, the above assays are limited by such factors as poor sensitivity, a small linear dynamic range of measurement, or the use of purified polymerase.
As will be apparent to those skilled in the relevant art, the measurement of DNA polymerase extension activity in accordance with the present invention as described herein represents a useful tool with far reaching applications such as, but not limited to, screening candidate-polymerase inhibitors in vitro, or detecting the presence any microbe (harboring active DNA polymerases) within a diverse range of sample types. This is a substantial improvement over the state of the present art, because if intended for these purposes, routine use of traditional polymerase assays that incorporate radiolabeled nucleotides is unattractive. Consequently, numerous non-radioactive DNA polymerase extension assays have been developed in recent decades. Despite successfully averting the use of radioactivity, current fluorescence-based DNA polymerase assays also suffer from various deficiencies. For example, detection of DNA polymerase activity via several existing non-radioactive assays is dependent upon the binding of PICOGREEN dsDNA reagent to newly-generated double stranded DNA (13,14). If intended to analyze DNA polymerase activity from freshly lysed organisms, PICOGREEN.-based assays would likely be hampered by background fluorescence via binding of PICOGREEN dsDNA reagent to genomic DNA. Microplate-based DNA polymerase assays have also been developed (15). Decreased sensitivity of microplate-based assays can be expected for numerous reasons, including dependence upon intermediate binding of either product or substrate to a microplate and/or inefficient incorporation of modified dNTPs by DNA polymerase. More recently, real-time measurement of DNA polymerase activity via molecular beacons has been described (16). Despite improved sensitivity, direct measurement of molecular beacon fluorescence could also potentially be hindered by exposure to crude cellular lysates.
SUMMARY OF THE INVENTION
The present invention improves upon the technology of the background art as described above, and provides a rapid, highly sensitive and quantitative assay, capable of measuring DNA polymerase extension activity from purified enzymes or directly from microbial lysates, including crude microbial lysates. The invention as described herein provides a significant and unexpected advancement toward sensitive detection of potentially any microorganism containing active DNA polymerase within a given sample matrix. The present invention involves methodology for enzymatic template generation and amplification (ETGA). Accordingly herein is described the first characterization of a novel ETGA methodology based upon the measurement of DNA polymerase extension activity coupled to a quantitative PCR readout. For the remainder of the disclosure herein, this type of diagnostic assay provided by the invention is referred to as DPE-PCR. The DPE-PCR assay of this invention can be used to measure low levels of purified enzyme and is capable of detecting endogenous DNA polymerase extension activity directly from microbial cell lysates.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
FIG. 1 is a Schematic overview of a preferred DPE-PCR diagnostic assay in accordance with the present invention, and wherein: (Step A) DNA polymerase is incubated with a substrate consisting of pre-annealed Oligo-1 and Oligo-2. (Step B) During a 20 minute incubation at 37° C., DNA polymerase extends only the 3′ end of Oligo-1. (Step C) 3 μL of the reaction mixture is subsequently placed into a hot start qPCR reaction containing uracil DNA glycosylase (UDG). Prior to activation of Taq, UDG degrades the deoxyuridine within Oligo-2, leaving only a single stranded product derived from polymerase-mediated extension of Oligo-1. (Step D) After activation of Taq, amplification is initiated via primer binding to the Oligo-1 extension product. (Step E) PCR cycling and detection via Taqman probe.
FIG. 2 is a schematic representation of the sensitive detection of purified DNA polymerase using DPE-PCR in accordance with a preferred embodiment of the present invention, and wherein: (A) A commercial source of DNA polymerase I was assayed in duplicate at 10 fold increments starting at 2×10 −5 Units (U) down to 2×10 −11 U per reaction. A representative DPE-PCR curve is shown for each polymerase input level and No Input Control (NIC). (B) A plot was constructed from n=4 data points per polymerase input level, taken from two independent experiments and linear regression analysis was performed (C) Triplicate reactions containing 2×10 −7 U of DNA polymerase I, Klenow, Klenow (exo−) and E. coli DNA Ligase were assayed in comparison to a NIC. A representative DPE-PCR curve is presented for each of the assayed enzymes and NIC (D) DPE-PCR signal was compared in reactions containing a dNTP mixture with either dCTP or ddCTP, a schematic representing the available sites for dCTP or ddCTP incorporation within the DNA substrate is presented adjacent to the DPE-PCR curves.
FIG. 3 is a schematic overview of coupling bead lysis to DPE-PCR in accordance with a preferred embodiment of the present invention.
FIG. 4 is a graphical representation of how the performance of DPE-PCR in accordance with the present invention enables sensitive and quantitative detection of gram negative and gram positive bacteria via measurement of DNA polymerase extension activity in crude lysates, and wherein: (A) Decreasing amounts of E. coli cfu were spiked into bead lysis-coupled DPE-PCR. No Input Controls (NIC) were also included to monitor reagent background levels. All cfu spikes and NICs were performed in triplicate. A representative DPE-PCR curve is shown below for each level of bacterial input. Colony count plating and gsPCR were performed in an effort to obtain a better estimate of the actual cfu placed into each reaction and is presented in Supplemental FIG. 3 (B) A plot of E. coli DNA polymerase activity and linear regression analysis is presented. Graphs were generated using the average Ct values obtained from triplicate reactions of bacterial spikes ranging from 1×10 5 -1×10 1 input cfu. (C and D) cfu titration experiments were performed for S. aureus exactly as described above for E. coli . Colony count plating and gsPCR were performed in an effort to obtain a better estimate of the actual cfu placed into each reaction.
FIG. 5 shows a graphical representation of the detection of bacteria by DPE-PCR in accordance with another preferred embodiment of the present invention, and wherein: (A) 5 μL of E. coli suspension were added to bead lysis-coupled DNA polymerase assays comprised of a dNTP mix containing either 50 μM dCTP or 50 μM ddCTP. DPE-PCR curves representing E. coli -derived DNA polymerase activity is presented. Approximate cfu input as determined by plating is presented in the upper left region of the qPCR graph (B) 5 μL of E. coli suspension were added to bead lysis tubes containing 50 μL reaction buffer comprised of a dNTP mix with either 50 μM dCTP or 50 μM ddCTP. Prior to lysis, 1 μL of dCTP [2.5 mM, 0.25 mM 0.025 mM 0.0025 mM] was added to selected ddCTP-containing reactions. Reactions containing dCTP alone or ddCTP alone were run in parallel as “non-terminated” and “terminated” comparators. The resultant DPE-PCR curves representing E. coli -derived DNA polymerase activity is presented. Approximate cfu input as determined by plating is presented in the lower left region of the qPCR graph (C) E. coli gene specific PCR was also performed on the same lysates used for DNA polymerase detection presented in FIG. 2B . Linear plots of dCTP-dependent rescue of bacterial DNA polymerase detection vs. gsPCR of genomic DNA are shown. Plots were generated using the average qPCR Ct values from triplicate reactions at the indicated conditions (D-F) ddCTP termination and dCTP rescue experiments were performed for S. aureus exactly as described above for E. coli.
FIG. 6 is a graphical illustration of another embodiment of the present invention in which DPE-PCR ais an indicator of E. coli viability in response to heat treatment, and wherein: (A) 200 μL aliquots of an E. coli suspension (˜2000 cfu/μL) were incubated at 25° C., 45° C., 65° C., 85° C. and 105° C. for 20 minutes. After heating, each bacterial stock was cooled to room temperature and 5 μL were transferred to the bead lysis-coupled DPE-PCR assay. DPE-PCR curves representing E. coli -derived DNA polymerase activity following each of the indicated temperature treatments are presented. (B) Plots were generated from triplicate DPE-PCR reactions and gsPCR of genomic DNA (from the same lysates) after the indicated temperature treatments of E. coli suspensions. Parallel plating was also performed in triplicate for each of the treated E. coli suspensions. Representative cfu monitoring plates are presented below the graph, revealing bacterial viability status after treatment at each temperature. (C) DPE-PCR is compared to gsPCR of genomic DNA in response to the various temperature treatments. “Fold Reduction of qPCR Signal” was calculated using the indicated equation and the values obtained were used to generate comparative bar graphs.
FIG. 7 is a graphical illustration of another embodiment of the present invention, in which DPE-PCR is an indicator of S. aureus viability in response to heat treatment, and wherein: (A) 200 μL aliquots of an S. aureus suspension (˜2000 cfu/μL) were incubated at 25° C., 45° C., 65° C., 85° C. and 105° C. for 20 minutes. After heating, each bacterial stock was cooled to room temperature and 5 μL were transferred to the bead lysis-coupled DPE-PCR assay. DPE-PCR curves representing S. aureus -derived DNA polymerase activity following each of the indicated temperature treatments are presented. (B) Plots were generated from triplicate DPE-PCR reactions and gsPCR of genomic DNA (from the same lysates) after the indicated temperature treatments of S. aureus suspensions. Parallel plating was also performed in triplicate for each of the treated S. aureus suspensions. Representative cfu monitoring plates are presented below the graph, revealing bacterial viability status after treatment at each temperature. (C) DPE-PCR is compared to gsPCR of genomic DNA in response to the various temperature treatments. “Fold Reduction of qPCR Signal” was calculated using the indicated equation and the values obtained were used to generate comparative bar graphs.
FIG. 8 sets forth Table 1, as referred to herein, in which results are set forth showing the sensitive and linear detection of 17 additional clinically relevant microbial species in accordance with the teachings of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
During the past fifty years, in vitro measurement of DNA polymerase activity has become an essential molecular biology tool. Traditional methods used to measure DNA polymerase activity in vitro are undesirable due to the usage of radionucleotides. Fluorescence-based DNA polymerase assays have been developed; however, they also suffer from various limitations. Herein is disclosed a rapid, highly sensitive and quantitative assay capable of measuring DNA polymerase extension activity from purified enzymes or directly from microbial lysates. When tested with purified DNA polymerase, the assay has been found to detect as little as 2×10 −11 U of enzyme (≈50 molecules), while demonstrating excellent linearity (R 2 =0.992). The assay was also able to detect endogenous DNA polymerase extension activity down to at least 10 colony forming units of input gram-positive or gram-negative bacteria when coupled to bead mill lysis while maintaining an R 2 =0.999. Furthermore, experimental evidence presented herein suggests that DNA polymerase extension activity is an indicator of bacterial viability, as demonstrated by the reproducibly strong concordance between assay signal and bacterial colony formation. Together, the novel methodology of the invention described herein represents a significant advancement toward sensitive detection of potentially any microorganism containing active DNA polymerase within a given sample matrix.
To further illustrate the foregoing concepts and advantages of the invention, the following examples are provided as illustrative of this invention, but are in no way to be construed as limitative thereof.
EXAMPLE
Materials and Methods:
DNA Substrate Preparation
The sequence of the DNA substrate (and qPCR primers presented below) was adapted from DNA oligos previously used to measure bacterial-derived ATP via T4 DNA ligase (18). Briefly, Oligo 1 and Oligo 2 (see FIG. 1 ) were pre-annealed and diluted to a working concentration of 0.01 μM.
DNA Polymerase Activity Reaction Using Commercial Polymerase
DNA Pol I (NEB cat #M0209L), Klenow (NEB cat #M0210S) and Klenow exo(−) (NEB cat #M0212S) were diluted to the indicated U/μL stock in Tris EDTA (T.E.) pH 8.0. To begin, 2 μL of DNA polymerase stock at each concentration were placed into a 50 μL polymerase assay mixture containing the following components: 50 μM dNTP, 20 mM Tris pH 8.0, 10 mM ammonium sulfate, 10 mM potassium chloride, 2 mM magnesium sulfate, 1% BSA, 0.1% Triton, 0.1% Tween, and 0.001 μM pre-annealed DNA substrate. Reactions were vortexed briefly and placed at 37° C. for 20 minutes. After 20 minutes, 3 μL of each reaction were immediately placed into a quantitative PCR (qPCR) reaction.
Detection by qPCR
The qPCR reaction master mix was prepared using the following components: LightCycler 480 Master Mix (Roche cat #04707494001), 333 nM of each primer, 166 nM Target probe (FAM), 166 nM internal control probe (TxRed), and 1.2 U of UDG (Bioline cat #BIO-20744). As a tool to monitor PCR inhibition, each qPCR reaction also included 40 copies of competitive internal control DNA. For each qPCR reaction, 3 μL of DNA polymerase reaction were added to 27 μL of master mix and a two-step qPCR was run on a SmartCycler (Cepheid, Sunnyvale Calif.) as follows: Initial incubation of 40° C. for 10 minutes and 50° C. for 10 minutes and at 95° C. for 5 minutes (to activate Taq), followed by 45 cycles of 5 s denaturation at 95° C. and 20 s annealing/extension at 65° C. Cycle threshold (Ct) values were generated automatically by the SmartCycler software using 2 nd derivative analysis of the emerging qPCR curves.
Bacterial Strains and Media
Staphylococcus aureus (ATCC 25923) and Escherichia coli (ATCC 25922) were used in this study. Cultures were grown in/on Brain-Heart Infusion liquid media/agar (Teknova.) The ATCC reference numbers and growth media for the additional 17 microorganisms tested are listed in FIG. 5 .
Detection of Bacterial DNA Polymerase Activity Following Bead Mill Lysis
S. aureus and E. coli cultures were grown to an OD 600 of 1.0±0.2 (approximately 1×10 9 cfu/mL.) For each organism, 1 mL of culture was pelleted and washed three times in T.E. Bacterial suspensions were serially diluted in T.E., and 5 μL of each stock were added to bead lysis-reactions containing 50 μL of lysis-reaction buffer. A titration curve of 1×10 5 to 1×10 0 cfu/reaction was performed in triplicate for each organism, including triplicate reactions without bacterial suspension (No Input Control). After the addition of 5 μL bacterial stock (or No Input Control), lysis/reaction tubes were bead milled for 6 min. at 2800 rpm, followed by incubation at 37° C. for 20 min. After a 20 minute incubation, samples were heated to 95° C. for 5 min. and removed to cool at room temperature. Samples were then spun at 12 k×g for 30 seconds and 3 μL of each reaction were placed into qPCR. Five micro-liters of each bacterial stock was plated to obtain more accurate cfu input levels. Organism-specific PCR was also performed on the same lysates used for DNA polymerase detection. Primer and probe sequences for S. aureus and E. coli gene specific PCR are listed in FIG. 2 .
Dideoxy Termination Experiments
Termination of Purified DNA Polymerase Extension Activity with ddCTP:
DNA polymerase assay reactions were prepared as described above with a dNTP mix containing either 50 μM dCTP or 50 μM ddCTP (Affymetrix #77332.) Reactions containing either dNTP mix were spiked with 2×10 −9 U of DNA polymerase I (New England Biolabs #M0209). Reactions were incubated at 37° C. for 20 minutes and 3 μL of each reaction were subsequently placed into qPCR.
Elimination of Microbial Detection Via ddCTP:
S. aureus and E. coli cultures were grown, washed and diluted as described above. To demonstrate ddCTP-dependent termination of microbial DNA polymerase, 5 μL of bacterial stock were added to bead lysis tubes containing 50 μL of reaction buffer with either 50 μM dCTP or 50 μM ddCTP. Lysis, incubation and qPCR were performed as described above. Five micro-liters of each bacterial stock were plated to determine more accurate cfu input levels. Gene specific PCR of genomic DNA was also performed on the same lysates used for DNA polymerase detection.
dCTP Rescue of Microbial Detection:
S. aureus and E. coli cultures were grown, washed and diluted as described above. Five micro-liters of bacterial stock were added to bead lysis tubes containing 50 μL of reaction buffer with 50 μM ddCTP. Prior to lysis, 1 μL of dCTP at 2.5 mM, 0.25 mM 0.025 mM 0.0025 mM was added to ddCTP-containing reactions. Reactions containing 50 μM dCTP alone and ddCTP alone were run in parallel as “non-terminated” and “terminated” comparators. Lysis, incubation and qPCR were performed as described above. Five micro-liters of each bacterial stock were plated to determine more accurate cfu input levels. Gene-specific PCR was also performed on the same lysates used for DNA polymerase detection.
Viability Assessment Experiments
S. aureus and E. coli cultures were grown, washed and diluted as described above. Two hundred micro-liters of bacterial stocks at approximately 2000 cfu/μL (in T.E.) were incubated at 25° C., 45° C., 65° C., 85° C. and 105° C. for 20 minutes. After heating, samples were cooled to room temperature and 5 μL of each bacterial stock were added to bead lysis tubes containing 50 IA of reaction buffer. Lysis, incubation and qPCR were performed as described above. Five micro-liters of each bacterial stock (treated at various temperatures) were also added to 1 ml of T.E. and 50 μL were plated for colony count determination. Gene specific PCR was also performed on the same lysates used for DNA polymerase detection.
Results and Discussion
In the development of the present invention, it was set out to develop a rapid, simple, highly sensitive and quantitative assay capable of measuring DNA polymerase extension activity derived from purified commercial sources or freshly lysed cells, which would improve upon and overcome the disadvantages of the foregoing described methodologies of the know art. FIG. 1 shows a schematic overview of the mechanisms involved in coupling DNA polymerase extension activity to qPCR. Notably, Oligo 2 (see FIG. 1 , step C) is removed by uracil DNA glycosylase (UDG) prior to Taq activation, thus preventing non-specific extension of the substrate just prior to PCR cycling. A microbial detection method linking T4 DNA ligase activity to PCR amplification has been previously reported (18), which contains similarities to our DPE-PCR assay and is another example of an ETGA methodology. However, during the development of the present invention a modified version of this method, aimed at detecting NAD-dependent DNA ligase activity, suffered from various limitations (unpublished data), leading to the development of the novel DNA polymerase-based approach of the invention as described herein.
Sensitive and Linear Detection of Purified DNA Polymerase Extension Activity
An experiment was performed to determine the approximate analytical sensitivity of the DPE-PCR assay using commercially available DNA polymerase I. As shown in FIG. 2A , detection of DNA polymerase I was achieved over a wide range of input enzyme. In fact, measurement of DNA polymerase I extension activity is achieved down to as little as 2×10 −11 units (U) of enzyme (equivalent to approximately 50 molecules of polymerase). To our knowledge, detection of DNA polymerase extension activity at this level is unrivaled in existing DNA polymerase assays. In theory, this level of sensitivity could enable single microbe detection as E. coli has been reported to contain approximately 400 DNA polymerase I molecules per cell (11). Regression analysis also showed a strong positive linear correlation (R 2 =0.992) between the DPE-PCR cycle threshold (Ct) values and units of input commercial DNA polymerase I after graphing data from two independent limit of detection experiments ( FIG. 2B ). After sensitivity and linearity experiments were performed, it was important to determine if the DPE-PCR assay signal was independent of intrinsic exonuclease activity. To this end, we subsequently compared signals generated by 2×10 −7 U of DNA polymerase I to those generated from DNA polymerase I lacking 5′→3′ exonuclease activity (Klenow) and another version of the enzyme lacking all exonuclease activity (Klenow exo−). For additional specificity and background signal determination, E. coli DNA ligase at 2×10 −7 U and a No Input Control (NIC) were tested in parallel. As shown in FIG. 2C , both Klenow and Klenow exo—were detected at similar levels when compared to wild type DNA polymerase I, providing evidence that the DPE-PCR assay signal is derived from DNA polymerase-dependent extension and not intrinsic exonuclease activity. In addition to using exonuclease free polymerases, we set out to further demonstrate that DPE-PCR assay signal is derived from DNA polymerase-dependent extension of the DNA substrate prior to qPCR. Since incorporation of dideoxy nucleotides is a well-established method used for termination of DNA polymerase chain extension activities (19,20), we chose to substitute dCTP with dideoxyCTP (ddCTP) within our reaction mix. The schematic shown in FIG. 2D reveals the first possible position within the substrate that ddCTP can be incorporated by DNA polymerase. If ddCTP is incorporated into this position, the extension product of Oligo 1 would be insufficient in length for subsequent detection by qPCR primer 1 ( FIG. 1 ). As shown in FIG. 2D , substitution of dCTP with ddCTP eliminates signal generated by DNA polymerase I, thus demonstrating that the DPE-PCR assay signal is dependent upon DNA polymerase extension of the substrate prior to qPCR. The presence of a low copy internal amplification control confirms that qPCR was not inhibited by the presence of low amounts of ddCTP that are carried over from the DNA polymerase assay reagents (Supplemental FIG. 1C ). In addition, we feel it is important to note that we have sporadically observed a weak, but detectable signal in the absence of input-DNA polymerase (No Input Control). Due to the exquisite sensitivity of the DPE-PCR assay, we have demonstrated that weak background noise signals can be derived from several potential sources such as, but not limited to, DNA polymerase contamination present in the reagents prior to reaction assembly, DNA polymerase introduced by the operator during experimental setup and/or incomplete degradation of Oligo 2 ( FIG. 1 ) prior to activation of Taq (unpublished data). Notably, these irregular sources of background noise are controllable by instituting stricter reagent preparation procedures and good aseptic technique.
Sensitive Universal Detection of Microbes Via Measurement of Endogenous DNA Polymerase Extension Activity Directly from Cell Lysates
In addition to detecting purified polymerase activity, a simple universal method that measures microbial-derived DNA polymerase activity would be highly desirable. If achieved, such a method could enable the screening of candidate antimicrobial agents in actively growing cultures, thus allowing comparison of DNA polymerase extension activity to organism proliferation. Additionally, measurement of DNA polymerase extension activity could be used to screen environmental or biological samples for the presence of any microorganism harboring active DNA polymerase. To this end, we developed a simple method that couples microbial lysis to a DPE-PCR assay provided by the invention. As shown in FIG. 3 , a liquid sample known to contain, or suspected of containing, microbes is added to a bead mill lysis tube, disrupted and immediately transitioned into the DPE-PCR assay. We chose one gram negative bacteria ( E. coli ) and one gram positive bacteria ( S. aureus ) to demonstrate the ability of our assay to measure microbial-derived DNA polymerase extension activity in crude cellular lysates. As shown in FIG. 4A , when linked with bead mill lysis, the DPE-PCR assay is capable of detecting a wide dynamic range of input E. coli , down to and below 10 colony forming units (cfu) per lysis tube. Linear regression analysis of E. coli detection was also performed down to 10 cfu of input bacteria and showed a strong positive linear correlation between input cfu and DNA polymerase extension activity signal as indicated by an R 2 value of 0.999 ( FIG. 4B ). Colony count plating and E. coli -gene specific qPCR (gsPCR) were run in parallel, confirming both the input level of cfu per reaction and the ability to monitor intact genomic DNA from the exact same lysates. DNA polymerase extension activity from S. aureus lysates was detected to a similar input level ( FIG. 4C ). S. aureus detection was plotted down to 10 cfu of input bacteria and also showed a strong linear correlation between input cfu and DNA polymerase extension activity signal (R 2 =0.999, FIG. 4D ). Colony count plating and gsPCR were performed in parallel to confirm the amount of S. aureus present in each bead lysis tube, as well as the presence of directly analyzable genomic DNA. Complete tables of plating, gsPCR and DNA polymerase activity results for both E. coli and S. aureus can be found in FIGS. 3 and 4 . We subsequently tested the ability of the DPE-PCR assay to measure DNA polymerase activity from seventeen additional clinically relevant microorganisms. As shown in Table 1, we were able to detect DNA polymerase activity from all seventeen additional organisms including six gram-negative bacteria, six gram-positive bacteria and five Candida species. Detection of the seventeen additional microbes exhibited a strong positive linear correlation to input cfu with impressive low limits of detection. To date, and without failure we have similarly tested and detected a total of 31 different microbial species (data not shown). The upper linear dynamic ranges have yet to be fully characterized. More results containing parallel plating data and DPE-PCR results for each of 17 additional microbes are presented in FIG. 8 . Together, these data support the notion that the performance of DPE-PCR in accordance with the teachings of the present invention has the potential to be useful as a universal “pan” test for the sensitive detection of any microbe in a normally sterile environment.
As shown in FIG. 2D , substitution of dCTP with ddCTP in the reaction mix represents a powerful tool for blocking the detection of DNA polymerase-dependent extension activity within our assay. To demonstrate that the signal derived from bacterial spikes was dependent upon their DNA polymerase extension activity, and not the other endogenous bacterial enzyme activities present in the lysates, we set up an experiment to compare DPE-PCR signals obtained from E. coli and S. aureus using a standard DNA polymerase reaction mix containing (dATP,dTTP,dGTP, dCTP) versus a reaction mix containing (dATP,dTTP,dGTP, ddCTP). As shown in FIG. 5A , when compared to the standard reaction mix, substitution of ddCTP blocked the generation of signal derived from E. coli cfu spikes ( FIG. 5A ). A dCTP rescue experiment was subsequently performed by comparing DNA polymerase extension activity from bacteria lysed in a reaction mix containing 100% ddCTP (50 μM), to those containing 50 μM ddCTP spiked with increasing amounts of dCTP (see materials and methods for a detailed description of rescue experiments). FIG. 5B demonstrates the rescue effect that increasing amounts of dCTP has on quantifiable DNA polymerase extension activity derived from E. coli lysates. In addition to measuring microbial DNA polymerase extension activity, gsPCR was run in parallel to verify that equivalent amounts of E. coli were present in each of the assayed lysates. A graphical comparison of DNA polymerase activity versus presence of genomic DNA is presented in FIG. 5C . Signal termination (via ddCTP) and dCTP rescue experiments were subsequently repeated with S. aureus and similar results were obtained ( FIG. 5D-F ). Tables containing DPE-PCR and gsPCR data for both E. coli and S. aureus can be found in FIGS. 6 and 7 . qPCR internal control values are provided to demonstrate that low levels of ddCTP carried over into qPCR are not inhibitory, and thus are not responsible for the disappearance of DNA polymerase activity signal ( FIGS. 6A and 7A ). Together, the data presented in FIG. 5 strongly support the claim that the DPE-PCR assay is specifically detecting microbial DNA polymerase extension activity and signal is not derived from substrate modification via enzymatic activities other than DNA polymerase.
Measurement of DNA Polymerase Extension Activity as an Indicator of Bacterial Viability
Traditional methods for determining bacterial viability are dependent upon growth and visualization of a particular microbe on solid medium (21). Although bacterial growth and visualization is the current industry gold standard, the traditional cfu viability determination methods are undesirable due to the length of time required for cfu formation. Furthermore, the ability to grow on solid media or in liquid culture can vary dramatically from one microbe to another, thus potentially limiting the detection of certain fastidious organisms (22). Due to the aforementioned limitations of traditional methods, there is a growing need in a wide variety of pharmaceutical (23), environmental, food processing and clinical testing arenas for the rapid assessment of microbial viability. Consequently, numerous molecular methods have been developed in an effort to quickly assess microbial viability status within a given matrix (24). Despite being rapid and sensitive, molecular methods that detect the presence of nucleic acid often fall short of representing an accurate measurement of cell viability. For example, amplification of endogenous DNA or RNA is a poor indicator of bacterial viability, due to the persistence of nucleic acid after cell death (25, 26). We set out to determine the feasibility of using DNA polymerase extension activity as an indicator of bacterial viability. To this end, an experiment was designed to compare detection of DNA polymerase extension activity and PCR-mediated detection of genomic DNA as indicators of bacterial viability following various amounts of heat treatment. To begin, E. coli suspensions were treated at increasing temperatures for a fixed period of time. After heat treatment, bacteria were subsequently assayed for the presence of both DNA polymerase extension activity and genomic DNA. Heat treated and non-heat treated bacterial stocks were also plated in parallel to monitor bacterial viability via the presence of visible cfu. FIG. 6A represents the levels of E. coli DNA polymerase extension activity measured after the indicated amounts of heat treatment. Notably, a significant drop in E. coli DNA polymerase extension activity was observed after incubation of bacterial suspensions between 45° C. and 65° C. ( FIG. 6A ). In contrast, gsPCR signal obtained from the same lysates remained relatively constant at all temperatures and is graphically compared to DNA polymerase activity in FIG. 6B . Plating results presented below the graph further demonstrate that increasing levels of heat treatment are sufficient to prevent cfu formation and are paralleled by a dramatic loss of DNA polymerase activity; however, dead cells still contribute genomic DNA levels very close to their original input levels confirming that gsPCR is a poor indicator of the presence of viable cells ( FIG. 6B ). In FIG. 6C , the bar graphs further highlight the relative abilities of DPE-PCR and gsPCR to monitor the disappearance of cfu in response to lethal amounts of heat treatment. Subsequently, we wanted to test whether measurement of DNA polymerase extension activity could be used to indicate the viability status of a gram positive organism as well. The previous E. coli experiments were repeated with S. aureus under the same conditions.
FIG. 7A-C show similar results obtained from heat treatment experiments repeated with S. aureus . Collectively, the strong concordance between the presence of cfu and DNA polymerase extension activity shown in FIGS. 4, 6, 7 , and Table 1 of FIG. 8 , demonstrates that DPE-PCR performed according to this invention has potential to be used as a general indicator of cell viability, and may additionally present the possibility of measuring DNA polymerase extension activity from microbes exposed to other clinically or pharmaceutically relevant agents (bacteriostatic and bactericidal) aimed at reducing cell proliferation or viability.
In summary, in accordance with the present invention there has been developed a novel, highly sensitive, quantitative and rapid DPE-PCR assay. In addition to quantitative detection of extremely low levels of purified enzyme, we have demonstrated the ability of DPE-PCR to reproducibly measure DNA polymerase extension activity from less than 10 cfu of bacteria via coupling to bead lysis. We have also demonstrated the potential for DPE-PCR to universally detect microbes by testing a panel of microorganisms comprised of seven gram-negative bacteria, seven gram-positive bacteria and five Candida species. Furthermore, preliminary evidence that the DPE-PCR assay can be used to assess bacterial viability was provided via the reproducibly strong correlation between DNA polymerase extension activity and proliferation as indicated by the presence of cfu. Considering the data disclosed herein, it is presently believed that the novel methods and techniques of the invention such as the preferred DPE-PCR assay as disclosed herein, has the potential to become a useful tool for a wide range of testing applications within pharmaceutical, environmental, food and clinical settings.
The contents of all references, patents and published patent applications cited throughout this application, are incorporated herein by reference to the same extent as if each individual publication, patent or patent application was specifically and individually indicated to be incorporated by reference.
The foregoing detailed description has been given for clearness of understanding only and no unnecessary limitations should be inferred therefrom as modifications will be obvious to those skilled in the art. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed inventions, or that any publication specifically or implicitly referenced is prior art.
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.
While the invention has been described in connection with specific embodiments thereof, it will be understood that it is capable of further modifications and this application is intended to cover any variations, uses, or adaptations of the invention following, in general, the principles of the invention and including such departures from the present disclosure as come within known or customary practice within the art to which the invention pertains and as may be applied to the essential features hereinbefore set forth.
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A method for performing a diagnostic assay for the detection of the presence or amount of a microorganism within a sample matrix containing active DNA polymerase, is disclosed. The method utilizes the measurement of DNA polymerase extension activity, wherein the assay comprises the steps of incubating DNA polymerase in the sample matrix with a selected suitable substrate, and performing PCR cycling and detection via the use of a selected suitable nucleic acid probe, thereby to detect endogenous DNA polymerase extension activity in the sample matrix as an indication of the presence or amount of said microorganism.
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This application claims priority from German patent application serial no. 10 2011 075 775.9 filed May 13, 2011.
FIELD OF THE INVENTION
The invention concerns an arrangement for shifting a gearbox.
BACKGROUND OF THE INVENTION
The invention starts from a shifting arrangement of the type known as a claw shifting element. By means of this, a first transmission component is connected by an axially displaceable shifting or sliding sleeve to a second transmission component. The shifting sleeve and the transmission component to be connected have drive or shifting teeth, namely outer teeth and inner teeth, which by being pushed one inside the other form a rotationally fixed connection so that a torque can be transmitted or supported. The shifting sleeve must be engaged when the rotational speed difference is minimal, preferably zero. Due to the steep rotational speed gradient only a short amount of time is available for this. Thus, with conventional drive or claw teeth a relatively large tooth flank clearance must be provided to enable the claws to engage within the given time window. However, too large a tooth flank clearance is undesirable.
Drive teeth as used in known claw shifting elements have a relatively simple tooth profile, for example a trapezoidal or triangular profile. In the case of running gears in which the gearwheels mesh with one another by a rolling action, other tooth profiles such as involute profiles are used. The known running gears also have beveloid teeth, i.e. teeth for conical spur gears whose rotational axes intersect, cross, or can also be parallel to one another.
From DE 103 06 935 A1 by the present applicant a spur gear stage with beveloid gearwheels is known, which have equal-sized but oppositely directed cone angles. To reduce the rotational flank clearance the beveloid gearwheels are adjusted in the axial direction by a temperature-dependent element. Thus, the known gearwheel transmission has beveloid running gears for conical spur gearwheels with parallel axes.
Beveloid running gears are also known for driving so-termed lateral shafts in motor vehicle transmissions for an all-wheel drive system. From DE 10 2008 042 038 A1 by the present applicant a beveloid drive with intersecting or crossing rotational axes for a drive-train of a motor vehicle is known.
SUMMARY OF THE INVENTION
The purpose of the present invention is, with a shifting arrangement of the type described at the start, to enable a shifting process to take place even with larger rotational speed differences.
According to the invention, the drive teeth are formed as beveloid teeth, also called shifting teeth. According to the invention, the beveloid teeth until now known only as running gearing is used as shifting teeth. Beveloid teeth are involute teeth in which the profile displacement varies over the tooth width. The result is that the teeth of the shifting gears become thicker in the tooth width direction, so the flank clearance becomes smaller. At the beginning of the shifting displacement, i.e. when the sliding sleeve engages in the shifting teeth, the teeth—as viewed in the circumferential direction—are relatively narrow so the flank clearance is relatively large. In contrast, at the end of the shifting displacement the teeth are relatively thick, resulting in a small flank clearance. Thus, the flank clearance decreases along the direction of the shifting displacement. This has the advantage that engagement and disengagement are possible even with higher rotational speed differences. Beveloid teeth have the advantage of being produced by continuous machining, which therefore also brings cost advantages compared with known drive gears.
In a preferred embodiment the beveloid teeth are in the form of straight teeth, i.e. without any obliqueness. The straight teeth enable the shifting gears to be symmetrical, i.e. to have a symmetrical tooth profile.
In another preferred embodiment the beveloid teeth are oblique teeth with an angle of inclination β which is within a preferred range larger that 0° and smaller than 3°, particularly preferably 2°. The oblique teeth make it possible to have asymmetrical shifting gears, i.e. with an asymmetrical tooth profile.
In a further preferred embodiment the tooth flanks of the beveloid teeth have flank angles of inclination β L and β R which are equal for both flanks in the case of straight teeth. Thus, as viewed in the circumferential direction the thickness of the tooth profile increases symmetrically in the tooth width direction.
According to another preferred embodiment only one tooth flank of a tooth profile has a flank angle of inclination>0°, so that the tooth profile is asymmetrical. Preferably, the one tooth flank has a flank angle of inclination of about 4° and the other tooth flank a flank angle of inclination of 0°.
In a further preferred embodiment the shifting sleeve has inner shifting teeth, also called claws, whereas the second transmission component has outer shifting teeth. Thus, by axial displacement, the claws can be pushed over the shifting teeth of the second transmission component and the shifting process is carried out thereby. In this case the flank clearance is at a maximum at the beginning of the shifting displacement and at a minimum at the end of the shifting displacement.
According to another preferred embodiment the second transmission component is an element of a planetary gearset. Preferably the element is the sun gear, but it can also be the carrier or the ring gear of the gearset. In this way the planetary gearset element concerned can be connected by the shifting sleeve in a rotationally fixed manner to the first transmission component.
In a further preferred embodiment the shifting sleeve is supported in a rotationally fixed manner, for example on a transmission housing. In this way a planetary gearset element can be braked.
In another preferred embodiment the transmission is in the form of an automatic variable-speed transmission of a motor vehicle. Compared with conventional automatic transmissions this means that the known shifting elements in the form of disk clutches and/or brakes can be omitted in favor of shifting elements with beveloid shifting teeth. This saves fitting space, weight and costs.
BRIEF DESCRIPTION OF THE DRAWINGS
Example embodiments of the invention are illustrated in the drawing and described in more detail below, whereby further characteristics and/or advantages can emerge from the description and/or the drawings, which show:
FIG. 1 : A conical spur gear with beveloid teeth,
FIG. 1 a : A single tooth, shown in perspective,
FIG. 1 b : Tooth profile of the beveloid teeth shown in FIG. 1 ,
FIGS. 2 a , 2 b : Radial sections through shifting teeth according to the invention, at different shifting displacements,
FIGS. 3 a , 3 b : Symmetrical shifting teeth in the form of straight teeth with equal flank angles of inclination,
FIGS. 4 a , 4 b : Asymmetrical shifting teeth in the form of oblique teeth with different flank angles of inclination, and
FIGS. 5 , 6 : A shifting element with shifting teeth according to the invention for a planetary gearset, in different shifting positions.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a conical spur gear 1 with beveloid teeth 1 a and a tooth width 1 b , viewed in semi-section. The beveloid teeth 1 a have a profile displacement that varies over the tooth width b. This is indicated in FIG. 1 b by different tooth profiles 2 , 3 , 4 which correspond to the radial section planes at the points of the beveloid teeth 1 a identified by the arrows A, B, C. From this representation it can be seen that the tooth profile becomes thicker from the front face (arrow A) to the rear face (arrow C), the tooth thickness being measured in the circumferential direction,
FIG. 1 a shows a perspective view of a single tooth 5 of the beveloid teeth 1 a . The front end of the tooth 5 is called the toe 5 a and the rear end of the tooth 5 is called the heel 5 b . The result of the thickness variation is a tooth flank angle of inclination, as explained in more detail below.
FIGS. 2 a , 2 b show shifting teeth for a transmission component 6 and a sliding or shifting sleeve 7 . The transmission component 6 , which for example can be in the form of the sun gear of a planetary gearset (see FIGS. 5 , 6 ), has outer teeth 6 a whereas the shifting sleeve 7 has inner teeth 7 a , which are in tooth engagement with one another and can be displaced axially, i.e. in the shifting direction. The two sets of teeth 6 a , 7 a are in the form of beveloid teeth with flank angles of inclination that extend in opposite directions. FIG. 2 a shows the shifting teeth 6 a , 7 a at a shifting displacement point that corresponds to the middle of the total shifting displacement. The flank clearance between the two sets of teeth 6 a , 7 a is represented by the dimension j 1 .
FIG. 2 b shows the same shifting teeth 6 a , 7 a at a different shifting, namely two millimeters before the position shown in FIG. 2 a . In this case the flank clearance is denoted j 2 and it can be seen that j 2 is larger than j 1 . Owing to the chosen flank obliqueness angle of the beveloid teeth the flank clearance varies as a function of the shifting displacement (see also FIGS. 5 , 6 ), being relatively large at the beginning of the shifting displacement and relatively small at the end of the shifting displacement. This enables engagement and disengagement to take place even at higher rotational speed differences between the transmission component 6 and the shifting sleeve 7 . Furthermore, a larger flank angle of inclination also assists disengagement, i.e. the release of the shifting sleeve 7 .
FIGS. 3 a and 3 b show an example embodiment of the invention for shifting teeth 8 a , 9 a according to the invention, which are in the form of straight teeth with a symmetrical tooth profile. The outer teeth 8 a of the transmission component 8 have flank angles of inclination denoted β L and β R . From FIG. 3 b in particular it can be seen that the flank angles of inclination β L and β R of the two tooth flanks are equal. In a preferred example embodiment they are both equal to 2°. The flank angles of inclination β L and β R of the outer teeth 8 a of the transmission component 8 and of the inner teeth 9 a of the sliding sleeve 9 extend in opposite directions.
FIGS. 4 a and 4 b show a further example embodiment of the invention with asymmetrical shifting teeth 10 a , 11 a of the transmission component 10 and the shifting sleeve 11 . The shifting teeth 10 a have an angle of inclination β, preferably 2°. The tooth flanks have on one side a flank angle of inclination β R of 0° and on the other side a flank angle of inclination β L preferably of 4°. In this case the flank angle of inclination β R of 0° is on the thrust flank whereas the flank angle of inclination β L or 4° is on the trailing side of the shifting teeth.
FIG. 5 illustrates a section of an automatic variable-speed transmission of a motor vehicle, showing a planetary gearset 12 and a bearing support 13 fixed to the housing. The planetary gearset 12 has a sun gear 14 that meshes with a planetary gearwheel 15 which rolls around a ring gear 16 . On the sun gear 14 are arranged shifting teeth 14 a . In the bearing support 13 is arranged a sliding sleeve 17 , also called a shifting sleeve 17 , which is connected in a rotationally fixed manner by means of drive teeth 18 to the bearing support 13 , i.e. to a transmission housing (not shown). The shifting sleeve 17 is actuated hydraulically or pneumatically and has inner teeth in the form of beveloid shifting teeth 17 a . The shifting teeth 17 a are generally referred to as claw teeth or claws and, by displacing the shifting sleeve 17 axially, they can be brought into or out of engagement with the shifting teeth 14 a of the sun gear 14 . In the position shown in FIG. 5 the shifting teeth 17 a are in their open, i.e. disengaged position so there is no rotary connection between the sun gear 14 and the shifting sleeve 17 .
FIG. 6 shows the shifting sleeve 17 in its engaged position, i.e. with the shifting teeth 17 a fully engaged with the shifting teeth 14 a of the sun gear 14 . Thus, the shifting sleeve 17 produces a rotationally fixed connection between the sun gear 14 and the bearing support 13 fixed to the housing, i.e. the sun gear 14 is braked and supported relative to the transmission housing. The shifting teeth 14 a , 17 a correspond to the above-described beveloid teeth according to the invention with flank angles of inclination β L , β R , with a taper of about 2°. By an appropriate choice of the flank angles of inclination β L , β R the flank clearance along the shifting displacement of the shifting sleeve 17 can be adjusted optimally, and at the same time the disengagement of the shifting teeth is assisted.
INDEXES
1 Conical spur gear
1 a Beveloid teeth
2 Tooth profile
3 Tooth profile
4 Tooth profile
5 Tooth
5 a Toe
5 b Heel
6 Transmission component
6 a Outer teeth
7 Shifting sleeve
7 a Inner teeth
8 Transmission component
8 a Outer teeth
9 Shifting sleeve
9 a Inner teeth
10 Transmission component
10 a Outer teeth
11 Shifting sleeve
11 a Inner teeth
12 Planetary gearset
13 Bearing support
14 Sun gear
14 a Shifting teeth
15 Planetary gearwheel
16 Ring gear
17 Shifting sleeve
17 a Shifting teeth
18 Drive teeth
b Tooth width
β Angle of inclination
β L Flank angle of inclination of the left flank
β R Flank angle of inclination of the right flank
j 1 Tooth flank clearance
j 2 Tooth flank clearance
A Arrow (front side)
B Arrow (middle)
C Arrow (rear side)
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An arrangement for shifting a gearbox. The arrangement having first and second transmission components ( 14 ) and an axially movable shifting sleeve ( 17 ) such that the shifting sleeve ( 17 ) and the second transmission component ( 14 ) each have respective drive teeth ( 14 a, 17 a ) that can be brought into engagement with one another. The drive teeth are in the form of beveloid teeth ( 14 a, 17 a ).
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[0001] This invention relates to an improved process for producing an amended sodium carbonate product. More particularly, this invention relates to the manufacture of a sodium carbonate product, solids and/or liquor, that has an enhanced reactivity with carbon dioxide for the production of sodium bicarbonate free of the use during manufacture of additives that includes animal derivatives.
BACKGROUND OF THE INVENTION
[0002] Trona ore is mined and calcined for use in the manufacture of sodium carbonate which in turn can be used to make sodium bicarbonate (NaHCO 3 ), a valuable product. The naturally occurring trona ore material generally has the formula Na 3 H(CO 3 ) 2 .2H 2 O and is characterized as a hydroxyacid sodium carbonate. Trona is found in, or contiguous to, oil shale, and thus, contains large amounts of organics, which it is desirable to remove from the sodium carbonate product. Unfortunately, insoluble organic and inorganic materials are contiguous in the trona ore, and are not easily separated. These impurities impact the characteristics of the final soda ash produced.
[0003] The processes used to remove impurities and to produce commercial soda ash from crude trona ore include various steps of calcination, dissolution of the converted soda ash to concentrated liquor, solids/liquids separation steps, filtration and/or purification, evaporation/crystallization, and drying the monohydrate formed to anhydrous soda ash for industrial use.
[0004] In accordance with the present commercial process, the crushed and calcined trona ore is treated with water to dissolve the soluble sodium carbonate product. The resultant liquid solution, or liquor, is clarified, decanted and then filtered to remove the solids. Treatment of the solution with activated carbon may follow to remove some portion of the organic materials. However, treatment with activated carbon is expensive. In addition to the high costs of the activated carbon itself, there are several auxiliary processing costs; the carbon must be filtered out after the carbon is sufficiently inactivated, requiring additional manpower, testing and filtering equipment, and the spent carbon must be disposed of, which is also expensive.
[0005] After the carbon treatment step, when used, the liquor is evaporated to obtain a crystallized sodium carbonate product. Antifoam agents are often added in this step to prevent foaming that would foul condensing liquids. These liquids are reused as pure water when clean enough.
[0006] The pregnant mother liquor separated from the monohydrate crystals is recycled back to the evaporation units to recover the alkali value therein. Eventually the impurities in the liquors concentrate and a portion must be purged from the evaporation step to meet product quality requirements. The sodium decahydrate crystallization process is one process used to recover the alkali values in the waste purge stream.
[0007] Other waste streams and sodium carbonate-containing streams can be cooled using the sodium carbonate decahydrate process to recover alkali values from weak liquor streams. The crystals formed are separated from the weak bittern mother liquor and can be melted and conveniently reintroduced into the monohydrate process or used as feed stock to other sodium crystallization processes such as sodium bicarbonate and sodium sesquicarbonate. The resulting weak bittern mother liquor is also valuable as an alkalinity source for such processes as flue-gas desulfurization. The sodium carbonate decahydrate process is a valuable process for recovering alkali values from sodium carbonate processes.
[0008] When the sodium carbonate product is to be used to make sodium bicarbonate, the anhydrous soda ash is dissolved in water and the resultant sodium carbonate solution is then reacted with carbon dioxide to form sodium bicarbonate in accordance with the following reaction:
Na 2 CO 3 +CO 2 +H 2 O→2NaHCO 3
[0009] However, even if treated with activated carbon, objectionably some organic materials from the anhydrous soda ash are passed on to the sodium bicarbonate process. This residual organic material interferes with its ability to react with carbon dioxide.
[0010] Thus considerable engineering skill is needed to maximize the carbon dioxide adsorption efficiency of sodium carbonate and the rate of sodium bicarbonate crystal formation from sodium carbonate. An improved method for modifying the sodium carbonate source that enhances the carbonation reaction and avoids animal derivatives would be highly advantageous.
[0011] Sodium carbonate produced from the conventionally mined trona ore via the “monohydrate” process is known to contain dissolved organic matter and other insoluble materials. The liquor produced by dissolving the crude soda ash is sometimes treated with carbon to remove the dissolved organic matter which may cause foaming, crystal modification, and/or color problems in the final product. Sodium carbonate monohydrate crystals formed in the evaporation process are separated from the mother liquor and sent to the dryers to produce soda ash. The soluble impurities are recycled with the centrate to the crystallizer where they are further concentrated. To maintain final product quality, it eventually becomes necessary to remove the impurities with a crystallizer purge stream.
[0012] The purge stream from the evaporation process is sometimes cooled crystallizing sodium carbonate decahydrate and separating the decahydrate crystals to recover the alkali values therein. The decahydrate crystals can be melted and returned to the centrate system, or melted and fed directly to an evaporation unit, or used as a sodium source for the production of saleable sodium salts (e.g. dense soda ash, light soda ash, sodium bicarbonate, or sodium sesquicarbonate.)
[0013] The liquors from the separation, purification, and/or purge steps maybe sent to surface evaporation ponds or to abandoned underground mine workings. The sodium carbonate containing liquors from such disposals and/or natural mine waters, can be cooled using the “decahydrate” process to improve the purity of the crystals produced while recovering the sodium values therein. Sodium carbonate decahydrate formed when such waste streams are naturally or mechanically cooled can also be melted, filtered and purified, and re-cooled using the “decahydrate” process. The recovered alkali value can then be further processed to valuable sodium carbonate salts (e.g. sodium sesquicarbonate, sodium carbonate, or sodium bicarbonate).
[0014] The production of sodium carbonate using a combination of monohydrate and decahydrate processes is well known. Purification methods using carbon filtration and chemical additives such as DADMAC, quaternary amines, bentonite clays, and guar gums have been documented and patented.
[0015] For example, a method for removing anionic polymers and acidic impurities from aqueous trona solutions prior to crystallization whereby improved crystal formation is achieved is proposed in U.S. Pat. No.4,472,280, to Keeney.
[0016] U.S. Pat. No. 3,981,686, to Lobunez teaches a method for clarifying a carbonate process solution containing suspended insolubles so the suspended insolubles will readily settle out of the carbonate process solution.
[0017] U.S. Pat. No. 6,270,740 to Shepard, et al, issued in May, 2001 teaches a process comprising adding an amine additive at a rate of at least 0.017 gallons per ton of sodium carbonate produced, prior to the filtration step of the monohydrate process that results in modified sodium carbonate crystals which, when dissolved in water, have increased reactivity with carbon dioxide in the manufacture of sodium bicarbonate.
[0018] Presently, these processes include the presence of at least one nitrogen containing cationic compound chosen from the group consisting of water-soluble cationic polymers and/or fatty substituted quaternary ammonium salts.
[0019] Certain dietary requirements limit the use of animal derivatives. For instance, Kosher diets restrict among other things, fats derived from swine and other forbidden animals. Compounds produced from bovine bi-products present concern with bovine spongiform encephalopathy (mad cow disease) and other animal transmitted diseases. A process for producing saleable sodium salts without the use of animal derivatives would be beneficial.
[0020] The present invention differs from the system of U.S. Pat. No. 6,270,740 to Shepard, et al, in that the system of that patent employs tallow-based or fatty substituted quaternary amines, while the system of the present invention requires a quaternary amine that is free of animal derivatives. In accordance with the invention the two amine groups comprising suitable non-tallow or non-fatty substituted carbon structure, that yield the desired benefits are:
[0021] a) Dialkylethoxilated quaternary salts
[0022] b) Benzylalkyl quaternary salts.
[0023] We have found that in order to achieve the desired result, the non-tallow based, non-fatty substituted amine salt must be employed at a rate of about 0.020 to about 0.040 mols/min. Although these addition rates may be regarded as comparable to the addition rates of the prior______, the chemistry of the tallow-based amines is found to react substantially differently such that if one adds more than about 0.020 mols/min of the tallow-based amine of the prior______, there is a marked reduction in the product's CO 2 uptake, as shown by the table below:
TABLE 1 CO 2 Reactivity & Concentration Tallow-Based Amine CO 2 Uptake Gal/Ton SA Mols/Min 0.010 0.0087 0.015 0.0091 0.020 0.0106 0.025 0.0104 0.030 0.0067 0.035 0.0067 0.040 0.0068
[0024] It is apparent that, the product reactivity with respect to CO 2 decreases once the addition rate of the tallow-based amine goes above 0.021 mols/min.
SUMMARY OF THE INVENTION
[0025] We have found that the carbonation reaction to form sodium bicarbonate is enhanced when the sodium carbonate is produced using the process of the invention. In accordance with the present process, the addition of particular amounts of a cationic compound, e.g., a quaternary amine, to treat the 25-30% by weight sodium carbonate liquor prior to filtration, results in a modified sodium carbonate liquor product that, when crystallized and converted to any anhydrous product, is more readily and more thoroughly carbonated with CO 2 in the production of sodium bicarbonate. The cationic additive reacts with organic materials in the sodium carbonate liquor to form solid polymeric by-products. It is necessary that the treatment with a cationic compound is made prior to filtering the liquor. After filtering to remove the polymeric by-products and other solid materials, the liquor is evaporated or crystallized to produce a purified and modified sodium carbonate. During evaporation, additional antifoam agent may be added to control foaming and to insure the ability to re-use the generated condensate.
[0026] In addition to exceeding the maximum CO 2 reactivity that is achieved with a tallow-based amine (0.0220 vs. 0.0117 mols/min), the benefits of the present invention include treatment of supplementary recycle streams such as purge, mother liquor, and other waste streams such as mine water, underflow tails, bicarbonate waste, etc. This is beneficial because soda ash produced using these sodium carbonate sources, without the advantages of the invention, will produce crystals with substantially lowed, i.e. with reactivities similar to crystals made using conventional monohydrate, decahydrate, bicarbonate, or sesquicarbonate processes. Use of the present invention will produce crystals with reactivities averaging 0.0220 mols/min CO 2 uptake. The benefit of the present invention resides in the manufacture of sodium bicarbonate whereby the reactivity of the manufactured sodium carbonate to CO 2 in the conversion of the sodium bicarbonate is increased and without introducing chemicals from animal derivatives.
BRIEF DESCRIPTION OF THE DRAWING
[0027] The Figure comprises a typical flow diagram of the process for producing the improved sodium carbonate product in accordance with the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0028] In the course of the work leading to the invention several combinations of non-tallow based quaternary amines were bench tested and screened for effective foam prevention and increased carbon dioxide uptake. Certain preferred amines were discovered and tested for practical commercial production. The goal of retaining Kosher certification of the soda ash being produced for sale was also an important consideration. The testing continued to assure the reproducability of an effective and economic amine system that would yield the desired benefits.
[0029] Defoamers from various manufacturers were examined under a pass/fail system for plant trials. This initial screening consisted of establishing physical and chemical characteristics, effectiveness in foam prevention and foam suppression, and the ability to maintain/increase CO 2 uptake (BCT). Additionally, crystal size, crystal friability, bulk density, and impurity levels had to remain unchanged.
[0030] We have found that the most promising of these defoamers was the dialky lathozylated amine salt, GD 1103, obtained from Great Divide Chemicals which produced crystals with high CO 2 reactivity and performed successfully in plant trials. Additional runs to enhance the foam suppressing ability of this salt were undertaken; first, by increasing the concentration of the dialkylethoxilated amine (Quat 1) and then by adding a second non-tallow based quaternary amine of the family of benzylalkyl quaternary salts (Quat 2). A variety of combinations using these salts individually and in combination were tested to determine the most effective combination. Of the dialkyl and benzyalkyl substituents, generally those sales leaving an alkyl group of 1-4 carbon atoms are included.
[0031] Based on this testing, it was found that these salts were effective in obtaining crystals with a high CO 2 reactivity while still obtaining good foam control in the process, and that a combination of the chemicals with two quaternary amines yields a preferable result. GD 1110 was also plant tested and proved to have good defoaming properties and produced crystals with an average CO 2 reactivity of 0.0220 mols/min.
[0032] As the results obtained demonstrate, plant trials confirmed that only certain quaternary amine salt additives in accordance with the present invention significantly increased CO 2 reactivity. Although other chemicals tested use benzyl amines and other quaternary salts, they failed to yield a sodium carbonate product with the desired sufficiently high CO 2 reactivity. Other amines tested had the adverse effect of modifying the bicarbonate crystal during the manufacture of sodium bicarbonate and lacked crystal size distribution requirements.
[0033] In accordance with the invention a more effective and/or less costly mixture resides when the quaternary amine employed is elected from the family of diquaternary salts thereof.
[0034] We have found that the diquaternary amine system of the invention yields a superior soda ash. The product produced according to the inventor is distinctively different from that produced using the tallow-based amine described in U.S. Pat. No. 6,270,740 in at least the following respects:
[0035] CO 2 uptake values averaged 0.012 mols/min with peak values of 0.017 mols/min. CO 2 uptake of crystals made with the present invention average 0.0220 mols/min.
[0036] CO 2 reactivity decreases as the addition rates exceed 0.021 mols/min when using a tallow based amine. Up to 0.040 mols/min of the non-tallow based amine have been added without a decrease of CO 2 reactivity.
[0037] The amine described in the present invention does not have animal derivatives or fatty substitutes. Consequently, it fulfills certain dietary requirements (e.g. Kosher) and avoids concerns with animal transmitted diseases (e.g. bovine spongiform encephalopathy).
[0038] The present invention allows for production of soda ash with high CO 2 reactivity from recycle and waste streams that otherwise would have reactivity of 0.0075 mols/min.
[0039] Referring to the flow diagram of the drawing, the sequence of steps employed to make the improved modified sodium carbonate product of the invention is described.
[0040] As shown, trona ore is mined, crushed and fed to a calciner 10 to burn off volatile products, convert any sodium bicarbonate to carbonate, and liberate water. The calcined product is removed from the calciner 10 and the soluble salts are dissolved in water in a dissolver 11 to form a 25-30% by weight soda ash solution, which in turn is fed to a clarifier 12 . The supernatant liquor is removed through a line 4 , and the solids remaining at the bottom of the clarifier 12 are removed through a line 30 . The solids may be re-clarified in a second clarifier 14 and the supernatant solution withdrawn at line 31 and returned to the dissolver 11 as dissolver liquor supply.
[0041] A cationic additive is suitably injected into line 4 prior to the filter 15 . The resultant liquor/additive solid polymeric reaction product is filtered in a filter 15 . The filtered stream is evaporated by a single evaporator 20 where water is removed leaving a product slurry. Multiple evaporators, such as a second effect evaporator 20 A and a third effect evaporator 20 B can also be employed. Antifoam agent is added to the first effect evaporator 20 continuously and batch-wise to the second and third effect evaporators 20 A and 20 B solely to control foam generation. This slurry is fed to a centrifuge 21 where a modified monohydrate crystal sodium carbonate product is collected. This product is then fed to a steam tube dryer 22 where the water of hydration is removed. The resultant anhydrous sodium carbonate product is optionally and preferably screened and collected for storage in storage bins 30 .
[0042] The pregnant mother liquor (line 11 ) separated from the modified monohydrate crystal sodium carbonate product is recycled back to the evaporator units where it is further concentrated with impurities. To maintain final product quality, it eventually becomes necessary to remove the impurities with a crystallizer purge stream (line 14 ).
[0043] It is economically advantageous to recover alkali values from the mother liquor and purge streams, which are highly concentrated in sodium carbonate. It is further advantageous to purify these streams by reducing the concentration of impurities returned to the evaporator units as recycle.
[0044] In some cases, the purge stream (line 14 ) is cooled crystallizing sodium carbonate decahydrate ( 23 ) and separating the decahydrate crystals ( 24 ) to recover the alkali values therein. The separated solid sodium carbonate decahydrate crystals (line 21 ) can be melted ( 25 ) and recycled back to evaporator units ( 20 ) or further processed into saleable sodium salts (line 26 ) (e.g. sodium carbonate, sodium bicarbonate or sodium sesquicarbonate). The weak bittern mother liquor stream (line 27 ) from the decahydrate crystallizer is suitable for flue-gas desulfurization, or can be stored at a surface or underground facility for future recovery.
[0045] The decahydrate process is also suitable for purifying the pregnant mother liquor stream and recovered waste streams from such sources as surface or underground tailings, mine waters, recycle streams from a sodium bicarbonate process, and other sodium carbonate containing streams with recoverable alkali values.
[0046] A cationic additive is suitably injected into the process prior to a final filtration. When the sodium carbonate-containing stream is fed to a decahydrate crystallizer, a quaternary amine is preferably injected into the melted decahydrate crystal containing stream followed by filtration prior to being fed as recycle to a monohydrate evaporator unit, or used as a feed source for other sodium salt processes such a sodium bicarbonate or sodium sesquicarbonate. The preferred cationic amine addition rate is 0.010-0.020 gallons per equivalent soda ash produced accounting for the recoverable sodium carbonate decahydrate.
[0047] When the sodium carbonate-containing stream is fed to a monohydrate evaporator unit, or other crystallizing units such as used to produce such sodium carbonate compounds as sodium bicarbonate or sodium sesquicarbonate, a quaternary amine is suitably injected into the process stream followed by filtration prior to the introduction to the processing units. The preferred cationic amine addition rate is 0.010-0.020 gallons per equivalent soda ash produced accounting for the recoverable sodium carbonate decahydrate.
[0048] The mother liquor (line 11 ) is preferably cooled using a decahydrate crystallizer ( 23 ) to further purify the feed stream (line 7 ) to the evaporator units and recover alkali values therein. The solid sodium carbonate decahydrate crystals are separated ( 24 ) and can be melted ( 25 ), the cationic additive injected at a preferred rate of 0.010-0.020 gallons per equivalent ton of sodium carbonate recovered, the resultant liquor produced filtered and recycled back to the sodium monohydrate evaporator units ( 20 ) or further processed into other sodium carbonate-containing salt crystals such as sodium bicarbonate or sodium sesquicarbonate crystals (line 25 ).
[0049] The purge liquor (line 14 ) is preferably cooled using a decahydrate crystallizer ( 23 ) to further purify the feed stream (line 7 ) to the evaporator units ( 20 ) and recover alkali values therein. The solid sodium carbonate decahydrate crystals are separated ( 24 ) and can be melted ( 25 ), the cationic additive injected at a preferred rate of 0.010-0.020 gallons per equivalent ton of sodium carbonate recovered, the resultant liquor produced filtered and recycled back to the sodium monohydrate evaporator units ( 20 ) or further processed into other sodium carbonate-containing salt crystals such as sodium bicarbonate or sodium sesquicarbonate crystals (line 25 ).
[0050] Other sodium carbonate-containing streams (such as surface or underground tailings, mine waters, and other recycle and/or waste streams) may be introduced to the process and adjusted in concentration to economically recover sodium carbonate values therein. The benefits of this invention are not efficiently realized when the cationic amine is added to the process streams prior to the clarification steps. When said sodium carbonate-containing streams enter the process as feed to the dissolving or clarification steps, some of the amine exits the system with the insoluble underflow materials. In these processing instances it is preferred that the amine be added to the resultant supernatant liquor then filtered prior to reporting to the monohydrate evaporation units. The preferred amine addition rate is 0.020-0.040 gallons of amine per ton of soda ash produced, accounting for the equivalent sodium carbonate recovered from the waste streams plus the sodium carbonate recovered from the virgin liquor stream into which the recovery stream was introduced.
[0051] Other sodium carbonate-containing streams (such as surface or underground tailings, mine waters, and other recycle and/or waste streams) may be introduced to a sodium carbonate decahydrate process after an adjustment for concentration to economically recover sodium carbonate values therein. In these processing instances it is preferred that the sodium carbonate value be recovered firstly by cooling with a decahydrate crystallizer ( 23 ) and the resultant crystals be melted ( 25 ), the cationic amine suitably injected into the resultant liquor, followed by filtration prior to reporting to downstream crystallization units. The preferred amine addition rate is 0.010-0.020 gallons of amine per ton of soda ash produced, accounting for the equivalent sodium carbonate recovered from the waste streams.
[0052] Other sodium carbonate-containing streams (such as surface or underground tailings, mine waters, and other recycle and/or waste streams) may be introduced to a sodium carbonate decahydrate process after an adjustment for concentration to economically recover sodium carbonate values therein. In processing instances where the sodium carbonate-containing stream is filtered first, followed by cooling using a decahydrate crystallizer to recover the alkali values therein for processing to sodium carbonate salts, the cationic amine is suitably injected into the process stream prior to filtration ( 26 ) at a preferred amine addition rate of 0.010-0.020 gallons of amine per ton of soda ash produced, accounting for the equivalent sodium carbonate recovered from the waste streams plus sodium carbonate recovered from the virgin liquor stream into which the recovery stream was introduced.
[0053] The mother liquor (line 11 ) may be filtered to remove impurities prior to reporting as recycle or feed to a sodium monohydrate, sodium decahydrate, or other evaporator/crystallizers used to produce sodium carbonate-containing salts. In this case, the cationic additive is injected prior to the filtration step at a preferred rate of 0.010-0.020 gallons per equivalent ton of sodium carbonate recovered, the resultant filtered liquor recycled back to monohydrate evaporator units or further processed into other sodium carbonate salt crystals such as sodium bicarbonate or sodium sesquicarbonate crystals.
[0054] The purge liquor (line 14 ) may be filtered to remove impurities prior to reporting as recycle or feed to a sodium monohydrate, sodium decahydrate, or other evaporator/crystallizers used to produce sodium carbonate-containing salts. In this case, the cationic additive is injected prior to the filtration step at a preferred rate of 0.010-0.020 gallons per equivalent ton of sodium carbonate recovered, the resultant filtered liquor recycled back to monohydrate evaporator units or further processed into other sodium carbonate salt crystals such as sodium bicarbonate or sodium sesquicarbonate crystals.
[0055] The cationic surfactant compounds useful in the invention comprise organo quaternary amines, and in particular dialkylethoxylated quaternary amine salts, benzyl alkyl quaternary amine salts, or a combination of both salts or a blend thereof with a non-tallow, non-fatty substituted carbon chain builder. The amine additive is injected into the mother liquor obtained from the primary clarifier 12 prior to filtering. The quantity of amine additive added to the liquor is from 0.020 to 0.040 gallons of the amine per ton of soda ash produced. Forty to seventy percent of the total addition must be added to the filtration feed pipeline 6 . The production rate of soda ash can be calculated based on the measured soda ash liquor concentration and liquor feed rate entering the evaporator ( 20 ) or decahydrate crystallizer ( 23 ) bodies, less the system losses due to purge, centrifuge recycle and dryer losses caused by air flow entrainment and the like. The quantity of amine additive added to other liquor sources such as melted decahydrate, mine waters, recovered waste streams from surface or underground tailings, other sodium containing streams and recycle streams is from 0.010 to 0.020 gallons per equivalent soda ash recovered from said streams. The calculation accounts for feed concentration, feed rate, recovery and losses. It is preferred that the amine be added to such streams after crystallization from such processes as a decahydrate crystallizer, the crystals separated from the weak bittern mother liquor, melted, and filtered. The amine addition point is after, i.e. follows, the melting step and is prior to the filter step. Alternatively, the amine addition point may occur prior to a filtration step and followed by monohydrate evaporation, decahydrate crystallization, or other crystallization step such as production of sodium bicarbonate or sodium sesquicarbonate.
[0056] Adherence to the present process sequence results in a modified anhydrous soda ash product with a very substantially improved reactivity, or uptake, of carbon dioxide in the production of sodium bicarbonate. About 200% or higher carbon dioxide uptake over that of an activated carbon-treated sodium carbonate product, and about 290% over that of the untreated prior art sodium carbonate product, is obtained when all the amine is added to the evaporators with no pre-filtration. Further, since the polymeric by-products formed by reaction of the cationic additive and the organic materials are filtered prior to feeding to the crystallizer, this does not exhaust the foam control capability of the residual amine. However, the addition of the antifoaming agent directly to the second and third effect evaporators in a batch-wise manner may be reduced or even eliminated.
[0057] Although organo quaternary amines have been used as surfactants in the past to control foaming that occurs in the evaporator/crystallizer system the presence of the surfactants in the liquor, still containing organic materials, is thought to produce aliphatic carboxylic acids. And, although the exact reasons for the improved results in accordance with the present invention are not entirely understood, it is believed that it is these aliphatic organic acids negatively affect the carbonation step.
[0058] The present process permits removal of more of the objectionable organic impurities in the original liquor, and the reactivity of the soda ash product is enhanced. The present product has the reactivity of a much purer soda ash, and thus more organics can be tolerated in the sodium carbonate product obtained in accordance with the invention. Thus the present process is more tolerant of changes in organics content of the soda ash solutions, which may vary with their natural source.
[0059] Although the level of organics in the sodium carbonate solution in the evaporators may still be within the usual range or 200-300 ppm present in the feed stream after activated carbon treatment of the liquor, the use of the present cationic additives, in the required amounts, to the mother liquor prior to the filtration step, unexpectedly enhances the ability of the sodium carbonate to react with CO 2 in the carbonation step to form NaHCO3. This unexpected enhancement in productivity is about 290%. Further, foaming at the evaporator/crystallizer is controlled without increases in the addition rate, and the overall production cost for producing sodium bicarbonate from natural sources is not increased.
[0060] Using a no-pre-filtration antifoam addition to the evaporators, the uptake of CO 2 to form sodium bicarbonate is about 0.0075 mols/min. Using an activated carbon treated sodium carbonate solution, the uptake reached about 0.011 mols/min., more than an order of magnitude higher. Using a tallow-based amine as described in U.S. Pat. No. 6,270,740, uptake values averaged 0.012 mols/min. with peak values of 0.017 mols/min. uptake of carbon dioxide.
[0061] The soda ash produced using the process of the invention were further compared to results using various carbon filtering schemes; the more significant observations are summarized below:
[0062] a. The amine additive should be introduced continuously into the liquor stream, rather than added to the evaporator batchwise as is typically done in monohydrate processes for foam control. In accordance with the invention, values above 0.022 mols/min have been achieved when at least 40-70% of the amine additive is added to the liquor which is filtered prior to evaporation/crystallization.
[0063] b. At least 0.020 gallons of amine additive per ton of soda ash to be produced should be introduced into the virgin liquor to initiate the improvement found herein. It is preferred that between 0.020 and 0.040 gallons of amine additive per ton of soda ash to be produced be added. The amine should primarily be introduced prior to the filtration step, but the balance can be added to control evaporator foaming.
[0064] c. At least 0.010 gallons of amine additive per ton of soda ash to be produced should be introduced into other sodium carbonate-containing streams, i.e., non-virgin liquor streams, with the intent of recovering the sodium carbonate values therein using evaporation/crystallization processes such as the “monohydrate”, “decahydrate”, or “sodium bicarbonate” processes. It is preferred that the amine salt be added prior to a filtration step followed by the evaporation or crystallization. In processes where the sequence is evaporation/crystallization followed by melting of crystals for re-introduction as feed to a “monohydrate” or “sodium bicarbonate” process, it is important that at least 0.010 gallons of amine salt additive per ton of equivalent soda ash value in the recovered liquor be introduced into the liquor stream after the melting step and prior to a filtration step to initiate the improvement found herein. It is preferred that between 0.010 and 0.020 gallons of amine additive per ton of equivalent soda ash to be recovered be added.
[0065] d. At least 0.010 gallons of amine additive per ton of soda ash to be produced should be introduced into other sodium carbonate-containing streams with the intent of recovering the sodium carbonate values therein whereby further purification of the stream is achieved by filtering. It is preferred that the amine be added prior to a filtration step followed by the evaporation or crystallization. It is preferred that between 0.010 and 0.020 gallons of amine additive per ton of equivalent soda ash to be recovered be added.
[0066] When pre-filtration is not used, the reactivity for CO 2 adsorption in the sodium bicarbonate is only about 0.0075 mols/min. Using an activated carbon treated sodium carbonate solution, the uptake reached about 0.011 mols/min. Using a tallow-based quaternary amine salt added prior to filtration achieved an average 0.012 mols/min. with peak values reaching 0.017 mols/min. uptake for CO 2 . However, when using the system of the invention with a non-tallow based quaternary amine feed rate of 0.020-0.040 gallons per ton of soda ash produced with at least 40-70% of the total amine added introduced prior to filtration of the virgin liquor streams, increases averaged 0.022 mols/min. uptake of carbon dioxide were achieved.
[0067] Additionally, using the present process with a non-tallow based quaternary amine feed rate of 0.010-0.020 gallons per ton of soda ash recovered, the entire quantity being added to the sodium carbonate-containing stream introduced with the intent of recovering the sodium carbonate values therein, introduced prior to filtration of said sodium carbonate-containing streams followed by evaporation/crystallization, increases averaged 0.022 mols/min. uptake of carbon dioxide were achieved.
[0068] Also, using the present process with a non-tallow based quaternary amine feed rate of 0.010-0.020 gallons per ton of soda ash recovered, the entire quantity being added to the sodium carbonate-containing stream introduced with the intent of recovering the sodium carbonate values therein, where the process further purified said streams using filtration, introducing the amine prior to said filtration, achieved carbon dioxide uptakes averaging 0.022 mols/min.
[0069] Although the present invention has been described in terms of specific embodiments, variations apparent to one skilled in the art may be made without departing from the invention which should be limited only by the scope of the appended claims.
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n the manufacture of sodium carbonate having increased CO 2 uptakes the carbonation reaction to form sodium bicarbonate is enhanced by the addition of particular amounts of a cationic quaternary amine, selected from the family of dialkylethoxylated quaternary salts, benzylalkyl quaternary salts, or a combination of quaternary salts from these families, to treat the 25-30% by weight sodium carbonate liquor prior to filtration. The manufactured product yields a modified sodium carbonate liquor product that, when crystallized and converted to any anhydrous product, is more readily carbonated with CO 2 in the production of sodium bicarbonate. The cationic additive reacts with organic materials in the sodium carbonate liquor to form solid polymeric by-products. Thus the treatment with a cationic compound is made prior to filtering the liquor. After filtering to remove the polymeric by-products and other solid materials, the liquor is evaporated or crystallized to produce a purified and modified sodium carbonate. During evaporation, additional antifoam agent may be added to control foaming and insure the ability to re-use the generated condensate.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of provisional U.S. Patent Application Ser. No. 60/699,126, filed on Jul. 14, 2005.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
N/A
COPYRIGHT NOTICE
A portion of the disclosure of this patent 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 patent disclosure as it appears in the Patent and Trademark Office patent file or records, but otherwise reserves all copyrights rights whatsoever.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a screen-type storm barrier system for covering openings such as windows and doors. More particularly, the present invention relates to a heavy-duty screen assembly that is resistant to hurricane force winds and associated flying debris, burglars and vandals.
2. Description of Related Art
Over the past 20 years the United States has experienced numerous weather-related disasters each of which caused in excess of $1 billion in damages. In 2004, the State of Florida was subjected to direct hits from multiple hurricanes the combined effect of which resulted in damages of approximately 20 billion dollars.
In addition, population growth along the coastline of the United States has resulted in an increased risk to life and property from hurricane related damage. There are approximately 40 million permanent residents along the hurricane-prone coastline of the United States, with areas such as Texas, Florida, and the Carolinas, where hurricanes frequently strike, experiencing rapid population growth. Furthermore, many coastal areas experience substantial but temporary population increases from holiday, weekend, and vacation visitors during hurricane season.
Homes, buildings, and other structures, suffer substantial damage when storm generated winds carrying windborne debris penetrate the structures through window and door openings. Hurricane shutters have long been used as barriers to protect window and door openings from the effects of storm generated winds. Equipping homes and other buildings with hurricane protection in the form of storm shutters is one of the most prudent actions one can take to protect life and property.
Accordingly, the background art reveals a number of storm shutters and other devices designed for permanent or removable installation on homes and buildings. Conventional storm shutters typically consist of corrugated metal panels affixed to the outside of a given structure. For example, U.S. Pat. No. 2,878,536, issued to Becker, discloses a shutter structure having overlapping corrugated panels. U.S. Pat. No. 4,333,271, issued to DePaolo et al., discloses a hurricane panel system for covering windows and doors wherein a plurality of corrugated metal panels are arranged in overlapping relationship to provide a protective structure. U.S. Pat. No. 5,345,716, issued to Caplan, discloses a storm shutter system comprising a combination of individual, interlocking modular elements. U.S. Pat. No. 5,852,903, issued to Astrizky, discloses a hurricane shutter comprising a pair of normally open doors that are swingable to a closed position. U.S. Pat. No. 5,911,660, issued to Watson, discloses a storm panel comprising a plurality of interlocking tiles interlocked together by a plurality of dovetail joints.
A significant disadvantage with conventional storm shutter panels is that installation is difficult and time consuming. In addition, installing panels over all of the window openings prevents light from entering the structure thereby darkening the interior. Accordingly, if power is lost, as often happens during severe storms, the occupants of the structure find themselves in total darkness.
A number of references disclosed in the background art reveal attempts to provide storm shutters that provide sufficient impact resistance while allowing light to enter to building. For example, U.S. Pat. No. 5,918,430, issued to Rowland, discloses a removable storm shield comprising transparent convex panels. U.S. Pat. No. 5,996,292, issued to Hill et al., discloses a perforated shutter system wherein at least one panel is formed of corrugations. U.S. Pat. No. 3,358,408, issued to Cooper et al., discloses an insulated light transmitting panel construction having corrugations in the side edges thereof. U.S. Pat. No. 4,685,261, issued to Seaquist, discloses a removable translucent storm shutter consisting of a ½″ thick polycarbonate sheet in an aluminum channel frame. U.S. Pat. No. 5,595,233, issued to Gower, discloses hurricane shutters formed of transparent, double-skinned panels that are strengthened by rods extending through the end channels. U.S. Pat. No. 5,457,921, issued to Kostrzecha, discloses a storm shutter wherein a plurality of corrugated shatter-resistant and transparent plastic sheets fastened to the structure using a mounting mechanism and fasteners inserted through key-way slots.
The present inventor has contributed to the field of screen-type wind abatement systems for windows and doors. U.S. Pat. No. 6,263,949, issued to Guthrie (the present inventor), discloses a screen system for covering openings such as windows and doors includes a frame having a screen-mounting portion for receiving an edge of a screen and a retainer bar. The screen is sandwiched between the frame and the retainer bar and the assembly is of heavy-duty constriction to resist high impact forces caused by hurricane force winds and accompanying flying debris. The retainer bar and frame can include one or more barbs to assist in capturing the screen and resisting forces. The retainer bar is also designed to pivot during assembly to tightly draw the screen across the opening in the frame. U.S. Pat. No. 6,263,949, is incorporated herein in its entirety by reference.
The prior art, however, fails to disclose a screen-type wind abatement system having both the strength to protect window and door openings from high winds and wind-borne debris, while also being easy to install and remove, as well as being aesthetically pleasing. Accordingly, there exists a need for a screen-type wind abatement system capable of withstanding hurricane force winds while also being light-weight and easy to install and remove.
BRIEF SUMMARY OF THE INVENTION
A screen-type wind abatement system for covering openings such as windows and doors according to the present invention is provided in a first embodiment wherein the system is removable or openable, and in a second embodiment wherein the system is permanently anchored to a structure in covering relation with a window opening. The system may be affixed directly to the structure (e.g. wall) or fastened directly to the window or door frame.
In the first removable embodiment, the system generally includes a mounting frame member anchored to the structure wall, a screen mounting member for receiving an edge of a screen pivotally connected to the mounting frame member, a retainer member for securing the screen, a metal screen having edges sandwiched between the screen mounting member and the retainer member, and a snap-fit cover for concealing fasteners used to connect the retainer member to the first frame member, and a snap lock mechanism for locking the first frame member in a closed configuration.
In the second embodiment, the system generally includes a mounting frame member, having a screen receiving portion for receiving an edge of a screen, anchored to the structure wall, window frame, or door frame, a retainer member for securing the screen, a metal screen having edges sandwiched between the first frame member and retainer member, and a snap-fit cover for concealing fasteners used to connect the retainer member to the first frame member. Both embodiments are of heavy-duty construction to resist high impact forces caused by hurricane force winds and accompanying flying debris. The snap-lock mechanism allows for quick and simple installation and removal the screen mounting member. The retainer preferably has a generally U-shaped cross-section including a cross member connected between first and second laterally spaced apart legs. A fastener cover is also contemplated to be mounted to the retainer bar for improved aesthetics.
Accordingly, the present invention provides a heavy-duty screen that can resist hurricane force winds and associated flying debris. For example, the screen of the present invention can resist the force of a two-by-four stud of lumber propelled at the screen at a force comparable to that which would be encountered under hurricane wind conditions. The screen of the present invention is designed to always be in position to cover and protect a window or door and eliminates the need for timely user intervention as discussed in the background section above. Still further, the present invention provides improved aesthetics for year round use and utilizes stainless steel to prevent corrosion that is typically encountered in coastal locations near an ocean where hurricanes commonly prevail. The screen system also protects against insects and vandals.
In accordance with these and other objects, which will become apparent hereinafter, the instant invention will now be described with particular reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 is a front view of an openable section of a screen-type wind abatement system according to the present invention;
FIG. 2 is a front view thereof with the screen removed and the retainer fasteners shown in an exploded view;
FIG. 3 is a side sectional view of the system in relation to the exterior of a structure;
FIG. 4 is a top sectional view of thereof showing the openable system in the closed configuration in normal view and the open configuration in phantom view;
FIG. 5 is an exploded view of the screen retaining portions of the system;
FIG. 6 is a side sectional view of the system adapted for direct anchoring to a structure in a non-openable installation;
FIG. 7 is a top sectional view thereof;
FIG. 8 is a sectional view of a frame member;
FIGS. 9 and 10 depict frame corner connections;
FIG. 11 depicts alternate embodiment openable system adapted for exterior un-latching of the openable screen frame; and
FIG. 12 depicts an alternate exterior end configuration for the embodiment depicted in FIG. 11 .
DETAILED DESCRIPTION OF THE INVENTION
With reference now to the drawings, FIGS. 1-4 , depict an openable screen-type wind abatement system, generally referenced as 10 , for covering openings such as windows and doors in accordance with the present invention. As best depicted in FIGS. 3 and 4 , screen-type wind abatement system 10 includes a first frame member 20 anchored to the structure wall, or alternatively to a window or door frame, a second frame member 30 having a screen mounting portion for receiving an edge of a screen 40 , a retainer member 50 for securing the screen, and a snap-on cover 60 for concealing fasteners. First frame member 20 may further be attached to an aluminum mounting frame, referenced as 21 , that has previously been affixed to the structure. The system provides an openable mounting system whereby a heavy duty screen 40 is in covering relation with a window or door opening. The assembly is preferably fabricated of extruded aluminum of sufficient heavy-duty construction to resist high impact forces caused by hurricane force winds and accompanying flying debris.
First frame member 20 preferably typically includes four frame members, namely left, right, top and bottom, connected at right angle corner connections using key members 14 internally inserted therein to secure the first frame members by press fit connection. Each frame member 20 includes a generally U-shaped base 22 for receiving a fastener 12 to secure the frame member to a structure. In addition, each frame member 20 defines a key receiving slot 24 , a projecting support arm 26 , and an arcuate portion 28 . Key receiving slot 24 receives an internal key member 14 to facilitate a secure corner-to-corner connection. Projecting arm 26 functions to provide a back-stop for engaging second frame member as discussed below.
As best seen in the sectional views of FIGS. 3-5 , second frame member 30 preferably typically includes four frame members, namely left, right, top, and bottom, connected at right angle corner connections using key members 16 and 17 internally inserted therein to secure the second frame members in a generally square or rectangular configuration by press fit connection. Each frame member 30 includes a generally square main body 32 having a projecting arm defining a screen receiving external surface 34 , and an internal key receiving slot 36 . Screen receiving external surface 34 defines first and second surfaces, referenced as 34 A and 34 B, forming a right angled surface for receiving an edge portion of a screen 40 in abutting contact therewith as best depicted in FIGS. 3 and 4 .
Screen 40 is anchored to frame member 30 , and particularly to external surface 34 by a retainer 50 having a saw-tooth shaped bottom surface 52 for engaging and anchoring screen 40 in a sandwiched configuration disposed between retainer bottom surface 52 and surface 34 A of frame member 30 . Retainer 50 is fixedly connected to frame member 30 by a plurality of fasteners as shown in FIG. 2 . The saw-tooth bottom surface 52 functions to securely anchor screen 40 such that the screen will withstand impact from windborne debris. As should be apparent, the shape retainer 50 and/or bottom surface 52 may be varied within the scope of the invention provided screen 40 is firmly anchored.
A screen assembly, is thus fabricated about an opening by first fabricating and affixing a mounting frame to the structure by connecting four first frame members 20 , namely left, right, top and bottom members, and securing the members to form an integral frame by insertion of key members 14 received within internal slots 24 . The integral frame formed by frame members 20 is then anchored to the wall of a structure in surrounding relation with an opening, such as a window or door, using suitable fasteners 12 connected to the structure through base 22 . Alternatively, the frame may be affixed directly to the frame of a window or door. Next a wind screen assembly is fabricated to a suitable size for mating with frame members 20 , by connecting four members 30 , namely left, right, top and bottom, secured at corners by key members 16 received within slots 36 . Key members 16 are preferably insertedly received within the mitered corner portions of members 30 and secured by peening from the exterior thereof. It has been found that connecting members 30 using key members 16 secured by peen punch provides an efficient and structurally secure connection. A screen 40 of suitable size is fitted within the frame assembly with the edges positioned in abutting engagement with surfaces 34 A and 34 B, whereafter the screen is secured by retainers 50 fixed by threaded fasteners 53 .
The frame assembly is further adapted on one side with a hinge member 70 for pivotal connection to arcuate portion 28 of mounting frame member 20 as best depicted in FIG. 4 . In addition, the opposite side is adapted with a snap-lock mechanism, generally referenced as 80 , including a mounting plate 82 affixed to frame member 30 , and a locking lever 84 pivotally connected thereto. Locking lever 84 operates by engaging projecting support arm 26 on a side frame member 20 to secure the frame and screen assembly in a closed position. Locking lever 84 may be manually disengaged to allow the frame and screen assembly to pivot outward and away from the structure to an open configuration.
FIG. 11 depicts an alternate embodiment wherein the frame assembly is further adapted with an a locking lever actuator 90 insertedly received, and movably disposed, within an aperture defined within frame member 30 , mounting plate 82 , and locking lever 84 . Lever actuator 90 includes a first end 92 disposed on the interior side of frame 30 and a second end 94 disposed on the exterior side of frame 30 . The first end 92 of lever actuator 90 is preferably threaded and includes an end cap 93 affixed to the end thereof, and a threaded nut 95 and washer 96 disposed between lever 84 and mounting plate 82 as best depicted in FIG. 11 . As should be apparent, actuator 90 functions to allow for exterior actuation of locking lever 84 . More particularly, locking lever 84 may be actuated from a locked configuration to an unlocked configuration (as seen in FIG. 11 ) from the exterior by grasping lever actuator 90 by the second end 94 and applying a force away from frame member 30 such that end cap 93 engages lever 84 and moves the lever to disengage arm 26 of frame member 20 . In addition, threaded nut 95 functions to selectively disable lever actuator 90 by rotation thereof such that nut 95 and washer 96 engage mounting plate 82 thereby preventing movement of actuator 90 and particularly end cap 93 in a manner that would cause disengagement of lever 84 from the locked configuration. FIG. 12 depicts an alternate embodiment lever actuator 97 having multiple actuating legs, referenced as 97 A and 97 B.
Accordingly, the present invention provides a heavy-duty screen that can resist hurricane force winds and associated flying debris. For example, the screen of the present invention can resist the force of a two-by-four stud of lumber propelled at the screen at a force comparable to the force encountered under hurricane wind conditions. The screen of the present invention is designed to always be in position to cover and protect a window or door and eliminates the need for timely user intervention as discussed in the background section above. Still further, the present invention provides improved aesthetics for year round use and utilizes stainless steel to prevent corrosion that is typically encountered in coastal locations near an ocean where hurricanes commonly prevail. More particularly, screen 40 is preferably a powder coated stainless steel mesh screen having meshed wire in the range of 0.018″-0.064″ diameter. An impact resistant screen in accordance with the present invention having 12″×12″ stainless steel screen with mesh size of 0.028″ and 0.032″ has been tested an approved in accordance with the Large and Small Missile Impact Rating of Dade County, Fla. As should be apparent, the screen system also protects against insects, and vandals due to the strength. An additional benefit of using a stainless steel mesh that has been powder coated with a dark color (such as black) is a substantial reduction of approximately 95% of the solar load transmitted to a structure through a window opening thereby resulting in substantial energy savings. As a result, an impact resistant screen system in accordance with the present invention has been recognized for by the United States Department of Energy as reducing energy consumption through the reduction of solar transmission through windows.
FIGS. 6-8 depict an alternate embodiment screen-type wind abatement system, generally referenced as 100 , adapted for permanent/non-openable installation on a structure in surrounding relation with a window or door opening, or alternatively for affixation directly to the a window frame or door frame. Accordingly, the present invention specifically contemplates a window system having an impact resistant screen integrally fabricated therewith. Wind abatement system 100 is formed by connection of four frame members 110 , namely left, right, top, and bottom, to form a generally square or rectangular frame assembly. Frame members 110 are affixed by insertion of key members 16 within internal slots 118 defined within each frame member. As should be apparent any suitable shaped frame assembly, however, is considered within the scope of the present invention. Each frame member 110 includes a generally planar rear surface 112 , terminating in a generally U-shaped projecting channel 114 for receiving a threaded fastener 102 for anchoring the frame member to a wall, a previously installed mounting frame 21 (as seen in FIGS. 3 and 4 ) or another part of the structure. A snap-on cover 60 may be installed within the U-shaped channel to conceal the fastener heads. Frame member 110 further includes a right-angled surface 116 for receiving the edge of a screen 40 in abutting relation therewith. Screen 40 is secured by a retainer 50 affixed to frame member 110 in engagement with surface 116 by fasteners 102 . A snap-on cap 60 is preferably affixed to retainer 50 to conceal the fasteners as best depicted in FIG. 6 . As should be apparent, anchoring frame members 110 directly to the structure using fasteners. FIGS. 9 and 10 illustrate the use of keys to form corner connections for affixing frame members to form a frame assembly.
The present invention that provides an impact resistant screen-type storm barrier that is Dade County/Florida Building Protocol Approved, certified by the Florida Energy Office on behalf of the United States Department of Energy for reducing energy consumption, while enhancing security by providing a burglar resistant barrier.
The instant invention has been shown and described herein in what is considered to be the most practical and preferred embodiment. It is recognized, however, that departures may be made therefrom within the scope of the invention and that obvious modifications will occur to a person skilled in the art.
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A screen-type wind abatement system is provided for protecting openings, such as window and door openings, in buildings and other structures. Both openable and non-openable systems are disclosed. A openable system includes a first frame member anchored to the structure wall, a second frame member pivotally connected to the first frame member and having a screen mounting portion for receiving an edge of a screen and a retainer, and a snap-lock mechanism for removably connecting the first and second frame members, whereby the screen is sandwiched between the second frame and the retainer in covering relation with a window or door opening. The assembly is of heavy-duty construction to resist high impact forces caused by hurricane force winds and accompanying flying debris. The snap-lock mechanism allows for quick and simple installation and removal the second frame member. A fixed system is disclosed for non-openable installations.
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BACKGROUND OF THE INVENTION
This invention relates mainly to a protective device for storage and transport containers. This invention also relates to an associated method for use in protecting contents of storage and transport containers.
A long standing problem in the shipping industry is damage to shipped goods. Containers holding fragile items are universally labeled with warnings such as "fragile" and "this side up." Despite such precautions, packages are nevertheless frequently subjected to treatment which damages their contents.
Besides impacts and misorientation, packages are sometimes subjected to other inordinately extreme conditions such as very low temperatures and severe jostling or shaking.
OBJECTS OF THE INVENTION
An object of the present invention is to provide a device attachable to a shipping container for aid in alleviating at least one of the above-mentioned conditions.
Another, more particular, object of the present invention is to provide such a device which assists in reducing the incidence of misorientation of packages during shipment and storage.
A further object of the present invention is to provide a device which can be used, for instance, by the insurance industry to at least partially determine treatment of a package during shipment.
Yet another object of the present invention is to provide an associated method for reducing the incidence of misorientation of packages during shipment and storage.
These and other objects of the present invention will be apparent from the drawings and detailed descriptions herein.
SUMMARY OF THE INVENTION
A protective device for storage and transport containers comprises, in accordance with the present invention, a sensor for detecting a physical condition of a predetermined kind and an attachment or connector for securing the sensor to a container. A timer is operatively connected to the sensor for determining that the detected physical condition has continued longer than a preselected duration. A wireless telecommunications transmitter is operatively connected to the timer for establishing a wireless telecommunications link to a predetermined remote receiver and transmitting, over the link to the receiver, a message that the detected physical condition has existed longer than the predetermined duration.
Where the physical condition is orientation of the container, the sensor includes components for detecting that the container is in an orientation other than a predetermined preferred orientation.
According to another feature of the present invention, the device further comprises a timing element operatively connected to the sensor for measuring a time interval during which the container is in an orientation other than the preferred orientation. A memory is operatively connected to the timing element for automatically storing the time interval in encoded form.
In addition, the device may further comprise a locking component operatively connected to the timing element and the memory for deactivating the timing element and for locking the memory to ensure integrity of contents of the memory upon an opening of the container.
Where the physical condition is temperature, the sensor includes means for detecting that the container has a temperature beyond a predetermined threshold. A timing element may be operatively connected to the sensor for measuring a time period during which the container is in a temperature range beyond the threshold, a memory being operatively connected to the timing element for automatically storing the time period in encoded form.
The storage of data on the periods of inappropriate conditions of the container provides a check on the care taken by the shipper. The device can be returned to the manufacturer for determining the shipment history with regard to the orientation of the container and its contents. This shipment history information is valuable to insurers (including the manufacturer under warranty) for allocating responsibility and liability.
The mechanism and/or circuit operatively connected to the timing element and the memory for deactivating the timing element and for locking the memory to ensure integrity of contents of the memory upon an opening of the container may include a switch or circuit tied to the lid of the container, e.g., via a string, wire or thread.
This feature of the invention serves to prevent a shipper from removing the device from a shipping container and reprogramming the memory before the device is returned to the manufacturer. Generally, it is contemplated that the buyer or other receiver of the shipped goods removes the protective device and returns it to the manufacturer. Of course, the sensor may also be deactivated so that it is inoperative during the return trip to the manufacturer. The memory also contains a recording of the time that the container was opened. If opening occurs prior to receipt by the customer, then a legal cause of action against the shipper may be entertained.
A method for use in protecting contents of storage and transport containers comprises, in accordance with the present invention, automatically and at least periodically monitoring a storage and transport container with fragile contents to detect whether the container has a pre-established physical condition. In the event that the container has the pre-established physical condition, it is automatically determined whether the container has had the pre-established physical condition for a time interval longer than a preselected duration. Upon determining that the container has had the pre-established physical condition for a time interval longer than the preselected duration, a wireless telecommunications link is established to a predetermined remote receiver. Upon the establishing of the link, a message is transmitted over the link to the receiver, the message informing that the container has had the pre-established physical condition for a time interval longer than the preselected duration.
Where the physical condition is an orientation other than a predetermined preferred orientation, the monitoring of the container includes detecting that the container is in an orientation other than the preferred orientation. Optional steps of the method are automatically measuring a time interval during which the container is in an orientation other than the preferred orientation and automatically storing the time interval in encoded form in a memory. The memory is preferably locked to ensure integrity of contents of the memory upon an opening of the container.
Wherein the physical condition is a temperature beyond a predetermined threshold, the monitoring of the container includes detecting that the container has a temperature in a range beyond the predetermined threshold. In that case, optional steps of the method include measuring a time period during which the container is in a temperature range beyond the threshold and automatically storing the time period in encoded form in a memory.
According to another feature of the present invention, the method includes automatically generating an alarm signal cognizable within a region about the container, upon detecting that the container has the pre-established physical condition. The generating of the alarm signal may include producing a sound wave via an electroacoustic transducer. The step of producing a sound wave may include the step of producing a voice message such as "Please straighten me out" or "Attention, attention, turn this box upright."
If perishable food or temperature sensitive equipment is being shipped in the container, an alarm sounds when the temperature of the container rises beyond a predetermined maximum. If living organisms are being shipped, then an alarm will sound if the temperature of the container falls below a pre-established minimum.
A device in accordance with the present invention provides an alarm signal to a remote location via a wireless telephone link in the event that a container with valuable contents is subjected to an undesirable and possibly damaging physical condition for longer than a prescribed period. Thus, the shipper, the addressee or other concerned party can take steps to trace the location or the container and/or alert responsible parties to rectify the undesirable situation. This procedure is in addition to providing a stimulus or reminder to shipping personnel at or about the location of the container to correct an unwanted condition of the container and its contents. Thus, the present invention serves as a supplement to the device and method described and claimed in U.S. Pat. No. 5,528,228.
The present invention is useful, for instance, where a container is placed in a cargo hold or other storage location which is not easily accessed by shipping, handling, or caretaker personnel. In such situations, even though an alarm may continue to be generated at the container for a substantial interval, the shipping, handling, or caretaker personnel may not be cognizant of the errant condition.
Other conditions of a container during shipment may be monitored and recorded. For example, the size and frequency of impacts may be monitored by a strain gauge network embedded in a flexible or resilient matrix and connected to an inertial mass also embedded in the matrix. The strain gauges are operatively connected to a monitoring circuit including a timer and a memory.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a schematic perspective view, on a reduced scale, of a protective device for storage and transport containers, showing disposition of the device in a shipping container, in accordance with the present invention.
FIG. 2 is a block diagram of selected functional components of the protective device of FIG. 1.
FIG. 3 is a block diagram of additional components optionally utilizable in the device of FIGS. 1 and 2.
FIG. 4 is a schematic perspective view of a composite impact sensor utilizable in a device in accordance with the present invention.
FIG. 5 is a block diagram of other components of the protective device of FIGS. 1 and 2, in accordance with the present invention.
DETAILED DESCRIPTION
As shown in FIG. 1, a protective device 10 for monitoring shipping conditions undergone by a storage and transport container 12 includes a housing or casing 14 attached via an adhesive layer 16, bolts (not shown) or other fastening elements to a side panel 18 of container 12.
As illustrated in FIG. 2, protective device 10 comprises a sensor 20 for detecting orientation and alarm componentry 22 operatively coupled to the sensor for generating a cognizable alert signal upon detection by the sensor that the container is in an orientation other than a predetermined preferred orientation. Sensor 20 may incorporate a gravity switch (not separately shown) for detecting when container 12 is not in an upright orientation.
Alarm componentry 22 includes an electroacoustic transducer 24 and a solid state memory 26. Memory 26 stores at least one digitally encoded voice message such as "Box not in correct orientation," "Please place container in upright position," "I am on my side; please stand me up." Upon receiving an activation signal from sensor 20 via an AND gate 28, memory 26 transmits the digitally encoded warning or command to a speech synthesis unit 30. Speech synthesis unit 30 converts the digitally encoded voice message from memory 26 into an analog signal which is fed to an electro-acoustic transducer 24 for acoustic reproduction.
Memory 26 and speech synthesis unit 30 may be replaced with an equivalent combination of elements such as a recording tape (not shown) and an audio playback unit (not shown).
The alarm componentry 22 of protective device 10 provides a stimulus or reminder to shipping personnel to right a misoriented package. Generally, it is contemplated that the alarm continues to sound until the container is placed in its preferred orientation.
As further illustrated in FIG. 2, device 10 also comprises a timer 34 including a time base 36 and a counter 38. Time base 36 generates a clock signal which is fed to an incrementing input 40 of counter 38 for measuring a time interval during which container 12 is in an orientation other than the upright orientation. The contents of counter 38 are incremented by the clock signal from time base 36 as long as an enabling input 42 of counter 38 is provided with a high logic signal. Counter input 42 is operatively connected to orientation sensor 20 via AND gate 28. Thus, counter 38 continues to measure time as long as orientation sensor 20 detects a misorientation of container 12 and as long as a de-activation switch 44 is transmitting a high logic signal to AND gate 28. Switch 44 changes its output to a low logic signal only upon the opening of container 12. To that end, switch 44 is connected to a lid 46 of container 12 via a wire 48 (FIG. 1).
Orientation sensor 20 is connected to a resetting input 50 of counter 38 and to an enabling input of a buffer register 52 via an inverter 54. Upon the righting of container 12 and a consequent reversion of the output of orientation sensor 20 to a low logic level from a high logic level, a high level logic signal from inverter 54 causes the contents of counter 38 to be transferred to buffer register 52 and induces the resetting of counter 38.
Inverter 54 is also connected to an incrementing input of a counter 56 which acts as an addressing and writing control for a solid state random access memory 58. Upon the incrementing of the contents of counter 56, the encoded time interval stored in buffer register 52 is transferred to an address location in memory 58 specified by the updated contents of counter 56. The time at which the loading of the encoded time interval into memory 58 occurs may also be stored in memory 58. This time is loaded from time base 36.
Thus, memory 58 contains an account or record of the intervals of misorientation of container 12. This record is terminated upon the opening of lid 46 and the consequent transmission of a low logic level disabling signal from switch 44 to AND gate 28. This disabling or deactivation signal effectively serves to lock memory 58.
Switch 44 may also be connected to time base 36 and at least indirectly to memory 58 for storing the time at which the container is opened. This time should correspond to the arrival of the container at the customer's location.
The contents of memory 58 enable a manufacturer to check on the care taken by a shipper or carrier. Device 10 can be returned to the manufacturer for determining the shipment history with regard to the orientation of the container and its contents. This shipment history information may be used by insurers for allocating responsibility and liability.
As additionally illustrated in FIG. 2, device 10 further comprises a detector or sensor 60 for measuring temperature. Alarm componentry 22 is operatively connected to temperature sensor 60 for generating a cognizable indicator signal upon measurement of a temperature beyond a pre-established threshold. To implement that function, sensor 60 is connected at an output to a pair of comparators 62 and 64 which may be analog elements such as operational amplifiers. Upon a falling of the temperature of container 12 below a predetermined minimum threshold (encoded in an input signal 66 to comparator 62), comparator 62 generates a signal of a high logic level which is fed to an AND gate 68. Provided that switch 44 is not generating a disabling signal, AND gate 68 passes the high logic level signal from comparator 62 on to a solid state memory 70. Memory 70 is enabled by that high logic level signal to transmit a digitally encoded voice message to speech synthesis unit 30. The message may be, for example, the words "I am too cold; please turn up the heat," or "Temperature below minimum limit; please reset temperature."
AND gate 68 is also connected to an enabling input 72 of a counter 74 which has an incrementing input 76 connected to time base 36 for receiving the clock signal output thereof. Counter 74 has an output connected to a buffer register 78 for loading a measured time interval into the buffer register upon the detection by sensor 60 of a decrease in temperature beyond the pre-established minimum. Sensor 60 is connected to an enabling or writing input of buffer register 78 via an inverter 80, as well as via comparator 62 and AND gate 68. Upon the appearance of a high logic level signal at the output of inverter 80, the contents of counter 74 are transferred to register 78 and the counter is reset. In addition, inverter 80 is coupled to an address counter 82 which controls the location in a memory 84 at which the time interval from register 78 is stored. Memory 84 may also be connected to time base 36 for recording the time at which the interval of reduced temperature occurred.
As also illustrated in FIG. 2, comparator 64 is connected to an AND gate 86 which also receives an enabling signal from switch 44. Upon detecting a rise in temperature of container 12 beyond a maximum encoded in a signal 88, comparator 64 issues a high logic level signal to AND gate 86. Provided that switch 44 is not generating a disabling signal due to the opening of lid 46 (FIG. 1), a high level logic signal is transmitted from AND gate 86 to a voice message memory 90 for inducing that circuit element to transmit a digitally encoded voice message to speech synthesis unit 30. The message may be, for example, the words "I am too hot; please turn down the heat," or "Temperature above maximum limit; please reset temperature."
The high logic level signal from AND gate 86 may also be transmitted to a high temperature history monitoring circuit 92 including elements structurally identical to the elements of a low temperature history monitoring circuit 94. Those elements include counter 74, register 78, inverter 80, counter 82, and memory 84. Monitoring circuit 94 thus memorizes the durations of the time intervals during which container 12 experienced excessively low temperatures.
As depicted in FIG. 3, device 10 may additionally comprise a plurality of impact sensors 96, 98 and 100 for detecting the sizes of impacts experienced by container 12 during shipment. As indicated in FIG. 4, sensors 96, 98 and 100 may take the form of respective strain gauges operatively connected to an inertial mass 102 and disposed together with the mass in a flexible or resilient medium 104 such as rubber.
As further depicted in FIG. 3, sensors 96, 98, and 100 are operatively connected to respective operational amplifiers or analog comparators 106, 108, and 110 which compare the outputs of the sensors with preset limits represented by signal inputs 112, 114, and 116. Sensors 96, 98, and 100 are also connected at their outputs to respective analog-to-digital converters 118, 120, and 122 which in turn are connected at their outputs to respective memories 124, 126, and 128. The digital output signals of converters 118, 120, and 122 are stored in memories 124, 126, and 128 at addresses determined by the contents of respective address counters 130, 132, and 134. The contents of counters 130, 132, and 134 are incremented upon the appearance of a high level logic signal at the outputs of operational amplifiers 106, 108, and 110.
Counters 130, 132, and 134 also control the writing process in memories 124, 126, and 128. Counters 130, 132, and 134 are disabled by a low-level logic signal from switch 44 upon the opening of container 12. This disabling prevents the writing of further impact information into memories 124, 126, and 128 and effectively locks the memories from erasure or further writing.
Time base 36 may be operatively connected to memories 124, 126, and 128 so that the times of the different impacts may be recorded.
FIG. 5 depicts components of protective device 10 (FIGS. 1 and 2) for generating an alarm or a message at a remote location when container 12 (and the contents thereof) has had a physical condition of a prescribed type for longer than a predetermined period. If that condition lasts for an extended period, damage may result to the contents of the container. Generally, the components of FIG. 5 serve as a back-up where an alarm generated at the container 12 has been ineffective to induce shipping, handling or caretaker personnel to rectify the undesired physical condition.
Counter 40 (FIG. 2) is connected at an output to a comparator 136 which has a second input 138 to which a signal representing a pre-established time interval is applied. Comparator 136 is coupled at an output to a telephone signal generator 140 of a type common in cellular telephones. Signal generator 140 produces a preprogrammed telephone signal which is amplified and otherwise prepared for long-distance transmission by a transmitter 142. The telephone signal from transmitter 142 is transmitted to a remote telephone station or computer via an antenna 144. The emitted signal 146, like conventional cellular telephone signals, may be reflected or relayed by a satellite.
Antenna 144 or, alternatively, a dedicated receiving antenna 148 picks up a confirmation signal 150 from the remote station. Confirmation signal 150 is detected by a receiver 152 which generates an enabling signal fed to a buffer register 154 for inducing the transmission of the contents of the buffer register to the remote telephone station or computer via transmitter 142 and antenna 144.
Comparator 136 has a second output which addresses a memory 156 to read out, to buffer register 154, a message that container 12 has been disposed in an undesired orientation for longer than the pre-established time interval encoded at the reference input 138 of comparator 136. This message preferably includes an identification of the particular container (and its contents), as well as a code for the type of undesired physical condition (misorientation), and may additionally identify the destination of the container and encode the duration of the undesired physical condition.
Emitted telephone signal 146 may be used by conventional triangulation or tracking technology to determine the precise geographic location of container 12. This geographic information may be useful in determining who is responsible for container 12, for example, where container 12 is transported by multiple shippers in seriatim.
As shown in FIG. 5, counter 72 (FIG. 2) is connected at an output to a comparator 158 which has an input 160 receiving a reference signal encoding a pre-established time interval. Upon determining that the output of counter 72 is equal to that pre-established time interval, comparator 158 issues a trigger signal to telephone signal generator 140 and a respective address signal to memory 156. In response to the address signal, memory 156 feeds to buffer register 154 a previously stored message. The message informs a person or computer at the remote telephone station that container 12 has had, for a time longer than the pre-established time interval encoded at the reference input 160 of comparator 158, a temperature lower than the predetermined minimum threshold encoded in the input signal 66 to comparator 62 (FIG. 2). This message includes an identification of the particular container (and its contents), as well as a code for the type of undesired physical condition (low temperature), and may additionally identify the destination of the container and encode the duration of the low temperature.
As further shown in FIG. 5, high-temperature history monitor 92 (FIG. 2) is connected at an output to a comparator 162 which has an input 164 receiving a reference signal encoding a pre-established time interval. Comparator 162 determines whether container 12 (and its contents) has had an impermissibly high temperature for longer than that pre-established time interval. If so, comparator 162 issues a trigger signal to telephone signal generator 140 and a respective address signal to memory 156. The trigger signal initiates the establishing of a long-distance telecommunications link, while the address signal induces memory 156 feeds to buffer register 154 a predetermined message. The message informs a person or computer at the remote telephone station that container 12 has had, for a time longer than the pre-established time interval encoded at the reference input 164 of comparator 158, a temperature higher than a predetermined maximum threshold.
It is to be noted that various refinements and optional capabilities may be provided for the functions described hereinabove with reference to FIG. 5. For example, history information pertaining to container 12 may be transmitted wirelessly via transmitter 142 and antenna 144, either upon the occurrence of an alarm condition, or periodically. Back-up telephone signalling codes may be provided in telephone signal generator 140, in the event that the first telephone station is busy. Alternatively, an automatic redialing feature may be provided.
Although the invention has been described in terms of particular embodiments and applications, one of ordinary skill in the art, in light of this teaching, can generate additional embodiments and modifications without departing from the spirit of or exceeding the scope of the claimed invention. It is to be noted, for instance, that the recording of time intervals of unsafe storage or shipping conditions may be implemented merely by storing the times that the intervals begin and the times at which they end. The durations may be computed subsequently from the time data.
Accordingly, it is to be understood that the drawings and descriptions herein are profferred by way of example to facilitate comprehension of the invention and should not be construed to limit the scope thereof.
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A protective method for storage and transport containers comprises a sensor for detecting orientation, an attachment element for securing the sensor to a container, and an alarm operatively coupled to the sensor for generating a cognizable alert signal upon detection by the sensor that the container is in an orientation other than a predetermined preferred orientation. The alarm may include an electroacoustic transducer and means for reproducing a voice message. A timer operatively connected to the sensor measures a time interval during which the container is in an orientation other than the preferred orientation. A memory is operatively connected to the timer for automatically storing the time interval in encoded form. A mechanism and/or circuit may be operatively connected to the timer and the memory for deactivating the timer and for locking the memory to ensure integrity of contents of the memory upon an opening of the container. The method may also include a detector for measuring temperature. The alarm is operatively connected to the detector for generating a cognizable indicator signal upon measurement of a temperature beyond a pre-established threshold. The timer is operatively connected to the temperature detector for measuring a time period during which the container is in a temperature range beyond the threshold, while the memory is operatively connected to the timer for automatically storing the time period in encoded form.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a semiconductor device, a process for producing the same, a carrier substrate and a process for producing the same.
2. Description of the Related Art
As small-sized electronic equipments, such as mobile phones or others, have been come into wide use, there has been a demand for minimizing the size and cutting the production cost of semiconductor devices to be installed in such electronic equipments. A conventional semiconductor device, wherein a semiconductor chip mounted onto a lead frame is resin-shielded, has a problem in that an area extending between inner and outer leads or a mounting area is relatively large. Further, in a BGA (ball grid array) type semiconductor device, there is another problem in that the production cost is high because it necessitates a substrate for mounting a semiconductor chip.
To minimize a size of a semiconductor device and to reduce a mounting area therefor, as well as to cut the production cost, a semiconductor device has been proposed, for example, in Japanese Unexamined Patent Publication (Kokai) No. 9-162348. The semiconductor device disclosed in Kokai No. 9-162348 includes a semiconductor chip mounted onto a chip-cementing resin, a resin package in which the semiconductor chip is shielded with epoxy resin, and a metallic film covering a resinous projection formed on a mounting surface of the resin package, which metallic film is electrically connected to an electrode section of the semiconductor chip by wire-bonding. This semiconductor device is advantageous in that inner and outer leads are unnecessary, contrary to the case wherein a lead frame is used, no substrate is necessary for mounting the semiconductor chip as in the BGA type packages, and the metallic film facilitates heat dissipation as well as eases the mounting operation of the chip onto the substrate because the metallic film has the same function as the connector terminals.
In the above-mentioned semiconductor device of a type wherein a high-frequency semiconductor chip is mounted, the mounting part metallic film on which the semiconductor chip is mounted is preferably used as a ground terminal for preventing noise from entering so that the electric properties are stabilized. Accordingly, it is necessary to electrically connect the ground terminal to the mounting part metallic film.
For example, in a semiconductor device 51 shown in FIG. 6, a mounting part metallic film 53 on which a semiconductor chip 52 is mounted and a connector part metallic film 54 electrically connected to the semiconductor chip 52 are partially extended at the side of the mounting surface. A ground connector part 55 is extended outward from a peripheral edge of the mounting part metallic film 53 . A ground electrode of the semiconductor chip 52 and the ground connector part 55 are electrically connected to each other with a wire 56 , and a signal electrode and the connector part metallic film 54 are electrically connected to each other with a wire 58 .
To design the mounting part metallic film 53 as compactly as possible and to make a length of the wire 56 as short as possible, the ground connector part 55 is preferably provided as close as possible to the semiconductor chip 52 . Thereby, there has been a demand for forming the mounting part metallic film 53 in a stepwise configuration. For forming the mounting part metallic film 53 in a stepwise configuration, a process for producing a carrier substrate for the production of the semiconductor device 51 will be described with reference to FIGS. 7 ( a ) to 7 ( h ), 8 ( a ) and 8 ( b ). In this regard, a process for forming the mounting part metallic film 53 will mainly be explained, while avoiding the illustration of the connector part metallic film 54 in FIGS. 7 ( a ) to 7 ( b ).
In FIG. 7 ( a ), an etching resist (photosensitive resist) 61 is coated on the respective surfaces of a metallic substrate 60 , such as a copper plate. Then, as shown in FIG. 7 ( b ), the exposure and development are carried out while overlaying a photo-mask on the etching resist to result in a pattern 62 having a central vacant space of a required size (see FIG. 8 ( a )). Thereafter, as shown in FIG. 7 ( c ), a first half etching is carried out (to remove approximately a quarter of the thickness of the metallic plate 60 ) so that a connector recess 63 is formed. In this regard, when the metallic plate 60 is a copper plate, ferric chloride is preferably used as the etching liquid. Subsequently, in FIG. 7 ( d ), the etching resist 61 is stripped off to result in the connector recess 63 in the metallic substrate 60 .
In FIG. 7 ( e ), an etching resist (photosensitive resist) 61 is again coated on the metallic substrate 60 on which the connector recess 63 has been formed, and the exposure and development are carried out while overlaying a photo-mask on the etching resist in alignment therewith to result in a pattern 64 having a central vacant space of a required size (see FIG. 8 ( b )). Then, a second half etching is carried out (to remove an approximately quarter of a thickness of the metallic substrate 60 ) in FIG. 7 ( f ) so that a mounting recess 65 is formed. Next, in FIG. 7 ( g ), the etching resist 61 is stripped off to form the connector recess 63 and the mounting recess 65 having different thicknesses from each other in a stepwise configuration. In this regard, an area and a thickness of the half etching are freely adjustable by changing the design of the central vacant space pattern in the photo-mask.
Next, in FIG. 7 ( h ), a multi-layered metallic film is formed, while coating the remainder of the metallic substrate 60 other than the connector recess 63 and the mounting recess 65 with a resist, not shown, by the electrolytic plating, vapor deposition or sputtering. Thus a carrier substrate 66 on which the mounting part metallic film 53 is formed in a stepwise configuration.
The repetition of the steps of coating the etching resist 61 onto the metallic substrate 60 and half-etching the same after being exposed and developed complicates the production process to increase the production cost. To form the first central vacant pattern 62 and the second central vacant pattern 64 of different sizes at a position aligned with each other, a highly accurate alignment is required, which causes the generation of many rejected products to lower the yield.
SUMMARY OF THE INVENTION
Accordingly, an object of the present invention is to provide a semiconductor device capable of being mass-produced at a low cost, a method for producing the same, a carrier substrate used therefor and a method for producing the same by solving the above-mentioned problems in the prior art to simplify the manufacturing process.
According to the present invention, there is provided a semiconductor device comprising: a semiconductor element having at least one signal electrode and at least one ground electrode; a mounting part metallic film having a bottom area on which the semiconductor element is mounted and a stepped area located at a periphery of the bottom area and being higher in horizontal level than the bottom area; a connector part metallic film spaced from the mounting part metallic film and arranged at a peripheral region thereof; electrical connecting means for electrically connecting the signal electrode of the semiconductor element to the connector part metallic film and connecting the ground electrode of the semiconductor element to the stepped area of the mounting part metallic film; and a resin for shielding the semiconductor element, the electrical connecting means, and at least mounting/connecting sides of the mounting part metallic film and the connector part metallic film.
At least one of the mounting part metallic film and the connector part metallic film comprises a four-layered film consisting of a gold layer, a palladium layer, a nickel layer and a palladium layer sequentially layered from a bottom.
According to another aspect of the present invention, there is provided a carrier substrate adapted to be used for producing a semiconductor device, the substrate comprising: a metallic base having at least one reference surface, a central recessed area and a stepped recessed area located at a periphery of the central recessed area, a depth of the central recessed area from the reference surface being greater than that of the stepped recessed area from the reference surface; the area; the metallic base also having a peripheral recessed area spaced from the stepped recessed area and arranged at a peripheral region thereof; a mounting part metallic film formed on the central recessed area and the stepped recessed area; and a connector part metallic film formed on the peripheral recessed area.
In the same manner as the above, at least one of the mounting part metallic film and the connector part metallic film comprises a four-layered film consisting of a gold layer, a palladium layer, a nickel layer and a palladium layer sequentially layered from the metallic base.
According to still another aspect of the present invention, there is provided a process for producing a carrier substrate comprising the following steps of: coating respective surfaces, including a reference surface, of a metallic base with etching resist; partially removing the etching resist on the reference surface of the metallic base so as to form a central vacant pattern, a ring-like vacant pattern at a periphery of the central vacant pattern, and a connection vacant pattern spaced from the ring-like vacant pattern; half-etching the metallic base by using the etching resist as a mask and side-etching a part of the metallic base between the central vacant pattern and the ring-like vacant pattern so as to form a mount recessed area including a central recessed area and a stepped recessed area located at a periphery of the central recessed area, a depth of the central recessed area from the reference surface being greater than that of the stepped recessed area from the reference surface and also to form a peripheral recessed area spaced from the stepped recessed area and arranged at a peripheral region thereof; forming a mounting part metallic film and a connector part metallic film on the mount recessed area and on the peripheral recessed area, respectively; and removing the etching resist from the metallic base.
According to further aspect of the present invention, there is provided a process for producing a semiconductor device comprising the following steps of:
(a) forming a carrier substrate;
(b) mounting a semiconductor element, having at least one signal electrode and at least one ground electrode, on the bottom area of the mounting part metallic film;
(c) electrically connecting the signal electrode of the semiconductor element to the connector part and connecting the ground electrode of the semiconductor element to the stepped area of the mounting part metallic film;
(d) shielding, with a resin for shielding the semiconductor element, the electrical connecting means, and at least mounting/connecting sides of the mounting part metallic film and the connector part metallic film so as to form a shielded part; and
(e) removing the shielded part from the carrier substrate together with the mounting part metallic film and the connector part metallic film.
A process further comprising a step for forming a stud bump on at least one of the mounting part metallic film and the connector part metallic film of the carrier substrate, after the semiconductor element is mounted on the bottom area of the mounting part metallic film.
The shield part is removed from the carrier substrate by etching the metallic base. Otherwise, the shield part is removed from the carrier substrate by peeling the shield part off the carrier substrate.
BRIEF DESCRIPTION OF THE ATTACHED DRAWINGS
FIGS. 1 ( a ) to 1 ( j ) illustrate a process for producing a semiconductor device;
FIG. 2 is a sectional view of one example of a metallic film;
FIG. 3 is a view as seen in the arrowed direction C—C in FIG. 1 ( b );
FIGS. 4 ( a ) to 4 ( c ) illustrate some variations of the etching resist pattern;
FIG. 5 shows etching conditions in one embodiment of the present invention;
FIG. 6 is a sectional view of a prior art semiconductor device;
FIGS. 7 ( a ) to 7 ( h ) illustrate a conventional process for producing a carrier substrate; and
FIGS. 8 ( a ) and 8 ( b ) illustrate a prior art etching resist, respectively.
DETAILED DESCRIPTION OF THE EMBODIMENTS
The present invention will be described in more detail below with reference to a preferred embodiment illustrated in the attached drawings.
In this embodiment, a description will be made of a semiconductor device carrying a high-frequency analog IC thereon used for an electronic equipment such as a mobile phone and a process for the production thereof. FIGS. 1 ( a ) to 1 ( j ) illustrate a process for producing the semiconductor device; FIG. 2 is a sectional view of one example of a metallic film; and FIG. 3 is a view as seen in the arrowed direction C—C in FIG. 1 ( b ).
Initially, a structure of the semiconductor device will be explained. With reference to FIG. 1 ( j ), reference numeral 1 denotes a semiconductor device having the following structure. A semiconductor chip 2 is mounted onto a bottom of a mounting part metallic film 4 formed in a stepwise configuration via an adhesive layer 3 . A material excellent in heat dissipation ability and electro-conductivity, such as an electro-conductive epoxy resin containing silver particles, is preferably used for forming the adhesive layer 3 . A ground electrode in an electrode section 2 a of the semiconductor chip 2 is electrically connected to a shoulder 4 a formed around the bottom of the mounting part metallic film 4 at a level higher than the bottom with a gold wire 6 or the like. Also, a signal electrode in the electrode section 2 a of the semiconductor chip 2 is electrically connected to a connector part metallic film 5 formed around the mounting part metallic film 4 at a space between the both with a gold wire 6 or the like. The semiconductor chip 2 , the mounting part metallic film 4 carrying the semiconductor chip 2 and the connector part metallic film 5 are embedded in a resin-shielding part 7 formed of epoxy resin. The mounting part metallic film 4 and the connector part metallic film 5 are exposed on a mounting surface of the resin-shielded part 7 . According to this embodiment, the mounting part metallic film 4 is also used as a die pad, a heat sink and a ground terminal, while the connector part metallic film 5 functions as a connector terminal used as a signal line.
The mounting part metallic film 4 and the connector part metallic film 5 are formed of a multi-layered metallic film. In this embodiment, as shown in FIG. 2, the multi-layered metallic film is constituted as a four-layer film of a gold layer 9 , a palladium layer 10 , a nickel layer 11 and a palladium layer 12 sequentially overlaid on the outer layer defining the mounting surface. Various combinations of metallic layers may be adoptable while taking the solder adhesiveness of the outer layer with a substrate terminal and that of the inner layer with the wire 6 into account.
Next, with reference to FIGS. 1 ( a ) to 1 ( j ) and FIG. 3, a process for producing the semiconductor device 1 will be described below:
In FIG. 1 ( a ), an etching resist 14 is coated on respective upper and lower surfaces of a metallic substrate 13 such as a copper plate. The thickness (t) of the metallic substrate is preferably about 0.125 mm. For example, a photosensitive resin is preferably used as the etching resist 14 . After overlaying a photo-mask (not shown) on the etching resist 14 , part of the etching resist 14 is removed in correspondence with an area in which a metallic film is to be formed by the exposure and development of the etching resist, resulting in a resist pattern 15 shown in FIG. 1 ( b ). More concretely, as shown in FIG. 3, a square central vacant pattern 20 and a square ring-like vacant pattern 21 surrounding the central vacant pattern 20 are formed, respectively, in correspondence to an area in which a mounting recess 16 of the metallic substrate 13 is to be formed. Also, a connection vacant pattern 22 (not shown in FIG. 3) is formed as shown in FIG. 1 ( b ) in correspondence to an area in which a connection recess 17 of the metallic substrate 13 is to be formed. As shown in FIG. 3, the width of the ring-like vacant pattern 21 is preferably 0.03 mm to 0.06 mm and the width of the etching resist 14 between the central and ring-like vacant patterns 20 , 21 is preferably 0.04 to 0.06 mm.
Next, in FIG. 1 ( c ), the metallic substrate 13 is half-etched while using the etching resist as a mask to form the mounting recess 16 and the connection recess 17 . More concretely, part of the metallic substrate 13 is removed between the ring-like vacant pattern 21 and the central vacant pattern 20 by the side etching to form the mounting recess 16 having a shoulder or stepped area higher than the central part, and simultaneously therewith, the connection recess 17 is formed around the mounting recess 16 at a distance from the latter.
In such a manner, the mounting recess 16 and the connection recess 17 surrounding the former at a distance therefrom are formed by a single exposure etching process including half-etching and side-etching. In this regard, an area and/or a depth of the half-etching is freely adjustable by changing a design of the mask for the ring-like vacant pattern 21 and the central vacant pattern 20 , such as a size and/or a shape thereof. When a copper plate is used as the metallic substrate 13 , ferric chloride or the like is preferably used as the etching liquid. The depth of the mounting recess 16 (the central part thereof) and the depth of the connection recess are substantially the same and preferably about ½t≈0.06 mm to 0.08 mm.
Then, in FIG. 1 ( d ), a multi-layered metallic film is formed in the mounting recess 16 and the connection recess 17 by electrolytic plating while using the etching resist 14 as a mask to result in the mounting part metallic film 4 and the connector part metallic film 5 , respectively. The multi-layered metallic film is a four-layered film, as described above, consisting of a gold layer 9 , a palladium layer 10 , a nickel layer 11 and a palladium layer 12 sequentially overlaid on the outer layer defining the mounting surface. In this regard, the mounting recess 16 and the connection recess 17 may be electrolytically plated after the etching resist 14 has been removed and, instead, a separate resist pattern for the plating has been formed, the electrolytic plating may be carried out in the mounting recess 16 and the connection recess 17 .
The metallic film can be formed not only by the electrolytic plating but also by the vapor deposition or the sputtering. To enhance the separation of the metallic film from the metallic substrate 13 , the mounting recess 16 and the connection recess 17 may be coated with material for enhancing the separation such as an electro-conductive paste.
Next, in FIG. 1 ( e ), a carrier substrate 18 is obtained by removing the etching resist coating the respective surfaces of the metallic substrate 13 . The mounting part metallic film 4 is formed in a stepwise configuration (as a two-step shoulder in this embodiment) in the central portion of the carrier substrate 18 , and the connector part metallic film 5 is formed around the former at a plurality of positions.
Then, in FIG. 1 ( f ), the semiconductor chip 2 is mounted onto the mounting part metallic film 4 formed in the carrier substrate 18 via the adhesive layer 3 .
Next, in FIG. 1 ( g ), stud bumps 19 such as gold bumps are formed on the shoulder 4 a of the mounting part metallic film 4 and the connector part metallic film 5 . The stud bump 19 may be formed as disclosed, for example, in Japanese Unexamined Patent Publication (Kokai) No. 10-79448 by ball-bonding a gold ball to the palladium layer 12 , using supersonic welding while using a capillary, once collapsing the gold ball by the downward movement of the capillary, and cutting a gold wire by the upward movement of the capillary. By collapsing the gold ball in such a manner, it is possible to firmly bond the gold ball to the palladium layer 12 . Also, since the stud bump 19 and the wire 6 are of the same material, the adhesiveness between the both is facilitated. In this regard, the stud bump 19 may be omitted if the wire 6 can be directly adhered to the connector part metallic film 5 and the shoulder 4 a.
Then, in FIG. 1 ( h ), the electrode section 2 a of the semiconductor chip 2 is electrically connected to the stud bumps 19 formed in the mounting part metallic film 4 and the connector part metallic film 5 by the wire 6 . In this process, the wire-bonding is carried out in such a manner that one end of the wire 6 is initially bonded to the electrode section 2 a , then the other end is bonded to the stud bump 19 . Or, one end of the wire 6 may be initially bonded to the stud bump 19 , then the other end is bonded to the electrode section 2 a . In the latter case, it is possible to reduce the height of a wire loop. In this regard, the gold wire 6 may be a covered wire covered with an insulating material.
Next, in FIG. 1 ( i ), the carrier substrate 18 is introduced into a resin-shielding device (not shown) to be shielded with epoxy resin. The semiconductor chip 2 and the surface of the mounting part metallic film 4 and the connector part metallic film 5 on which the semiconductor chip is to be mounted are covered with the resin-shielding part 7 .
Then, in FIG. 1 ( j ), the resin-shielding part 7 is separated from the carrier substrate 18 together with the mounting part metallic film 4 and the connector part metallic film 5 . The separation process may be carried out either by removing the metallic substrate 13 by etching, except for regions corresponding to the mounting part metallic film 4 and the connector part metallic film 5 , or by mechanically stripping the resin-shielding part 7 off the carrier substrate 18 .
Since the mounting part metallic film 4 of the semiconductor device 1 is formed in a stepwise configuration by the half-etching, it is possible to connect the shoulder 4 a formed in the direct vicinity of the semiconductor chip 2 to the ground electrode of the semiconductor chip 2 with the wire 6 of the least length. Thereby, it is possible to form the mounting part metallic film 4 in the ground terminal section, which prevents noise from entering the semiconductor chip 2 to enhance the shielding effect.
Also, since the mounting part metallic film 4 can be formed in a stepwise configuration through a single exposure etching process, it is possible to simplify the production process of the semiconductor device 1 to a great extent, whereby the semiconductor device can be mass-produced at a low cost.
According to the carrier substrate 18 used in the semiconductor device 1 and the method for producing the same, since the mounting part metallic film 4 can be formed in a stepwise configuration by a single exposure etching process, it is unnecessary to carry out a second or further exposure etching process which needs a high accuracy alignment of a photo-mask with an etching pattern formed through a first exposure etching process as in the prior art, resulting in the reduction of rejected product to improve the yield.
FIGS. 4 ( a ) to 4 ( c ) illustrate some variations of the etching resist pattern 14 , such as shown in FIG. 3 . In FIG. 4 ( a ), there is a square central vacant pattern 20 similar to that of FIG. 3 and there are three square ring-like vacant patterns 21 , i.e., inner, intermediate and outer vacant patterns 21 . Consequently, there are three square ring-like etching resist patterns 14 , i.e., inner, intermediate and outer etching resist patterns 14 . The width A of these square ring-like vacant patterns 21 is preferably 0.044 mm. The width B of the outer and intermediate etching resist patterns 14 between the ring-like vacant patterns 21 is preferably 0.036 mm. The width C of the inner etching resist pattern 14 between the inner ring-like vacant pattern 21 and the square central vacant pattern 20 is preferably 0.040 mm.
The etching resist pattern 14 shown in FIG. 4 ( b ) is similar to that of FIG. 4 ( a ), except that the outer and intermediate resist patterns are regularly intermittent. The width F of the vacant patterns 21 is preferably 0.030 mm. The width G of the intermittent etching resist pattern 21 is preferably 0.050 mm. The width H of the inner, continuous etching resist pattern 21 is preferably 0.040 mm.
The etching resist pattern 14 shown in FIG. 4 ( c ) is also similar to that of FIG. 4 ( a ), except that the inner, intermediate and outer square ring-like vacant patterns 21 are regularly intermittent. The width G of the intermittent vacant patterns 21 is preferably 0.030 mm. The width F of the outer and intermediate etching resist patterns 14 is preferably 0.050 mm. The width H of the inner etching resist pattern 14 is preferably 0.040 mm.
FIG. 5 is a schematic cross-sectional view taken along X-X′ of FIG. 4 ( a ) and also shows etching conditions in the case of using the etching resist pattern as shown in FIG. 4 ( a ). D indicates a dimension from the upper surface of the metallic substrate 13 to the top of shoulder area of the mounting recess 16 and E indicates a dimension from the bottom of shoulder area to the central part of the mounting recess 16 . If the etching time is too long, the dimension D (D≧0.010 mm) will be unacceptable in such a manner that the etching in the vacant pattern 21 will not be completed. On the other hand, if the etching time is too long, the dimension E (E≧0.015 mm) will be unacceptable in such a manner that the area of the mounting recess 16 corresponding to the central vacant pattern 20 will be excessively etched. This is due to the difference in etching speed. Therefore, it will be necessary to regulate the etching time so as to satisfy both the dimensions D and E.
When the semiconductor device and the method for the production thereof according to the present invention are used, it is possible to connect the shoulder formed in the direct vicinity of the semiconductor chip to the ground electrode of the semiconductor chip with a wire of the least length because the mounting part metallic film is formed in a stepwise configuration by half etching. Thereby, the mounting part metallic film can be formed in the ground terminal section to prevent noise from entering the semiconductor chip and to enhance the shielding effect.
Since the mounting part metallic film can be formed in a stepwise configuration through a single exposure etching process, it is possible to simplify the process for producing the semiconductor device to a great extent, whereby the semiconductor device can be mass-produced at a low cost.
According to the carrier substrate used in the semiconductor device and the method for producing the same, since the mounting part metallic film can be formed in a stepwise configuration by a single exposure etching process, it is unnecessary to carry out a second or further exposure etching process which needs a high accuracy alignment of a photo-mask with an etching pattern formed through a first exposure etching process as in the prior art, resulting in a reduction of rejected products to improve the yield.
While the description has been made on the preferred embodiments as stated above, the present invention should not be limited to the above-mentioned embodiments but, of course, includes various changes and modifications thereof without departing of the spirit of the invention. For example, structures and/or materials of the multi-layered metallic film may be properly variable or the number of the shoulders 4 a of the mounting part metallic film 4 may be optionally selectable.
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A semiconductor device comprises a semiconductor element having a signal electrode and a ground electrode. A mounting part metallic film has a bottom area on which the semiconductor element is mounted and a stepped area located at a periphery of the bottom area and being higher in horizontal level than the bottom area. A connector part metallic film is spaced from the mounting part metallic film and arranged at a peripheral region thereof. The signal electrode of the semiconductor element is electrically connected to the connector part metallic film and the ground electrode of the semiconductor element is electrically connected to the stepped area of the mounting part metallic film. The semiconductor element is shielded with resin together with mounting/connecting sides of the mounting part metallic film and the connector part metallic film.
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FIELD OF THE INVENTION
The invention relates in general to battery powered devices, and more specifically to battery power management using logical partitioning and/or information flow between a battery and a device or subsystem.
BACKGROUND
Increasing use of portable computing or electronic devices has led to increased reliance on battery power. Devices such as cell phones, personal digital assistants (PDAs), small computers, e-mail devices, audio players, video players, etc., are complex devices often having many functions and subsystems. Typically, one battery is used to provide all of the device's power needs.
Some devices, such as portable computers, allow power-management. Thus, it is possible to designate when a portable computer will go into a low-power mode after an interval of non-use. Low power modes can include standby, hibernate, and the like. Other ways to manage power can include controlling subsystems such as the display screen, disk drive, etc., and placing these subsystems in higher or lower power modes according to determinations made by hardware or software running in the device, or according to determinations made by a user of the device. However, because battery power is so important to a portable device, it is desirable to provide more control and flexibility over the device's use of battery power and in how a device interacts with a battery.
SUMMARY
A logically partitioned battery in accordance with embodiments of the present invention can be utilized to implement a power conservation regime that can increase emergency life, reduce feature power grab during lower or moderate power situations, and/or otherwise extend an overall utility of a device. Logical battery partition constraints can be imposed on a device's subsystems by mechanisms in the battery and/or associated battery management circuitry without necessarily requiring coordination with other device electronics and/or software. Further, the charging and/or discharging of the battery itself can be regulated according to such logical partitions. In effect, a single physical power source may “look” different to different subsystems by using such logical battery partitioning.
In one embodiment, a power management system in a portable computing device having a plurality of subsystems can include: (i) a battery coupled to the subsystems; (ii) a first battery variable provided to a first subsystem to indicate a characteristic of a first logical battery partition; and (iii) a second battery variable provided to a second subsystem to indicate a characteristic of a second logical battery partition.
In one embodiment, a user interface for logical battery partition control in a portable computing device can include: (i) a first portion for configuring a number of logical battery partitions; (ii) a second portion for mapping between an application and at least one of the logical battery partitions; and (iii) a third portion for indicating a function for each of the logical battery partitions.
In one embodiment, a method of controlling logical battery partitions in a portable computing device supporting a plurality of applications can include: (i) arranging the logical battery partitions; (ii) monitoring each of the logical battery partitions; and (iii) adjusting a battery variable accessed by at least one of a plurality of applications.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates an example portable computing device arrangement in accordance with embodiments of the present invention.
FIG. 2 shows an example logical battery partitioning structure in accordance with embodiments of the present invention.
FIG. 3 shows an example system including logical battery partitioning in accordance with embodiments of the present invention.
FIG. 4 shows an example logical battery partition arrangement and mapping to subsystems in accordance with embodiments of the present invention.
FIG. 5 illustrates a block level diagram of an example system including various hardware subsystems in accordance with embodiments of the present invention.
FIG. 6 shows an example user interface for logical battery partition management in a portable computing device in accordance with embodiments of the present invention.
FIG. 7 shows a simplified flow diagram of an example method of controlling logical battery partitions in accordance with embodiments of the present invention.
DETAILED DESCRIPTION
Electronic devices and batteries typically interface or provide information flow, such as: alarm flags, over/under-voltage notifications, over/under-current notifications, average current flow, instantaneous current flow, estimates of total charge left in the battery, numerical integration of current flow measurements, cycle times, total cycles expended, temperature measurements, fuel gauges, safety circuit status, as well as charge/discharge device status, for example.
In particular embodiments, supplemental information can be provided, such as: (i) a structure of logical battery partitions; (ii) an amount of energy stored or a percentage of charge available in one or more of the battery partitions; (iii) a current flow into or out of one or more of the battery partitions; (iv) a status of one or more devices or current flow controllers that can indicate a charge/discharge of one or more of the battery partitions; and/or (v) a pattern of signals that may be needed to initiate charge/discharge of one or more such partitions.
Referring now to FIG. 1 , an example portable computing device arrangement in accordance with embodiments of the present invention is indicated by the general reference character 100 . Portable computing device 102 can include embedded controller 104 , battery subsystem 106 , user interface control 108 , and display 110 , for example. Although battery subsystem 106 is described primarily with respect to batteries, it can include any other suitable type of energy-providing mechanisms, such as capacitors and/or any suitable combination of capacitors and batteries. Also, some features described herein may be adaptable to any other type of power source, such as where an external battery is used (e.g., a device obtaining power from a vehicle's battery), or where a standard line power is used (e.g., alternating current residential or business infrastructure power).
In particular embodiments, portable computing devices or other modular electronic devices capable of performing multiple functions may be able to extend a utility by prioritizing power functions. Accordingly, relatively low power functions may be available for a substantial period of time after relatively high power functions may no longer be accessible. For example, a cell phone may lose an ability to display color, graphics, or elaborate sounds, yet the cell phone can still maintain an ability to dial “911” or another emergency access number. Further, such a cell phone may benefit from a logical battery partitioning that can protect dialing functions even when other functions may no longer be able to operate due to power constraints.
Some multi-purpose devices can have a much higher general utility or emergency utility than others, and such priorities can be assigned based on predetermined settings, such as may be provided via a user interface, for example. A logically partitioned battery can be utilized to implement a power conservation regime that can increase emergency life, reduce feature power grab during lower or moderate power situations, and/or can otherwise extend an overall utility of the device. For example, this can be done by constraining lower priority functions, applications, and/or subsystems from power consumption when a higher priority request for power is made.
In addition, the prioritization of power accessing resources, as well as other features associated with logical battery partitions, can be managed without substantially relying on algorithms. For example, such algorithms may be supported by high level functions (e.g., running a particular program) that may not be in operation at a given time, or that may be otherwise relatively power hungry. Accordingly, these logical battery partition constraints can be imposed on a device's subsystems by mechanisms in the battery and/or associated battery management circuitry without necessarily requiring coordination with other device electronics and/or software. Further, the charging and/or discharging of the battery itself can be regulated according to such logical partitions.
Referring now to FIG. 2 , an example logical battery partitioning structure in accordance with embodiments of the present invention is indicated by the general reference character 200 . Battery subsystem 202 can interface with logical partitioning 204 . For example, logical partitioning 204 may include battery charge/discharge control 206 . Also, applications 208 can interface with logical partitioning 204 . Further, “applications” as used herein can include any process, hardware subsystem, internal or external device, software-controlled function, software application, virtual computer, shared hardware resource, battery monitoring tools or protocols, or other appropriate entity.
Logical battery partitioning in accordance with embodiments of the present invention can generally provide battery variable control, such as charge/discharge control, accessibility control, and information flow to/from associate applications. Further, control or adjustment to such battery variables can be done in accordance with predetermined settings, as may be provided by a user or managed by an administrator, may be machine learnable, or may be preset to certain values, for example. Also, logical battery partitions including power-based partitions may be maintained relatively close to a physical battery system.
In particular embodiments, battery charge or drain (i.e., “use”) control based on logical battery partitions can be utilized such that: (i) certain portions or logical battery partitions can be used before, after, or concurrently with other battery portions; (ii) various logical battery partitions can be used together, independently, or in any other scheme as determined via predetermined settings; (iii) a battery will or will not charge in particular modes of software or by portions of hardware, regardless of a measurement by that hardware subsystem of the battery being relatively full or relatively empty; and/or (iv) multiple software applications or other battery monitoring tools can gather different suites of information from the battery so that one application may be unable to draw charge from the battery while another is capable of drawing charge on demand.
A logical battery partition can be configured so that its use in particular modes of software or by portions of hardware are regulated by controlling an interface between the battery and/or battery management control and a mapped device, subsystem, application, or the like. Further, such interface control can include providing battery measurement information to the device or a subsystem relating to a battery partition, regardless of the actual status of the battery itself. For example, a request for a battery measurement by a hardware subsystem can result in the battery management system providing an indication of the battery being relatively full or relatively empty, regardless of the actual battery charge, in order to reflect the management system's desire to allocate the subsystem's energy use to a particular logical partition.
In particular embodiments, logical battery partitions can be used such that designated portions of a battery can have access thereto restricted or allowed by particular: (i) modes of software; (ii) portions of hardware; (iii) battery protocols; and/or (iv) modes of control. Of course, any suitable access control can also be utilized in accordance with embodiments of the present invention.
In particular embodiments, information flow to/from associated applications can be used such that: (i) multiple software applications, hardware subsystems or devices, or other battery monitoring tools or protocols can gather different information from the battery; (ii) a battery that deliberately indicates an empty status to certain applications, hardware subsystems, or battery monitoring tools or protocols when the battery is in fact not empty; (iii) a battery that deliberately indicates a full status to certain applications, hardware subsystems, or battery monitoring tools or protocols when the battery is in fact not full; (iv) a battery that can indicate a full or an empty status depending upon criteria determined in part or in full by an application, device, tool, or protocol querying or examining the battery; and/or (v) a mechanism for configuring any such criteria so that higher level applications, tools, or protocols can revisit the priorities, partitions, or any predetermined setting associated with the battery.
Referring now to FIG. 3 , an example system including logical battery partitioning in accordance with embodiments of the present invention is indicated by the general reference character 300 . Battery subsystem 302 can interface with logical partitioning 304 . For example, logical partitioning 304 may include one or more battery charge/discharge control hardware 306 , as well as one or more battery charge/discharge control software 308 . Also, applications that may interface with logical partitioning 304 can include processes 310 and hardware subsystems 312 .
Battery charge/discharge hardware 306 can be physically located within battery subsystem 302 , in hardware subsystems 312 , or in any other suitable location. For example, battery charge/discharge hardware 306 can be included in a battery adapter for battery subsystem 302 . Further, as will be discussed in more detail below, processes 310 and/or hardware subsystems 312 can include one or more systems (e.g., hardware systems) that may be partially or fully integrated with other system components. Also, hardware subsystems 312 may include one or more processes (e.g., 310 ). Thus, in particular embodiments, a software process might span different hardware subsystems.
Also, a software process might have different power modes so as to scale depending on battery charge available. In particular embodiments, such available battery charge may be available charge for a designated partition, or the available battery charge may represent charge from another partition, or another group of battery partitions. In this fashion, applications such as software processes can utilize battery charge associated with one or more logical battery partitions.
In particular embodiments, hardware subsystems 312 may be equipped to communicate battery information. Alternatively, in particular embodiments where hardware subsystems 312 may not be equipped so as to communicate battery information, another device or dedicated hardware resource may be employed to facilitate such communication.
Referring now to FIG. 4 , an example logical battery partition arrangement and mapping to subsystems in accordance with embodiments of the present invention is indicated by the general reference character 400 . Applications/subsystems 402 can include any number of subsystems, processes, applications, or the like. For example, applications/subsystems 402 can include hardware subsystems 404 - 0 , 404 - 1 , . . . through 404 -N. Also, logical battery partitions 406 can correspond or be mapped to the hardware subsystems in this particular example. Accordingly, logical battery partitions 406 can be arranged as logical battery partitions (LBP) 408 - 0 , 408 - 1 , . . . through 408 -N, and LBP 408 - 0 can map to hardware subsystem 404 - 0 , LBP 408 - 1 can map to hardware subsystem 404 - 1 , and so on through LBP 408 -N mapping to hardware subsystem 404 -N.
Thus, a particular hardware subsystem may interface with a corresponding logical battery partition, and not necessarily directly with a physical battery subsystem. For example, hardware subsystem 404 - 1 may access LBP 408 - 1 with a request for battery availability, and LBP 408 - 1 may indicate to hardware subsystem 404 - 1 that a certain percentage of battery power is available, whereas LBP 408 -N may indicate to hardware subsystem 404 -N that a completely different percentage of battery power remains when faced with the same request and a same physical battery power. In this fashion, any designated battery variable can be controlled by a logical battery-partition, and a corresponding hardware subsystem can remain essentially unaware of this logical partitioning layer.
Referring now to FIG. 5 , a block level diagram of an example system including various hardware subsystems in accordance with embodiments of the present invention is indicated by the general reference character 500 . Battery subsystem 502 can interface with logical partition control 504 . For example, logical partition control 504 may include battery charge/discharge control hardware 506 , as well as battery charge/discharge control software 508 . In addition, logical partition control 504 can include access control 516 and information flow control 518 .
In particular embodiments, logical battery partitioning can be effectuated by battery control/management system and/or circuitry (e.g., logical partition control 504 ) within the battery subsystem (e.g., 502 ) itself, or associated therewith, to create the impression in associated device subsystems that there are multiple different batteries. Thus, in particular embodiments, these associated subsystems may not be explicitly aware of this logical partitioning effect. In this fashion, associated subsystems can react to reports of characteristics (e.g., charge, voltage, etc.) of a mapped logical battery partition, and the given partition may essentially be a fabrication created by the battery management system in order to prioritize power use in the device, or adjust any other battery variable, for example.
Applications that may interface with logical partition control 504 can include cell phone 510 , shared hardware resources 512 , and Windows OS-based computer 514 , for example. As another example, an MP3 player and a cell phone (e.g., 510 ) may be integrated into one “device” with separate processors, but that can share input/output or another hardware resource (e.g., 512 ), such as a display screen, a keyboard, connectors, or the like. In such a case, a shared battery resource (e.g., a logical battery partition or battery bus) can be utilized for one or more of the applications and/or devices in the system.
Referring now to FIG. 6 , an example user interface for logical battery partition management in a portable computing device in accordance with embodiments of the present invention is indicated by the general reference character 600 . An example user interface can include partition setup 602 , application setup 606 , and battery partition function 610 . Partition setup 602 can include partition 604 - 0 , partition 604 - 1 , . . . partition 604 -Y, and may be used to define logical battery partitions. Application setup 606 can include partition mapping 608 , and may be used to map an application to a particular logical battery partition. Battery partition function 610 can include priority 612 - 0 , battery information altering 612 - 1 , . . . function X 212 -X, and may be used to designate supported functions for each logical battery partition.
Such predetermined settings, as may be utilized for control or adjustment to associated battery variables, may be provided by a user or managed by an administrator, may be machine learnable, or may be preset to certain values, for example. Thus, particular embodiments may not require that a user input any or all such interface options. However, any preferences or predetermined settings that a user might provide (e.g., via a user interface), or that may be provided by another means, can be saved for future access. In particular embodiments, battery subsystems can include or be associated with unique identifiers (IDs), or nonvolatile storage elements (e.g., electrically erasable programmable read-only memory (EEPROM)) can be utilized to save such preferences. In this fashion, a particular logical partitioning arrangement can be associated with a physical battery, for example.
Referring now to FIG. 7 , a simplified flow diagram of an example method of controlling logical battery partitions in accordance with embodiments of the present invention is indicated by the general reference character 700 . The flow can begin ( 702 ) and a logical battery partitioning, partition mapping to applications, and battery partition function, can be determined ( 704 ). Such predetermined settings can be input or provided by using a user interface, which can be viewed through a display in a portable computing device (e.g., display 110 of FIG. 1 ), for example.
Next, each battery partition associated with a subsystem, device, or application can be monitored ( 706 ). If no adjustment is needed ( 708 ), such monitoring ( 706 ) can continue. However, if an adjustment is needed ( 708 ), a battery partition variable related to an associated subsystem, device, and/or application can be adjusted ( 710 ) and the flow can complete ( 712 ). Further, control or adjustment to such battery variables can be done in accordance with predetermined settings, as may be provided by a user or managed by an administrator, may be machine learnable, or may be preset to certain values, for example.
Although particular embodiments of the invention have been described, variations of such embodiments are possible and are within the scope of the invention. For example, although specific logical battery partitioning and battery variables have been described, other types of partitioning and/or characteristics can be controlled in accordance with embodiments of the present invention. Also, applications other than portable computing devices or the like can also be accommodated in accordance with particular embodiments. Embodiments of the invention can operate among any one or more processes or entities including users, devices, functional systems, and/or combinations of hardware and software.
Any suitable programming language can be used to implement the functionality of the present invention including C, C++, Java, assembly language, etc. Different programming techniques can be employed such as procedural or object oriented. The routines can execute on a single processing device or multiple processors. Although the steps, operations or computations may be presented in a specific order, this order may be changed in different embodiments unless otherwise specified. In some embodiments, multiple steps shown as sequential in this specification can be performed at the same time. The sequence of operations described herein can be interrupted, suspended, or otherwise controlled by another process, such as an operating system, kernel, etc. The routines can operate in an operating system environment or as stand-alone routines occupying all, or a substantial part, of the system processing. The functions may be performed in hardware, software or a combination of both.
In the description herein, numerous specific details are provided, such as examples of components and/or methods, to provide a thorough understanding of embodiments of the present invention. One skilled in the relevant art will recognize, however, that an embodiment of the invention can be practiced without one or more of the specific details, or with other apparatus, systems, assemblies, methods, components, materials, parts, and/or the like. In other instances, well-known structures, materials, or operations are not specifically shown or described in detail to avoid obscuring aspects of embodiments of the present invention.
A “computer-readable medium” for purposes of embodiments of the present invention may be any medium that can contain, store, communicate, propagate, or transport the program for use by or in connection with the instruction execution system, apparatus, system or device. The computer readable medium can be, by way of example only but not by limitation, an electronic, magnetic, optical, electromagnetic, infrared, or semiconductor system, apparatus, system, device, propagation medium, or computer memory.
A “processor” or “process” includes any human, hardware and/or software system, mechanism or component that processes data, signals or other information. A processor can include a system with a general-purpose central processing unit, multiple processing units, dedicated circuitry for achieving functionality, or other systems. Processing need not be limited to a geographic location, or have temporal limitations. Functions and parts of functions described herein can be achieved by devices in different places and operating at different times. For example, a processor can perform its functions in “real time,” “offline,” in a “batch mode,” etc. Parallel, distributed or other processing approaches can be used.
Reference throughout this specification to “one embodiment”, “an embodiment”, “a particular embodiment,” or “a specific embodiment” means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention and not necessarily in all embodiments. Thus, respective appearances of the phrases “in one embodiment”, “in an embodiment”, or “in a specific embodiment” in various places throughout this specification are not necessarily referring to the same embodiment. Furthermore, the particular features, structures, or characteristics of any specific embodiment of the present invention may be combined in any suitable manner with one or more other embodiments. It is to be understood that other variations and modifications of the embodiments of the present invention described and illustrated herein are possible in light of the teachings herein and are to be considered as part of the spirit and scope of the present invention.
Embodiments of the invention may be implemented by using a programmed general purpose digital computer, by using application specific integrated circuits, programmable logic devices, field programmable gate arrays, optical, chemical, biological, quantum or nanoengineered systems, components and mechanisms may be used. In general, the functions of the present invention can be achieved by any means as is known in the art. For example, distributed, networked systems, components and/or circuits can be used. Communication, or transfer, of data may be wired, wireless, or by any other means.
It will also be appreciated that one or more of the elements depicted in the drawings/figures can also be implemented in a more separated or integrated manner, or even removed or rendered as inoperable in certain cases, as is useful in accordance with a particular application. It is also within the spirit and scope of the present invention to implement a program or code that can be stored in a machine-readable medium to permit a computer to perform any of the methods described above.
Additionally, any signal arrows in the drawings/Figures should be considered only as exemplary, and not limiting, unless otherwise specifically noted. Furthermore, the term “or” as used herein is generally intended to mean “and/or” unless otherwise indicated. Combinations of components or steps will also be considered as being noted, where terminology is foreseen as rendering the ability to separate or combine is unclear.
As used in the description herein and throughout the claims that follow, “a”, “an”, and “the” includes plural references unless the context clearly dictates otherwise. Also, as used in the description herein and throughout the claims that follow, the meaning of “in” includes “in” and “on” unless the context clearly dictates otherwise.
The foregoing description of illustrated embodiments of the present invention, including what is described in the Abstract, is not intended to be exhaustive or to limit the invention to the precise forms disclosed herein. While specific embodiments of, and examples for, the invention are described herein for illustrative purposes only, various equivalent modifications are possible within the spirit and scope of the present invention, as those skilled in the relevant art will recognize and appreciate. As indicated, these modifications may be made to the present invention in light of the foregoing description of illustrated embodiments of the present invention and are to be included within the spirit and scope of the present invention.
Thus, while the present invention has been described herein with reference to particular embodiments thereof, a latitude of modification, various changes and substitutions are intended in the foregoing disclosures, and it will be appreciated that in some instances some features of embodiments of the invention will be employed without a corresponding use of other features without departing from the scope and spirit of the invention as set forth. Therefore, many modifications may be made to adapt a particular situation or material to the essential scope and spirit of the present invention. It is intended that the invention not be limited to the particular terms used in following claims and/or to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include any and all embodiments and equivalents falling within the scope of the appended claims.
Thus, the scope of the invention is to be determined solely by the appended claims.
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A logical battery partitioning approach is disclosed. In one embodiment, a power management system in a portable computing device having a plurality of subsystems can include: (i) a battery coupled to a plurality of subsystems; (ii) a first battery variable provided to a first subsystem to indicate a characteristic of a first logical battery partition; and (iii) a second battery variable provided to a second subsystem to indicate a characteristic of a second logical battery partition. A battery variable can include an accessibility control, or a percent of battery power available, for example.
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FIELD OF THE PRESENT INVENTION
[0001] The present invention relates to a fingertip oximeter, and more particularly, to a fingertip oximeter allowing observation of a measurement result displayed thereon from any of surrounding directions.
[0002] In another aspect, the present invention relates to a method for allowing observation of a measurement result of the fingertip oximeter from any of surrounding directions.
[0003] In the third aspect, the present invention relates to a fingertip oximeter that reports a measurement result through a voice, informing the user and others nearby of the result.
BACKGROUND OF THE PRESENT INVENTION
[0004] The fingertip oximeter, widely used for measuring the oxyhemoglobin and pulse, employs a non-invasive measurement technology.
[0005] The fingertip oximeter runs in such a way that it determines the oxyhemoglobins number and pulse rate by measuring the absorption rate for a selected wavelength of light wave. In particular, a beam of light from a photoelectric light emitter is arranged to pass through the organism tissue of the user, and is converted to an electrical signal after being detected by a light receiver. Thereby, an oxygen saturation level (i.e. SpO2) of arterial blood flowing through the finger of the user is obtained and presented on a display of the oximeter.
[0006] In the prior art, however, the user can observe a measurement result in only one direction. When observing the result, the user has to bend his/her finger to properly observe the displayed information if it is not easy to read. But bending the finger may lead to partial occlusion of arterial blood capillary so that the strength of pulse will decrease and the strength of signal is weakened. As a result, the precision of measurement falls.
SUMMARY OF THE PRESENT INVENTION
[0007] The object of the present invention is to provide a fingertip oximeter allowing observation of a measurement result thereon from any of surrounding directions, in which when observing the result, the user does not to bend his/her finger to properly observe the displayed information even if it is not easy to read, so as to avoid the partial occlusion of arterial blood capillary, thus to prevent from any decrease of the strength of pulse and further prevent from any decrease of the strength of signal, as a result, the precision of measurement can be improved.
[0008] Another object of the present invention is to provide a method for allowing observation of a measurement result of a fingertip oximeter from any of surrounding directions.
[0009] The further object of the present invention is to provide a fingertip oximeter that can report a measurement result through a voice, informing the user and others nearby of the measurement result.
[0010] Thus, according to the first aspect of the present invention, there is provided a fingertip oximeter characterized in that it has a plurality of display modes which are sequentially presented in a circulating way, allowing a user to easily observe a measurement result from any of surrounding directions.
[0011] Preferably, one of the display modes is switched to the next by pressing a button manually, or they are switched automatically.
[0012] Preferably, the display mode refers to a pattern of presenting a measurement result, or a pattern of presenting a combination of a heading and a measurement result; and the heading is presented in an upright standing or upside-down standing way.
[0013] Preferably, the measurement result comprises a measurement parameter, a measurement parameter and a pulse column, or a measurement parameter and a waveform; the measurement parameter can be presented in a landscape upright standing, a portrait right laying way, a landscape upside-down standing way, or a portrait left laying way.
[0014] Preferably, the fingertip oximeter comprises a signal drive unit, a signal acquisition & amplification unit, a power supply unit for supplying power to the fingertip oximeter, buttons, a central processing unit, and a display, in which the buttons are adapted to input an instruction for updating a display mode of the fingertip oximeter; the central processing unit is adapted to determine whether any button is pressed down, upon such an operation is detected, to set a new display mode and update the display mode in use with the new one, and to transmit a signal regarding the new display mode to the display; and the display is adapted to receive the signal regarding the new display mode from the central processing unit, and present the measurement result in the new display mode.
[0015] Preferably, the central processing unit at least comprises a press scan unit, a switching & setting unit, and a display update unit, in which the press scan unit is adapted to determine whether any button is pressed down, and upon such an operation is detected, to transmit a first signal regarding the operation to the switching & setting unit; the switching & setting unit is adapted to receive the first signal from the press scan unit, set a new display mode in consideration of the display mode in use, and transmit a second signal regarding the new display mode to which the display mode in use is to be switched to the display update unit; and the display update unit is adapted to receive the second signal from the switching & setting unit, update the display mode in use, and transmit a third signal regarding the new display mode to the display.
[0016] According to the second aspect of the present invention, there is provided a method for allowing observation of a measurement result of a fingertip oximeter from any of surrounding directions, characterized in that the method comprises the following steps of: 1) inputting an instruction for updating a display mode of the fingertip oximeter in use; 2) switching and updating the display mode in use to a new display mode, and transmitting a signal regarding the new display mode to a display after the instruction is detected; and 3) displaying a measurement result in the new display mode after the display receives the signal on updating the display mode in use.
[0017] Preferably, the step 2) further comprises the sub-steps of detecting the instruction for updating the display mode in use; setting a new display mode to which the display mode in use is to be switched; and updating the display mode in use with the new display mode, and transmitting a signal regarding the new display mode to a display.
[0018] Preferably, the display mode refers to a pattern of presenting a measurement result, or a pattern of presenting a combination of a heading and a measurement result; and the heading is presented in an upright standing or upside-down standing way.
[0019] Preferably, the measurement result comprises a measurement parameter, a measurement parameter and a pulse column, or a measurement parameter and a waveform; the measurement parameter is presented in a landscape upright standing, a portrait right laying way, a landscape upside-down standing way, or a portrait left laying way.
[0020] According to the third aspect of the present invention, there is provided a fingertip oximeter that can reports a measurement result through a voice to the user and others nearby.
[0021] According to the present invention, the user can easily observe a measurement result of the fingertip oximeter from any of surrounding directions, without the need of bending his/her finger when observing the measurement result, which avoids partial occlusion of arterial blood capillary due to bended finger, thus, prevents from decrease of the strength of pulse, so does not weaken the strength of signal, so as to improve the precision of measurement.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] FIG. 1A to FIG. 1F are schematic views of different display modes of the oximeter according to one embodiment of the present invention.
[0023] FIG. 2 is a block diagram of the oximeter according to one embodiment of the present invention.
[0024] FIG. 3 is a flow diagram of updating a display mode of the oximeter according to one embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0025] The embodiments of the present invention are described in detail in combination with the drawings below.
[0026] According to an embodiment of the present invention, the display of the oximeter is an organic light emitting display (OLED), which is a 64×128 dot array monochrome display. The color of the first 16 rows of the display is configured as yellow, while that of the other 48 rows is configured as blue in the embodiment. But different displays and displaying patterns may be applied.
[0027] In practice, the display mode usually refers to a pattern in which a measurement result or a combination of a heading and a measurement result is presented. The way in which the heading is presented could be set to upright standing or upside-down standing as required. Landscape or portrait appearance is also available.
[0028] The measurement result comprises a measurement parameter, a measurement parameter and a pulse column, or a measurement parameter and a waveform. The way in which the measurement parameter is presented includes landscape upright standing, portrait right laying, landscape upside-down standing, or portrait left laying. The way in which the pulse column is presented includes the pulse column's left display, center display, or right display. The way in which the waveform is presented could be solid standing or outlined standing as required. Landscape or portrait appearance is also available.
[0029] The above described display options can be used in combination according to the situation of usage.
[0030] In this embodiment, the display mode refers to the way in which the heading and the measurement result are presented.
[0031] In this embodiment, the display screen is divided into a heading area and a parameter area. The heading area occupies the top 16 rows as a yellow block, while the parameter area fills the following 48 rows as a blue block. Characters in the heading area can only be displayed with a certain height, and in an upright standing or upside-down standing appearance. The height of characters in the parameter area is not fixed. Some graphics or waveforms can also be displayed in the parameter area. In this area, characters can be displayed in an upright standing, an upside-down standing, a left laying, or a right laying appearance.
[0032] Referring to FIG. 1A to FIG. 1F , six display modes are illustrated in an embodiment of the present invention.
[0033] Referring to FIG. 1A , in Mode 0 , the heading (SPO2% and PR) is displayed in a landscape upright standing way, measurement parameters ( 98 and 80 ) are displayed in a landscape upright standing way, and a pulse column is displayed in a landscape left standing way. Here, the pulse column is adapted to indicate strength of pulse.
[0034] Referring to FIG. 1B , in Mode 1 , the heading (PR and SPO2%), measurement parameters ( 80 and 98 ), and the pulse column are respectively displayed in a portrait upright standing way, a portrait right laying way, and a centered standing way.
[0035] Referring to FIG. 1C , in Mode 2 , the heading (SPO2% and PR), measurement parameters ( 98 and 80 ), and the pulse column are respectively displayed in a landscape upside-down standing way, a landscape upside-down standing way, and a right standing way.
[0036] Referring to FIG. 1D , in Mode 3 , the heading (SPO2% and PR) is displayed in a landscape upright standing way, measurement parameters ( 98 and 80 ) are displayed in a portrait left laying way, and the pulse column is displayed in a centered standing way.
[0037] Referring to FIG. 1E , in Mode 4 , the heading (SPO2% and PR) is displayed in a landscape upright standing way, measurement parameters ( 98 and 80 ) are displayed in a landscape upright standing way, and a landscape solid waveform is displayed.
[0038] Referring to FIG. 1F , in Mode 5 , the heading (SPO2% and PR) is displayed in a landscape upright standing way, measurement parameters ( 98 and 80 ) are displayed in a landscape upright standing way, and a landscape outlined waveform is displayed.
[0039] When the fingertip oximeter is powered on and initialized, the operating modes and parameters of the display are set up. At the beginning of measurement, the display mode is set to 0 initially.
[0040] Referring to FIG. 2 , according to an embodiment of the present invention, as the central processing unit (CPU) 12 detects that the button 11 is pressed down for one time, the display mode is updated once. When the button 11 is pressed down again, the display mode is also updated again. Each time the button 11 is pressed down, the display mode is switched from Mode 0 to Mode 5 one by one and then to go back to Mode 0 to continue the next cycle again. Therefore, the measurement result can be easily observed from any of surrounding directions.
[0041] These six display modes form only one embodiment of the present invention. Other display modes are also possible in practice according to the present invention. For example, the central processing unit 12 can be configured to automatically update the display mode sequentially from Mode 0 to Mode 5 one by one and then back to Mode 0 to repeat the next cycle at a specific interval, so that the measurement result of the fingertip oximeter can be easily observed from any of surrounding directions. The interval can be predetermined as required to make the display cycle time of the modes faster or slower.
[0042] In addition, according to another embodiment of the present invention, the fingertip oximeter can be integrated with the voice making technology from prior art, speaking any number corresponding to the measurement result, to automatically report the measurement result through a voice. Consequently, the user and others nearby can be informed of that result directly, making the users more conveniently to use the fingertip oximeter.
[0043] Referring to FIG. 2 , the fingertip oximeter based on one embodiment of the present invention comprises a signal drive unit 14 , a signal acquisition & amplification unit 15 , a power supply units 16 and 17 for supplying power to the fingertip oximeter, a central processing unit 12 , a display 13 , and buttons 11 . The buttons 11 for inputting an instruction to update a display mode of the oximeter are connected with the power supply unit for activating the power supply unit to supply power to the oximeter. The central processing unit 12 is adapted to determine whether any button 11 is pressed down, set a new display mode to which the display mode in use is to be switched in response to pressing-down of the button 11 , update the display mode in use, and transmit a signal regarding the new display mode to the display 13 . The display 13 is adapted to receive the signal regarding the new display mode from the central processing unit 12 , and display the measurement result in the updated display mode.
[0044] According to one embodiment of the present invention, the signal drive unit 14 and the signal acquisition & amplification unit 15 can be made use of prior art.
[0045] Referring to FIG. 2 , the central processing unit 12 at least comprises a press scan unit 121 , a switching & setting unit 122 , and a display update unit 123 . The press scan unit 121 is adapted to determine whether any button 11 is pressed down, and transmit a first signal regarding pressing-down of the button 11 to the switching & setting unit 122 in response to pressing-down of the button 11 . The switching & setting unit 122 is adapted to receive the first signal from the press scan unit 121 , set a new display mode to which the display mode in use is to be switched, and transmit a second signal regarding the new display mode to the display update unit 123 . The display update unit 123 is adapted to receive the second signal regarding the new display mode from the switching & setting unit 122 , update the display mode in use with the new display mode, and transmit a third signal regarding the new display mode to the display 13 .
[0046] The signal drive unit 14 , under control of the central processing unit 12 , is adapted to make a light emitter emit a beam of light. The signal acquisition & amplification unit 15 is adapted to receive the light passing through the measured tissue, convert it to an electric signal, and transmit the electric signal to the central processing unit 12 .
[0047] In this embodiment, the power supply unit includes a power input unit 16 and a power output & management unit 17 . The button 11 and the power input unit 16 are connected with the power output & management unit 17 respectively.
[0048] According to one embodiment of the present invention, the central processing unit 12 makes use of a C8051F007 chip available from CYGNAL Corporation, which has a 2304-byte data memory, a 32K FLASH memory, a 4-channel 12-bit A/D (Analog/Digital) converter, a 2-channel 12-bit D/A (Digital/Analog) converter, 2 comparators, a on-board 2.4V voltage reference, a on-board clock source, and a 4-channel 16-bit counter/timer.
[0049] According to one embodiment of the present invention, the display 13 is an OLED for presenting the measurement result. The I/O (Input/Output) interface of the central processing unit 12 is driven directly.
[0050] In this embodiment, the power input unit 16 consists of two AAA alkaline batteries or rechargeable batteries, providing a voltage of 2.3 to 3.3V.
[0051] According to one embodiment of the present invention, the output of the power output & management unit 17 is +3.3V and +8V. When turning off, the power input can be disconnected so that the output of the power supply becomes 0V.
[0052] The power output of 2.3V to 3.3V is converted to a 3.3V and 8V output through a MT1860 power chip. The maximum power output is 400 mA, with a frequency of 1 MHz in PWM (Pulse Width Modulation) mode.
[0053] The power management is carried out by using the button or I/O output. When the button 11 is pressed down, the voltage output is +3.3V. The central processing unit 12 takes over power control and outputs a voltage of +8V if it detects that the button 11 is pressed down.
[0054] The power supply works as usual after releasing the button 11 . If the master chip cannot detect any data for 8 seconds, the system is shut down, being in the sate of turning off.
[0055] If it detects that the voltage input is as low as lower than +2.7V, then a low-battery-voltage alert is displayed to prevent the input power supply from damage.
[0056] After the button 11 is pressed down, a low level signal or a high level signal is generated, and an interrupt is further made, so the central processing unit 12 is aware of the fact that the button 11 is pressing down in this way. The central processing unit 12 then sets a new display mode and switches current display mode to the new display mode.
[0057] The central processing unit (CPU) 12 may make use of a chip other than that described above. In addition, the analog comparison input involved in this embodiment for transmitting information regarding pressing-down the button 11 to the central processing unit 12 can be replaced with an I/O interface input or an interrupt interface input.
[0058] In another aspect of the present invention, there is provided a method for observing a measurement result of a fingertip oximeter, comprising the following steps of: step 1) inputting an instruction for updating a display mode of the fingertip oximeter in use; step 2) switching and updating the display mode in use and transmit a signal regarding a new display mode to a display of the fingertip oximeter after detecting the instruction; and step 3) presenting a measurement result in the updated new display mode after the display receives the signal regarding the new display mode.
[0059] Preferably, step 2) further comprises the following sub-steps of detecting the instruction for updating the display mode of the fingertip oximeter in use, setting a new display mode to which the display mode in use is to be switched; updating the display mode in use with the new display mode, and transmitting a signal regarding the new display mode to the display.
[0060] Now, a method for observing a measurement result of the fingertip oximeter from any of surrounding directions is described according to one embodiment the present invention. The method comprises such steps that step 1) the user inputs an instruction for updating a display mode of the fingertip oximeter in use by pressing the button 11 down; step 2) the central processing unit 12 sets a new display mode to which the display mode in use is to be switched, updates the display mode in use with the new display mode, and transmits a signal regarding the new display mode to the display 13 after detecting pressing-down of the button 11 ; and step 3) the display 13 receives the signal regarding the new display mode to be presented from the central processing unit 12 , and presents a measurement result in the updated new mode.
[0061] Preferably, step 2) further comprises such sub-steps that the press scan unit 121 determines whether the button 11 is pressed down, and transmits a first signal regarding pressing-down of the button 11 to the switching & setting unit 122 if it detects that the button 11 is pressed down; the switching & setting unit 122 receives the first signal from the press scan unit 121 , and sets a new display mode to which the display mode in use is to be switched, and transmits a second signal regarding the new display mode to the display update unit 123 ; and the display update unit 123 receives the second signal from the switching & setting unit 122 , updates the display mode in use, and transmits a third signal regarding the new display mode to the display 13 .
[0062] Referring to FIG. 3 and FIGS. 1A to 1F , the method is further described below with the example of the foregoing six display modes.
[0063] When the fingertip oximeter is in off status, it will be turned on if the button 11 is pressed down for the first time. And then, the fingertip oximeter is automatically powered on and initialized. The initial display mode is set to Mode 0 .
[0064] From then on, once the central processing unit 12 detects that the button 11 is pressed down, the display mode will be updated. If the button 11 is pressed down again, the display mode is switched to another new display mode. In this way, the display mode is switched from Mode 0 to Mode 5 one by one and return the initial Mode 0 again, and then to be in the next cycle. Thus, the measurement result can be easily observed from any of surrounding directions.
[0065] In particular, the press scan unit 121 of the central processing unit 12 determines whether the button 11 is pressed down at a specific interval. If the button 11 has not yet been pressed down, the display update unit 123 and a blood oxygen parameters & waveform processing unit will continue to try to detect it again and again in the same way as that of prior art. Once it is detected that the button 11 is pressed down, a first signal regarding its pressing-down is transmitted to the switching & setting unit 122 to be processed; the switching & setting unit 122 receives the first signal detected by the press scan unit 121 , performs a specific counting operation, filters noise signals resulted from the button's trembling, sets a new display mode (Mode 1 ) to replace the original display mode (Mode 0 ), initializes the screen of the display with the new display mode, and transmits a second signal regarding the new display mode (Mode 1 ) to the display update unit 123 ; the display update unit 123 checks the display update flag at a specific interval, and displays a measurement result on the display 13 in the new display mode (Mode 1 ) if any parameters and waveforms are updated.
[0066] In this embodiment, the display mode is changed to Mode 1 if the button 11 is pressed down for the first time, to Mode 2 if the button 11 is pressed down for the second time, and so on.
[0067] The changing sequence of display modes is not fixed. The sequence of display modes can be adjusted to satisfy specific needs. In addition, other display modes can be added to make a comprehensive set of display modes.
[0068] With the present invention, the user can easily observe a measurement result from any of surrounding directions, without the need of bending his/her finger, so the precision of measurement is guaranteed.
[0069] All embodiments described above are illustrative, not restrictive for the present invention.
[0070] Although the present invention has been described in several embodiments, it will be appreciated by those skilled in the art that the present invention can be modified or improved in these or those ways, without departing from the spirit and scope of the present invention indicated by the appended claims.
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There is provided a fingertip oximeter that has a plurality of display modes which are presented sequentially in a circulating way, allowing users to easily observe a measurement result from any of surrounding directions. The present invention makes users to be able to observe a measurement result of the fingertip oximeter from any of surrounding directions, without the need of bending his/her finger. Thus, any partial occlusion of the arterial blood capillary can be avoided, so that strength of the pulse will not decrease, and strength of the signal will not be affected. As a result, the precision of the measurement is improved.
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This application is a continuation of my application Ser. No. 08/113,380, filed Aug. 30, 1993, and now abandoned.
BACKGROUND OF THE INVENTION
This invention relates to contour projectors, and more particularly to an improved method and means for projecting onto the screen of the projector erect and unreversed optical images of both the contour of a workpiece, and the face of the workpiece--i.e., the same surface of the workpiece that is being observed by the operator.
In my U.S. Pat. No. 4,223,986, which is assigned to the same assignee as the present application, I disclosed a contour projector having a surface illuminator (a first light source) that was designed to project either a horizontal or vertical beam of light onto the back or rear surface of a workpiece positioned below and in front of the viewing screen of the projector. With the workpiece in this position the front face or front surface thereof, which can be observed by the operator, is positioned in the path of a second light source referred to as the contour or profile illuminator. This construction causes the contour illuminator to project through a lens system onto the projector screen the outline or contour of the workpiece, at the same time that the illuminated rear surface of the workpiece is also projected through the same lens system onto the viewing screen. As a result, while the contour illuminator in fact presents on the screen an erect and unreversed optical image of the contour of the workpiece, the image projected onto the screen by the surface illuminator is not the same image as would be perceived by an operator gazing at the front surface of the workpiece. On the contrary, the image projected by the surface illuminator is the back side of the workpiece, and hence the reverse of the surface which is being observed by the operator.
It is an object of this invention, therefore, to provide an improved method of projecting onto the screen of a contour projector machine not only an upright and unreversed contour image of a workpiece, but also an upright and unreversed image of the front surface of the workpiece, so that the operator will be observing on the screen the image of the exact surface of the workpiece which her or she observes while standing in front of the machine.
Still another object of this invention is to provide for a contour projector or the like an improved projection system which is designed to project upright and unreversed contour and surface images of a workpiece onto either upright or horizontally disposed screens.
Other objects of the invention will be apparent hereinafter from the specification and from the recital of the appended claims, particularly when read in conjunction with the accompanying drawings.
SUMMARY OF THE INVENTION
In one embodiment a workpiece is supported on the frame of a contour projector machine with the front face thereof positioned to be observed by an operator standing in front of the machine, and in spaced, confronting relation to the inclined face of a first mirror mounted in a front section of the frame forwardly of the workpiece. A contour illuminator, which is mounted in the frame rearwardly of the workpiece in horizontal registry with the face of the first mirror, projects a beam of light onto the rear surface of the workpiece, and in so doing projects a contour image of the workpiece onto the face of the first mirror. A surface illuminator, which is mounted adjacent the front of the frame beneath the first mirror, projects a beam of light upwardly through a beam splitter and a series of lenses onto the face of the first mirror, which lies in a plane inclined at approximately 45° to the beams of both illuminators, so that light from the surface illuminator is directed onto the front face of the workpiece. An image of the illuminated front face of the workpiece thus appears also in the face of the first mirror in combination with the contour image of the workpiece.
The combined images are then reflected downwardly by the first mirror onto the beamsplitter, which then reflects the combined images rearwardly of the frame to a second mirror, and from there through a series of magnification lenses onto a third mirror which projects an enlargement of the combined images onto the rear surface of the machine's projection screen. The result is that the image perceived by an operator gazing at the screen will be an upright and unreversed image of both the contour and the front face of the workpiece.
In a second embodiment the contour illuminator is positioned beneath the workpiece, and light from a surface illuminator is projected from an inclined mirror downwardly onto the upper surface of a workpiece. This permits a combined upright and unreversed image of the contour and upper face of the workpiece to be projected on a screen which may be mounted substantially horizontally on the frame.
THE DRAWING
FIG. 1 is a schematic side elevational view of a contour projector containing novel projection apparatus made according to one embodiment of this invention; and
FIG. 2 is a schematic side elevational view of another form of contour projector having therein novel projection apparatus made in accordance with the second embodiment of this invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawing by numerals of reference, and first to FIG. 1, 10 denotes generally a contour projector machine having mounted on the frame 12 thereof a conventional work support 13, which is designed releasably to support a workpiece W, or the lie, in an operative position on the machine. Mounted in the front section of the machine to project a beam of light vertically upwardly is a surface illuminator 15, which may be of the type disclosed in my above-noted U.S. Pat. No. 4,223,986. The beam of light from the illuminator 15 is projected in a vertical plane onto one side of a beamsplitter 17, which is mounted adjacent the front of frame 12 above the illuminator 15 to lie in a plane which is inclined at approximately 45 degrees to the plane containing the beam emitted by the illuminator 15. This beam of light passes through the beam splitter 17 and upwardly through a set of relay lenses 18 and onto the face of a reflector or mirror 19. Mirror 19 is mounted in the front section of the frame 12 adjacent the upper end thereof to lie in a plane which is inclined also at approximately 45 degrees to the vertical plane containing the beam of light transmitted from the illuminator 15, thereby to reflect such beam horizontally rearwardly in the same vertical plane, and onto the front surface of the workpiece W positioned on the support 13. The front face of the workpiece--i.e., the surface which can be observed by an operator standing in front of the machine 10, is thus illuminated by the light from illuminator 15.
A second light source in the form of a conventional contour illuminator 21 is mounted in the frame 12 horizontally rearwardly of the workpiece W, and in such a manner that it directs a horizontal beam of light also in the same vertical plane as the beam of light from illuminator 15, and onto the rear surface of the workpiece W. As a consequence, light from the illuminator 21 projects onto the surface of the mirror 19 the outline or contour image of workpiece W. At the same time, the beam of light from the illuminator 15, which illuminates the front face of the workpiece, also causes an image of the front face of workpiece W to be formed on the surface of the mirror 19. Mirror 19 in turn directs downwardly through the lenses 18 and onto the upper face of the beam splitter 17 both an image of the front surface of the workpiece, and a contour or outline of the workpiece. These combined contour and surface images of the workpiece are then reflected from the upper face of the beamsplitter 17 horizontally rearwardly in the same vertical plane as the beams from illuminators 15 and 21, and through a second relay lens system 16 and onto the face of a second mirror 23, which is mounted in frame 12 to lie in a plane inclined to the axis of the light transmitted from the face of the beam splitter 17. Mirror 23 in turn projects the combined contour and surface images also in the same vertical plane as the beams from illuminators 15 and 21, and through a series of magnification lenses 24 onto the face of a third mirror or reflector 25, which is mounted in the machine adjacent the upper, rear surface thereof. Mirror 25 registers with the rear surface of a projection screen 26 of conventional design, which is mounted in a cowling or the like adjacent the upper end of the machine frame 12 so that its front face will be viewable by an operator standing in front of the machine.
The result is that the axes of the light beams from illuminators 15 and 21, and the optical axes of the images projected from mirror 19 to the screen 26, all lie in the same vertical plane. Moreover, the image which is projected onto screen 26 will be an enlarged view of the front face of the workpiece W exactly as seen by an operator standing in front of the machine (i.e., an upright and unreversed image) as will be the image of the profile or outline of the workpiece as created by the illuminator 21. As noted above, this contrasts with the type of image heretofore projected onto the screen of conventional contour projectors of the type in which the projected image generated by the surface illuminator is the image of the rear surface of the workpiece, rather than the front surface thereof, which is the surface which normally is observed by the operator standing at the front of the machine. As a consequence, the novel projection apparatus disclosed herein permits substantially greater accuracy in inspecting and measuring workpieces.
Referring now to the embodiment illustrated in FIG. 2, wherein like numerals are employed to denote elements similar to those employed in the first embodiment, 30 denotes generally a modified contour projector machine having a frame 32 which is designed to support the associated viewing screen 33 in a substantially horizontal position adjacent the front of the machine. In this embodiment the workpiece W is held by a work support 34 in registry with an opening formed in the upper surface of the frame 32 rearwardly of the screen 33. The bottom or underside of the workpiece W registers with a first light source in the form of a conventional profile illuminator 21, which in this embodiment is mounted in the frame beneath the work support 34 in order to project a beam of light vertically upwardly in a vertical plane toward the underside of the workpiece.
Mounted in frame 32 above and to the rear of the work support 34 is a conventional surface illuminator 15, which directs a beam of light horizontally in the same plane as the beam from illuminator 21, and through a beam splitter 17 that is mounted in the upper end of frame 32 to lie in a plane inclined at approximately 45 degrees to the plane containing the center line of the beam of light emitted by illuminator 15. The light from illuminator 15 passes through the beam splitter 17 and the lens system 18 onto the inclined face of a mirror 19, which is also mounted in the upper end of frame 32 to overlie the workpiece W in a plane inclined at approximately 45 degrees to the plane containing the center lines of the beams of light emitted by both illuminators 15 and 21. The light from illuminator 15 is reflected downwardly by the mirror 19 onto the upper face of the work W, and consequently an image of this surface of the workpiece W appears on the face of mirror 19 along with the profile image created by the beam emitted by the contour illuminator 21.
The combined images of the upper surface of the workpiece W and its profile are then reflected horizontally rearwardly by the mirror 19, through the lens system 18 and onto the face of the beam splitter 17 remote from the illuminator 15. The combined images are then reflected by the beam splitter 17 downwardly in the same vertical plane containing the beams from illuminators 15 and 21, and through a series of relay lenses 35 onto the inclined face of another mirror 36 which is mounted in frame 32 adjacent the rear thereof, and directly beneath lenses 35. The combined images are then reflected by mirror 36 through various magnification lenses 37 onto the surface of another inclined mirror 38, which is mounted in frame 32 adjacent the front surface thereof; and the inclined surface of mirror 38 directs the combined images upwardly onto the rear or underside of the screen 33. As a consequence, the combined contour and surface images observed by the operator standing at the front of the machine 30 will be upright and unreversed--i.e., the contour and upper surface of the workpiece W projected onto screen 33 will appear to be the same but somewhat enlarged.
From the foregoing it will be apparent that the present invention provides a relatively simple and inexpensive means for reproducing on the screen of a contour projector, or the like, upright or unreversed images of both the profile and the illuminated surface of a workpiece as it appears upon being observed by an operator, thus greatly facilitating both observation and measurement of a workpiece. Moreover, in each embodiment it will be noted that the axes of the beams of light from the emitters 15 and 21, and the projected images of the contour and workpiece face, will lie in a common vertical plane.
While in the second embodiment the screen 33 is shown to be mounted in a substantially horizontal position it will be understood that it, as well as the associated workpiece W, could be mounted in planes inclined to the horizontal without departing from this invention. Moreover, although this invention has been illustrated and described in detail herein in connection with only certain embodiments thereof, it will be apparent that it is capable of still further modification, and that this application is intended to cover any such modifications as may fall within the scope of one skilled in the art, or the appended claims.
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A workpiece is mounted in a contour projector machine so that at least one of two opposed sides thereof can be observed by the operator. The side observed by the operator is illuminated by a surface illuminator, and an image thereof is projected onto the machine's projection screen also to be observed by the operator. The side of the workpiece opposite to the side observed by the operator is illuminated by a contour projector, which projects a contour image of the workpiece onto the projection screen simultaneously with the image of the illuminated surface observed by the worker, thus producing on the screen upright an unreversed images of both the contour and the observed side of the workpiece.
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BACKGROUND
[0001] The exemplary embodiments relate to a laundry basket and, more particularly, relate to a laundry basket having a dispensing chute for dispensing clothing articles from the laundry basket into, for example, a washing machine or dryer.
[0002] Current laundry baskets tend to be rectangular or round baskets which hold clothes needing to be laundered. These current laundry baskets may need to be placed on the floor or a surface immediately in front of a washing machine or dryer.
[0003] The clothing articles must then be lifted up into the washing machine or dryer from the laundry basket which may be an uncomfortable process for some individuals. The current laundry baskets do not facilitate the loading of clothing articles into a washing machine or dryer.
BRIEF SUMMARY
[0004] The various advantages and purposes of the exemplary embodiments as described above and hereafter are achieved by providing, according to a first aspect of the exemplary embodiments, a laundry basket which includes a main body and a chute that extends from, and away from, the main body. The main body has an enclosing side portion and an end portion, the enclosing side portion and end portion cooperating to form an enclosure having an open end and a closed end defined by the end portion. The main body is totally enclosed by the enclosing side portion except for a slit in the enclosing side portion that extends from the open end towards the closed end of the main body.
[0005] According to a second aspect of the exemplary embodiments, there is provided a laundry basket which includes a main body having an enclosing side portion and an end portion, the enclosing side portion and end portion cooperating to form an enclosure having an open end and a closed end defined by the end portion, the main body further comprising a slit in the enclosing side portion that extends from the open end towards the closed end of the main body; and a chute integral with the side portion and extending from, and away from, the open end of the main body.
BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS
[0006] The features of the exemplary embodiments believed to be novel and the elements characteristic of the exemplary embodiments are set forth with particularity in the appended claims. The Figures are for illustration purposes only and are not drawn to scale. The exemplary embodiments, both as to organization and method of operation, may best be understood by reference to the detailed description which follows taken in conjunction with the accompanying drawings in which:
[0007] FIG. 1 is a perspective view of a first exemplary embodiment of the laundry basket.
[0008] FIG. 2 is a side view of the first exemplary embodiment of the laundry basket.
[0009] FIG. 3 is a top view of the first exemplary embodiment of the laundry basket.
[0010] FIG. 4 is an end perspective view of the first exemplary embodiment of the laundry basket.
[0011] FIG. 5 is a cross sectional view of the first exemplary embodiment of the laundry basket of FIG. 3 in the direction of arrows 5 - 5 .
[0012] FIG. 6 is a cross sectional view similar to FIG. 5 showing a second exemplary embodiment of the laundry basket.
[0013] FIG. 7 is a cross sectional view similar to FIG. 5 showing a third exemplary embodiment of the laundry basket.
[0014] FIG. 8 is a top view of a first modification of the first exemplary embodiment of the laundry basket.
[0015] FIG. 9 is a cross sectional view of the exemplary embodiment of the laundry basket of FIG. 8 in the direction of arrows 9 - 9 .
[0016] FIG. 10 is a top view of a second modification of the first exemplary embodiment of the laundry basket.
[0017] FIG. 11 is a cross sectional view of the exemplary embodiment of the laundry basket of FIG. 10 in the direction of arrows 11 - 11 .
[0018] FIG. 12 is a perspective view of a fourth exemplary embodiment of the laundry basket.
DETAILED DESCRIPTION
[0019] A conventional laundry basket is made to hold clothing items but when it comes time to unload the clothing items, a user must reach down and lift the laundry items from the laundry basket and place the clothing items in a washing machine or dryer.
[0020] The exemplary embodiments are substantially different in that the user may simply lift the laundry basket and essentially “pour” the clothing items from the laundry basket into the washing machine or dryer. The exemplary embodiments are further improved by having a slit in the side of the laundry basket so that a user may place his/her hand through the slit and manually push the clothes out from the laundry basket and into the washing machine or dryer. The exemplary embodiments of the laundry basket may also be nested for convenient storage.
[0021] Referring to the Figures in more detail, and particularly referring to FIGS. 1 to 4 , there is illustrated a first exemplary embodiment of a laundry basket 20 . The laundry basket 20 includes a main body 22 and a chute 24 . The main body 22 includes a side portion 32 which substantially encloses the space 26 within the laundry basket 20 and an end portion 28 , partially shown in phantom. The main body 22 further includes a slit 30 in the side portion 32 . It should be understood that when it is stated that the side portion 32 substantially encloses the space 26 within the laundry basket 20 , it is meant that the side portion 32 encloses the space 26 except for the opening caused by the slit 30 .
[0022] The end portion 28 closes off the main body 22 at one end. The other end 34 of the main body 22 is open. The slit 30 extends from the open end 34 of the main body towards the end portion 28 and, most preferably, extends entirely from the open end 34 to the end portion 28 . The slit should have a width sufficient for a user's hand to comfortably pass through the slit 30 without chafing the user's hand. For purposes of illustration and not limitation, the width may be 3 to 5 inches. In addition, the side portion 32 may have some flexibility so that when a user places his/her hand in the slit 30 , the slit 30 may expand so that the user's hand may comfortably pass through the slit 30 . In this latter instance when the side portion 32 may have some flexibility, the width of the slit may be just 1 to 3 inches.
[0023] As noted earlier, the laundry basket 20 includes a chute 24 . For added strength and functionality, the chute 24 may be integrally formed with the main body 22 . The chute 24 preferably has sides 36 which gradually decrease in size as the end 38 of the chute 24 is reached. The chute 24 has a curvature (best seen in FIG. 4 ) which generally matches the curvature of the end portion 28 of the main body. It is preferred that the chute 24 be disposed so that it is opposite the slit 30 (as best seen in FIG. 4 ).
[0024] For ease of handling the laundry basket, the side portion 32 may have one of more handles 40 formed in or added to the side portion 32 . The end portion 28 in addition may have a handle 42 (as best seen in FIG. 4 ) formed in or added to the end portion 28 . The chute 24 may have an edge portion 44 (as best seen in FIG. 2 ) which extends away from the chute 24 . Within the edge portion 44 , or added to it, may be another handle 46 .
[0025] FIG. 5 is a cross sectional view of FIG. 3 in the direction of arrows 5 - 5 . It can be seen that the side portion 32 has a circular cross section which encloses the space 26 except for slit 30 in the side portion 32 .
[0026] The side portion 32 may alternatively have an oval cross section such as side portion 32 A in FIG. 6 or a rectangular cross section such as side portion 32 B in FIG. 7 .
[0027] The laundry basket 20 may be conveniently made by injection molding but other manufacturing processes may be used as well. The laundry basket 20 may be made from any suitable material such as a plastic or polymeric material.
[0028] In use, the user may open the door of the washing machine or dryer and place the edge portion 44 of the chute 24 on the edge of, or in, the washing machine or dryer. The user may then tilt the end portion 28 up using anyone of the handles 40 or 42 and place a hand within the slit 30 and slide toward the edge portion 44 to push the clothing articles within the laundry basket 20 down the chute 24 and into the washing machine or dryer.
[0029] In addition to using a user's hand to assist in the unloading of the clothing articles, the laundry basket 20 may further include a sliding member (not shown) or secondary bottom (not shown) which may be moved to push the clothing articles from the laundry basket 20 . The sliding member or secondary bottom may cooperate with the slit 30 .
[0030] Referring now to FIG. 8 , the laundry basket 20 of FIGS. 1 to 4 , now referred to as laundry basket 50 , has been modified by adding a soft material 52 within the slit 30 . The soft material 52 , may be, for purposes of illustration and not limitation, a foam rubber. The soft material 52 may serve the dual purpose of covering the slit 30 to prevent small clothing articles from falling through the slit 30 and to protect the user's hand while passing through the slit 30 .
[0031] FIG. 9 is a cross sectional view of FIG. 8 in the direction of arrows 9 - 9 showing the soft material 52 . The soft material 52 may be formed integrally with the side portion 32 (as shown in FIG. 9 ) or may be added to it later by adhering strips of soft material to the side portion 32 , such as by an adhesive or mechanical fasteners.
[0032] Referring now to FIG. 10 , the laundry basket 20 of FIGS. 1 to 4 , now referred to as laundry basket 60 , has been modified by adding a flexible material 62 within the slit 30 . The flexible material 62 , may be, for purposes of illustration and not limitation, soft brushes. The flexible material 62 may serve the dual purpose of covering the slit 30 to prevent small clothing articles from falling through the slit 30 and to protect the user's hand while passing through the slit 30 .
[0033] FIG. 11 is a cross sectional view of FIG. 10 in the direction of arrows 11 - 11 showing the flexible material 62 . The flexible material 62 may be formed integrally with the side portion 32 (as shown in FIG. 11 ) or may be added to it later by adhering strips of brush material to the side portion 32 , such as by an adhesive or mechanical fasteners.
[0034] Referring now to FIG. 12 , there is shown yet another exemplary embodiment. Laundry basket 70 shown in FIG. 12 is similar to the laundry basket shown in FIGS. 1 to 4 except that laundry basket 70 has a slit 72 which is not opposite the chute 24 .
[0035] Also shown in FIG. 12 are perforations 74 in the laundry basket 70 . Perforations 74 may serve the purpose of ventilation to allow airflow through the laundry basket 70 to remove odors. Perforations 74 may also serve to reduce the weight of the laundry basket 70 . Perforations 74 are shown only on the main body 22 of the laundry basket 70 but may also be placed on the chute 24 if desired. It should be understood that while perforations 74 are only shown on the exemplary embodiment 70 in FIG. 12 , perforations may be used in any of the exemplary embodiments.
[0036] It will be apparent to those skilled in the art having regard to this disclosure that other modifications of the exemplary embodiments beyond those embodiments specifically described here may be made without departing from the spirit of the invention. Accordingly, such modifications are considered within the scope of the invention as limited solely by the appended claims.
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A laundry basket which includes a main body and a chute that extends from, and away from, the main body. The main body has an enclosing side portion and an end portion, the enclosing side portion and end portion cooperating to form an enclosure having an open end and a closed end defined by the end portion. The main body is totally enclosed by the enclosing side portion except for a slit in the enclosing side portion that extends from the open end towards the closed end of the main body.
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This is a nationalization of PCT/FR01/00976, filed Apr. 2, 2001 and published in French.
BACKGROUND ART
The invention relates to the fabrication of substrates, in particular for optics, electronics or opto-electronics.
Substrates for use in the aforementioned fields are generally obtained industrially by cutting up ingots. In the case of monocrystalline silicon, for example, the ingots are obtained from a bath of molten silicon by the Czochralski drawing method (referred to hereinafter as CZ drawing) or from a polycrystalline ingot by the zone fusion method (referred to hereinafter as FZ drawing). These growing methods produce cylindrical ingots which are then cut into slices perpendicular to the axis of the cylinder, generally using an internal cut circular saw.
However, the above methods do not produce substrates with satisfactory dimensions for some applications. This applies in particular in the field of fabrication of large substrates that can be used to make flat or other shape display screens or solar cells.
To obtain larger monocrystalline silicon substrates, the document FR 2 752 768 proposes cutting ingots parallel to their longitudinal axis.
BRIEF SUMMARY OF THE INVENTION
One object of the invention is to propose another way of fabricating substrates from ingots.
Another object of the invention is to obtain substrates of a monocrystalline material, such as monocrystalline silicon, for example, with lower production costs than with prior art methods.
That object is achieved by a method of fabricating substrates, in particular for optics, electronics or opto-electronics, the method being characterized in that it includes:
an operation of implanting atomic species under the surface of a material in the form of a cylindrical ingot at an implantation depth distributed around a particular value by bombarding said atomic species onto an area of the cylindrical surface of the ingot, and
a detachment operation at a detachment depth in the vicinity of the implantation depth of the layer of material between the surface and the detachment depth to detach that layer from the remainder of the ingot.
Thus in accordance with the invention a substrate is obtained by peeling off the surface layer of a cylindrical ingot parallel to the axis of the cylinder.
It must be understood that the term “substrate” is used throughout this text in the widest sense of the term, in other words to designate either an element of material able to serve as a support for another element or a thick or thin, rigid or flexible, etc. film or layer.
The terms “cylinder” and “cylindrical” must also be understood in their primary sense. In this sense, a cylinder is a solid body generated by a straight line that moves parallel to itself along the surface of a curve. In this text a cylinder can therefore have a round cross section or a polygonal cross section.
The method according to the invention advantageously enables continuous fabrication of substrates.
Because the method according to the invention can be implemented continuously, it increases the productivity of the fabrication of substrates and therefore reduces production costs. The method is particularly beneficial if it is required to fabricate monocrystalline silicon substrates at low cost, for example.
The method according to the invention has the following advantageous features, independently or in combination:
the implantation of the atomic species is effected by continuously bombarding the cylindrical surface of the ingot with a localised beam that is swept in the longitudinal direction of the ingot while the ingot rotates about an axis parallel to the cylindrical surface; the implantation of the atomic species is effected by continuously bombarding the cylindrical surface of the ingot with a beam of elongate cross section corresponding to a given area while the ingot rotates about an axis parallel to the cylindrical surface; the implantation of the atomic species is effected by bombardment corresponding to a given area of successive zones adjacent the cylindrical surface of the ingot while the ingot rotates about an axis parallel to the cylindrical surface of the ingot between each bombardment and the next; the implantation of the atomic species is effected by continuously bombarding the whole of the cylindrical surface of the ingot, for example by immersing the ingot in a plasma; it further includes an operation of heating the cylindrical surface; the heating operation can be carried out before, during or after implantation; the heating operation can be carried out by the implantation itself; the heating operation reduces the necessary dose of atomic species implanted and/or encourages in situ healing of some implantation defects; it includes an operation of transferring the layer of material between the cylindrical surface of the ingot and the detachment depth onto a support; it includes an operation of pressing the layer of material between the cylindrical surface of the ingot and the detachment depth by means of a roller; this pressing operation causes a thermal shock if the roller is cooled or heats the ingot if it is heated and/or applies mechanical pressure and/or shear stresses to encourage and/or cause detachment from the ingot of the layer of material between the cylindrical surface of the ingot and the detachment depth; the support is adhesive; it includes an operation of covering the layer of material between the cylindrical surface of the ingot and the detachment depth with a liquid phase or gas phase deposit; the material is silicon; the atomic species comprise hydrogen ions; the atomic species comprise doping ions such as phosphorus, arsenic or boron ions; it includes operations of applying a layer to each face of the layer of material between the cylindrical surface of the ingot and the detachment depth by rolling those layers between rollers; it includes an operation of transferring at least one layer comprising circuitry patterns onto the layer of material between the cylindrical surface of the ingot and the detachment depth.
For the fabrication of display screens and solar cells in particular, amorphous or polycrystalline silicon deposited on a glass substrate is often used, because monocrystalline silicon can be deposited on glass, on quartz, etc. at present only by layer transfer techniques using a monocrystalline silicon substrate to form the layer that is transferred onto the glass substrate. The diameter of monocrystalline silicon substrates is limited at present to 200 mm or even 300 mm.
Using the method according to the invention, it is possible to fabricate larger monocrystalline silicon substrates. Even if the monocrystalline silicon substrates obtained with some variants of the method according to the invention do not have a perfect crystalline orientation, they have better qualities than amorphous or polycrystalline silicon. Thus when they are used to make flat screens they offer an improvement in terms of integration density (number of pixels per unit surface area), screen refresh rate, etc. When they are used to make solar cells they increase the efficiency of photo-electric conversion.
Whether the substrates are small or large, the fact that the method of fabricating them can be implemented continuously reduces their cost.
Note that the initial diameter of the ingot is of little importance, but its length is more important. As a general rule, the greater the diameter of an ingot the shorter its length. Accordingly, depending on the intended applications, it is preferable to use an ingot of smaller diameter, because it is easier to obtain in a greater length. However, the layer made by the method according to the invention is obtained from the cylindrical surface of an ingot. In some embodiments of the method according to the invention, this layer can initially be given a curvature that can prove critical in some circumstances. For example, if the layer is to be stored on a cylinder with the curvature reversed, mechanical stresses can be generated that degrade the quality of the layer, or even cause it to break. As the diameter of the ingot increases, these curvature problems can become less severe.
It can also be beneficial to use large-diameter ingots if it is necessary to reduce the period in the resulting layer of variation of its crystalline orientation with the direction in which it is wound.
What is more, the curvature and crystallographic orientation problems referred to above are considerably reduced, or even non-existent, if the method according to the invention is used with ingots which have a square cross section, for example. In this case, the layer made by the method according to the invention is obtained from plane faces whose crystallographic orientation is clearly defined.
A 200 mm diameter ingot is typically 1.5 m long. As a general rule, before they are used in the method according to the invention, these ingots are cut into 40 to 50 cm lengths.
What is more, an ingot as drawn has an ill-defined exterior shape (undulating diameter, etc). During a preliminary step of the method according to the invention, the ingot is turned or machined to obtain an ingot in the form of a regular cylinder or having a polygonal cross section. The turning or machining operation is carried out before or after the cutting operations previously referred to.
With silicon ingots, a layer of the order of 10 μm thick is obtained by implanting hydrogen ions with energies of the order of 1 MeV. However, what is essential is to have a sufficiently rigid mass of material between the detachment depth and the surface of the ingot to avoid problems associated with the fragility and deformability of the layers.
The detachment depth is advantageously determined so that the continuous layers formed by the method according to the invention are self-supporting.
In an advantageous variant of the method according to the invention the layer is reinforced to prevent problems associated with its fragility or deformability by depositing a film before the detachment operation or even before the heating operation, if any, or even before the implantation operation. This variant is particularly advantageous when it is required to fabricate layers that are too thin to be self-supporting. In the case of silicon, for example, a 10 μm deposit of SiO 2 proves sufficient to reinforce the mechanical strength of the layer formed (a material other than SiO 2 can equally well be used). As a general rule, and therefore not only for applications of the method according to the invention to the fabrication of silicon layers, deposition methods of the epitaxial, atomisation, paint, spray, etc. type are also feasible.
The amounts of the atomic species implanted are advantageously of the order of 10 17 to 10 18 /cm 2 . With these amounts, and a depth of penetration of the order of one to several tens of microns, it is possible to separate the layer of material between the surface and the detachment depth from the remainder of the ingot with no additional heating operation and with the application of limited stresses or even no stresses.
As a general rule, if stresses are applied to the layer, they are advantageously mechanical stresses (shear, tension, compression, ultrasound, etc.), electrical stresses (electrostatic or electromagnetic field), thermal stresses (radiation, convection, conduction, etc.), etc. Applying stresses can also entail directing onto the layer/ingot detachment interface a jet of fluid (liquid or gas) that is either continuous or varies in time. Thermal stresses in particular can be derived from the application of an electromagnetic field, an electron beam, thermo-electric heating, a cryogenic fluid, a supercooled liquid, etc.
Another aspect of the invention provides a device for fabricating substrates, in particular for use in optics, electronics or opto-electronics, which device is characterized in that it includes:
means for implantation of atomic species under the surface of a material in the form of a cylindrical ingot at an implantation depth distributed around a particular value,
detaching means for detaching a layer of material at a detachment depth in the vicinity of the implantation depth, and
rotation means for rotating a cylindrical ingot of the material about an axis parallel to the cylindrical surface of the ingot.
The above device implements the method according to the invention as previously described. It advantageously includes means for holding the layer of material between the cylindrical surface of the ingot and the detachment depth to gather up said layer after it is detached from the ingot. The holding means advantageously include a plurality of reversible gripping means distributed over roller drive means. The principle of such gripping means is known in the art. Such gripping means employ pressure differences, electrostatic forces, etc., for example.
BRIEF DESCRIPTION OF THE DRAWINGS
Other aspects, objects and advantages of the invention will become apparent on reading the following detailed description. The invention is explained with reference to the drawings, in which:
FIG. 1 is a diagrammatic perspective view of an ingot subjected to ion implantation and to the detachment of a layer of material by a first embodiment of the substrate fabrication method according to the invention;
FIG. 2 is a diagrammatic view of one example of a substrate fabrication device according to the present invention, in cross section relative to the axis of the cylinder of the ingot shown in FIG. 1 ;
FIG. 3 is a diagrammatic view of the use of a second embodiment of the method according to the present invention, in cross section relative to the axis of the cylinder of an ingot like that shown in FIGS. 1 and 2 ;
FIG. 4 is a diagrammatic view of the use of a third embodiment of the method according to the present invention, in cross section relative to the axis of the cylinder of an ingot like that shown in FIGS. 1 to 3 ;
FIG. 5 is a diagrammatic view of the use of a variant of the embodiment of the method according to the present invention shown in FIG. 4 , in cross section relative to the axis of the cylinder of an ingot such as that shown in FIGS. 1 to 4 ;
FIG. 6 is a diagrammatic view of the use of another variant of the embodiment of the method according to the present invention shown in FIG. 4 , in cross section relative to the axis of the cylinder of an ingot such as that shown in FIGS. 1 to 5 ;
FIG. 7 is a diagrammatic view of the use of a fourth embodiment of the method according to the present invention, in cross section relative to the axis of an ingot like that shown in FIGS. 1 to 6 ;
FIG. 8 is a diagrammatic view of the use of a fifth embodiment of the method according to the present invention, in cross section relative to the axis of an ingot like that shown in FIGS. 1 to 7 ;
FIG. 9 is a diagrammatic view of the use of a variant of the fourth embodiment of the method according to the present invention, in cross section relative to the axis of an ingot like that shown in FIGS. 1 to 7 ;
FIG. 10 is a diagrammatic view of the use of a sixth embodiment of the method according to the present invention, in cross section relative to the axis of an ingot like that shown in FIGS. 1 to 9 ;
FIG. 11 a is a diagrammatic view of a substrate obtained with a seventh embodiment of the method according to the invention, in section perpendicular to the surface subjected to bombardment by the method according to the invention, and FIG. 11 b is a diagram showing the concentration profile of the atomic species implanted as a function of the depth of implantation in the substrate shown in FIG. 11 a;
FIG. 12 a is a diagrammatic perspective view of three layers intended to be superposed in an eighth embodiment of the method according to the invention and FIG. 12 b shows the structure obtained after assembling the three layers shown in FIG. 12 a;
FIG. 13 is a diagrammatic view of the use of a ninth embodiment of the method according to the present invention, in cross section relative to the axis of the cylinder of the ingot shown in FIGS. 1 to 10 ; and
FIG. 14 is a diagrammatic view of a square cross section ingot used in a variant of the present invention, in cross section relative to the axis of the ingot.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The method according to the present invention is described hereinafter in the particular context of obtaining monocrystalline silicon substrates from an ingot obtained by CZ or FZ drawing. Silicon has been chosen because it is by far and away the most widely used material in the field of micro-electronics. However, the invention is not limited to this material. The invention applies generally to ingots of any monocrystalline, polycrystalline or amorphous materials, in particular semiconductors.
FIG. 1 shows an ingot 1 of monocrystalline silicon obtained by the CZ or FZ drawing process. It is approximately the shape of a circular cylinder with an axis X—X. The ingot 1 initially has a diameter of 200 mm and a length L=1.5 m and is usually cut into lengths. The drawing process is chosen to obtain an ingot 1 in which the faces perpendicular to the axis of the cylinder are oriented parallel to the <1, 0, 0> crystallographic plane. The <0, 0, 1> plane 3 and the <0, 1, 0> plane 5 are therefore parallel to the axis X—X of the ingot 1 .
Ten examples of implementation of the method according to the invention are described hereinafter.
EXAMPLE 1
In the first example, shown in FIG. 1 , the method according to the invention includes an operation 100 of implanting atomic species and a detachment operation 300 .
In this example, the atomic species are H − ions. They are implanted with a high energy. The beam made up of these ions is elongate in the longitudinal direction of the ingot. To obtain a 10 μm thick layer 2 of silicon the H − ions are accelerated with an energy of 725 keV. The amount of H − ions implanted is 1.21×10 17 /cm 2 .
The implantation operation 100 is carried out by sweeping a beam of accelerated atomic species over the surface of the ingot 1 , over the whole of its length, matching the rotation speed of the ingot 1 to the width of the beam and to the sweeping rate to obtain the appropriate dose.
The implantation depth Rp varies according to the crystallographic orientation of the implanted surface relative to the incident beam of atomic species. In applications in which variations in the thickness of the layer 2 are critical, modulation of the thickness of the layer 2 obtained is advantageously avoided by modulating the implantation energy as a function of the rotation angle. Note, however, that if an ingot 1 which has a square cross section is used, these problems of thickness variations can be reduced or even eliminated, because the implantation can be effected on faces whose crystallographic orientation is clearly defined.
The implantation operation 100 creates, within the volume of the ingot 1 , and at a depth close to the depth of penetration of the H − ions, a fragile layer dividing the ingot 1 into a lower region constituting the mass of the ingot 1 and an upper region constituting a layer 2 of material destined to form the required substrate.
In the example described here the layer 2 is approximately 10 μm thick. That thickness is sufficient to avoid deformation of the layer (for example the formation of blisters) and the implantation conditions produce sufficient fragility at the detachment depth for the layer 2 to be detached from the ingot 1 with less force.
The separated layer 2 is advantageously held to enable it to be unwound.
FIG. 2 shows a device 50 in accordance with the invention for fabricating substrates which implements the method illustrated by FIG. 1 . It includes means 110 for implanting H − ions, means 310 for holding the layer 2 when it has been separated from the ingot 1 , and rotation means 410 .
The implantation means 110 comprise an implanter which produces H − ions accelerated to an energy of the order of 1 MeV. This type of implanter was initially developed by the Japan Atomic Energy Research Institute (JAERI).
The rotation means 410 cause the ingot 1 to rotate about the axis X—X.
The holding means 310 comprise a support 6 . The support 6 is advantageously an adhesive film. The layer 2 is brought directly into contact with the support 6 . The support 6 is pressed against the layer 2 by an applicator roller 315 . The applicator roller 320 is mounted on a shaft that is mobile so that it can track the movement of the surface of the ingot 1 as its diameter is decreased by the removal of material. Accordingly, when the ingot 1 begins to rotate about the axis X—X, before it has been implanted, no transfer of the layer 2 onto the support 6 is effected. Then, when the implantation operation 100 is started, and the implanted area comes into contact with the support 6 , the latter enables the layer 2 to be transferred onto the support 6 . After contact with the layer 2 , it separates the latter from the remainder of the ingot 1 . The transfer of the layer 2 onto the support 6 can then continue.
EXAMPLE 2
A second example of implementation of the method according to the invention, shown in FIG. 3 , includes an implantation operation 100 , a heating operation 200 and a detachment operation 300 .
The species implanted are advantageously hydrogen ions. Hydrogen ions are implanted with an energy of the order of 700 keV and a dose of the order of 10 17 /cm 2 .
With the ingot 1 rotating continuously about its axis X—X in the device 50 , the area of the surface of the ingot 1 bombarded by the atomic species during the implantation operation 100 moves towards a heating area.
The heating operation 200 is carried out after the implantation operation 100 by heating means 210 . The heating operation 200 assists detaching the layer 2 between the surface and the detachment depth from the remainder of the ingot 1 . The heating operation 200 enables the doses of atomic species implanted to be reduced relative to the dose referred to in example 1.
The heating means 210 consist of a heating roller 215 in the form of a circular cylinder with its axis parallel to the rotation axis of the ingot 1 . The heating roller 215 is placed downstream of the implantation means 110 relative to the rotation direction of the ingot 1 . The heating roller 215 is in contact with the ingot 1 . The heating means 210 advantageously heat the surface of the ingot 1 locally to a temperature of around 500° C./600° C. The temperature is adjusted to suit the time of application of the heating means 210 and the implantation conditions, such as the implantation dose and energy. The dose and energy parameters also determine the temperature reached by the surface of the ingot 1 during the implantation operation 100 . This heating of the ingot 1 by implantation is taken into account in the thermal budget which determines the conditions of detachment of the layer 2 from the remainder of the ingot 1 . The time of application of the heating means 210 also depends on the application surface area, the rotation speed of the ingot 1 , etc.
The layer 2 is then transferred onto a support 6 , as described in example 1.
EXAMPLE 3
A third example of implementation of a device 50 for implementing a method according to the invention, shown in FIG. 4 , includes an implantation operation 100 and a heating operation 200 , like those of example 2, plus a detachment operation 300 performed with the aid of holding means 310 . The holding means 310 can employ a pressure difference, an electrostatic force, a reversible adhesion force (by application of a low-tack adhesive), etc.
If the holding means 310 are of the suction type, they advantageously comprise a bar 315 with its length parallel to the axis X—X of the ingot 1 . The bar 315 is hollow. The pressure inside the bar is reduced to hold the layer 2 reversibly by suction. Detachment of the layer 2 from the remainder of the ingot 1 is encouraged by the heating operation 200 .
To begin peeling the layer 2 off the ingot 1 , the holding means 310 are applied to the first area of the ingot 1 that has been subjected to the implantation operation 100 and the heating operation 200 . Because of the suction in the bar 315 , mechanical stresses are applied to the layer 2 . Those mechanical stresses are reinforced by movement E of the bar 315 away from the ingot 1 . A separation front F is then obtained.
The holding means 310 are moved by the means shown in FIGS. 5 and 6 , for example.
In the embodiment shown in FIG. 5 , bars 315 are distributed over the periphery of a drive roller 316 . The principle of FIG. 6 is the same as that of FIG. 5 , but the bars 315 are distributed over a conveyor belt 317 moving in a straight line between two drive rollers 316 .
In the embodiments shown in FIGS. 5 and 6 the pressure inside the bar 315 is reduced just before it comes into contact with the ingot 1 . At the moment of contact the bar 315 adheres to the surface of the ingot 1 . If the ingot has not been subjected to the implantation operation 100 and the heating operation 200 , in the area of contact between the ingot 1 and the bar 315 the latter move relative to each other and the contact is broken. On the other hand, if the ingot has been subjected to an implantation operation 100 in the area of contact between the ingot 1 and the bar 315 , the layer 2 is separated from the remainder of the ingot 1 and is held by the bar 315 . The vacuum in the bar 315 is broken when the area of the layer 2 held by the bar 315 reaches a take-up roller 8 .
This embodiment has the advantage over the previous embodiment that the layer 2 is subject to lower mechanical stresses because there is no reversing of the curvature of the layer 1 between the detachment operation 300 and the operation of storing it on the take-up roller 8 . holding means 310 and entrained by the support 6 .
In a variant of these embodiments of the method according to the invention, the layer 2 is transferred to a support (not shown in FIGS. 5 and 6 ). In this case, the layer 2 is moved away from the ingot 1 by the holding means 310 , as previously indicated, and then transferred to the support, to which it adheres. The layer 2 is then released by the holding means 310 and entrained by the support.
In this variant the layer 2 can be cut into sheets before or after it is transferred to the support 6 .
EXAMPLE 4
A fourth example of implementation of the method according to the invention includes an implantation operation 100 , an operation 400 of transfer onto a stiffener support 6 , and a heating operation 210 carried out before or during the transfer operation 400 .
This is shown in FIG. 7 .
In this example, the implantation operation 100 is carried out at an energy of 100 to 200 keV. This energy is insufficient to produce self-supporting layers 2 . The support 6 then acts as a stiffener. This prevents the layer 2 breaking and/or deforming (by forming blisters, for example).
The support 6 is advantageously an adhesive film. The adhesive film consists of a polymer resin, for example, or some other substance suited to this function, which becomes adhesive when it is heated or when it is irradiated with UV radiation. The adhesive film is stretched between two rollers 8 , 10 between which the ingot 1 is pressed onto the support 6 . The axes of the rollers 8 , 10 and the ingot 1 are parallel. The support 6 is initially wound onto a pay-out roller 10 .
The ingot 1 is rotated about its axis X—X by rotation means 410 .
In this example the heating means take the form of a roller 215 . The roller presses the support 6 and the layer 2 together and heats them at the same time. The support 6 serves as a stiffener which prevents deformation of the layer 2 (for example by blisters) that could otherwise occur during the heating operation that is virtually simultaneous with the coming into contact of the layer 2 and the support 6 . The heating operation 210 strengthens the adhesion between the support 6 and the layer 2 and contributes to making the ingot 1 fragile at the detachment depth.
After adhering to the support 6 , the layer 2 leaves the ingot 1 at the separation front F. Synchronizing the rotation of the ingot 1 with the movement of the support 6 propagates the separation of the layer 2 relative to the ingot 1 at the front F. At the separation front F, the material is sufficiently fragile for the mechanical stresses applied to the ingot 1 by the support 6 to complete detachment.
If the implantation and heating parameters are chosen accordingly, the detachment of the layer 2 from the ingot 1 has already occurred by the time of the heating operation 200 and the support 6 merely entrains the layer 2 away from the ingot 1 .
The combination of the layer 2 /support 6 is then wound onto a take-up roller 8 for storage.
As an alternative to the above, the support 6 can be preheated before it is brought into contact with the ingot 1 or the ingot 1 can be preheated before the support 6 is brought into contact with it.
In another variant of the embodiment of the method according to the invention described hereinabove a wedge, blade or some other type of mechanical contact or a jet of fluid, such as a gas, is used to initiate the separation of the layer 2 from the ingot 1 .
In a further variant of this embodiment, the support 6 takes the form of a plate 20 (see FIG. 9 ). The plate 20 is rigid. It is made of glass or quartz, for example. Thus an implantation operation 100 can be carried out after which the layer 2 is transferred to the plate 20 ; it can be heated to facilitate detachment and transfer of the layer 2 onto the plate 20 and adhesion of the layer to the plate. It is also possible to interrupt the implantation operation 100 to complete the transfer of a portion of the layer 2 already implanted onto the plate 20 and then start again with a new plate 20 .
EXAMPLE 5
A fifth example of implementation of the method according to the invention is derived from the fourth example, illustrated by FIG. 7 . The fifth example, illustrated by FIG. 8 , includes an implantation operation 100 , a heating operation 200 and an operation 400 of transfer onto a stiffener support 6 , as in the fourth example, but further includes an operation that creates a thermal shock. After the implantation operation 100 , the ingot 1 is at a relatively high temperature. By pressing a cooling roller 216 against the ingot 1 in the areas that have been subjected to the implantation operation, a thermal shock is produced that facilitates separating the layer 2 and the ingot 1 .
EXAMPLE 6
A sixth example of the implementation of the method according to the invention includes an implantation operation 100 , a heating operation 200 and a detachment operation 300 , all of which are of the same kind as those of example 4. However, it further includes an operation of covering the layer 2 deposited on the support 6 with a covering material 12 . The covering material 12 is deposited in the form of a film or in the liquid or gas phase. This example is illustrated by FIG. 10. A system of three layers 6 , 2 and 16 is then obtained. One example of use of an embodiment of this kind is described hereinafter in example 8.
EXAMPLE 7
A seventh example of implementation of the method according to the invention includes an implantation operation 100 which is advantageously effected simultaneously with H − ions and phosphorus ions ( FIG. 11 a ). With the same acceleration energy, the H − ions are implanted more deeply than the phosphorus ions, because they are not so heavy. The H − ions therefore determine the depth at which detachment occurs. The phosphorus ions produce an n-doped doping layer 16 . The layer underlying the doping layer 16 forms a p-doped layer 17 . FIG. 11 b shows the profile of the concentration C of the atomic species H − , P 2 H 6 and PH 3 as a function of the depth of implantation in the layer 2 and the ingot 1 shown in FIG. 11 a . Thus doping and implantation for the purpose of detachment can be carried out at the same time.
This example is advantageously completed by a heating operation 200 , a detachment operation 300 and a transfer operation 400 as described in example 4.
EXAMPLE 8
An eighth example of implementation of the method according to the invention is derived from the sixth and seventh examples described hereinabove. In the eighth example, shown in FIGS. 12 a and 12 b , the support 6 and the covering material 12 already incorporate patterns.
FIG. 12 a shows a support 6 , a layer 2 and a covering material 12 . The support 6 includes interconnection patterns (not shown). The silicon layer 2 is obtained from a silicon ingot 1 by the method according to the invention. The layer 2 includes an n-doped layer 16 that is advantageously doped with phosphorus or arsenic and a p-doped layer 17 , as indicated hereinabove in example 7. The covering material 12 also includes interconnection patterns. The combination of the three layers 6 , 2 and 12 is assembled by the method according to the present invention, for example the variant of the method illustrated by FIG. 6 . This produces a photovoltaic device like that shown in FIG. 12 b , in which the face including the covering material 12 is exposed to the photons 18 .
The covering material 12 provides an antireflection coating. The surface of the layer 2 is rough because it has not been polished after the detachment operation 300 of the method according to the present invention. This enables light 18 to penetrate into the layer 2 with multiple reflections.
EXAMPLE 9
In a ninth example of implementation of the method according to the invention, shown in FIGS. 13 a and 13 b , the implantation operation 100 is carried out over the whole of the surface of the ingot 1 . To this end the ingot 1 is placed in a plasma implantation chamber in which the atomic species are accelerated to the required voltage ( FIG. 13 a ).
The ingot 1 is then optionally subjected to a heating operation 200 , depending on the conditions used in the preceding implantation operation 100 .
The ingot 1 is then withdrawn from the implantation chamber to peel off the layer 2 . The layer 2 is advantageously transferred onto a support 6 , as in any of the preceding examples ( FIG. 13 b ).
In a variant of this example the ingot 1 is subjected to the other operations leading to the formation of the layer 2 in the same chamber as the implantation operation 100 .
EXAMPLE 10
A tenth example of implementation of the method according to the invention by using a device 50 , shown in FIG. 14 , includes an implantation operation 100 , a healing operation 200 , and a detachment operation 300 , conforming to those described in connection with example 2, but the ingot 1 has a square cross section relative to its longitudinal axis. The heating operation 200 and the detachment operation 300 are carried out simultaneously by means of a heating roller 215 . The heating roller 215 is mounted on a shaft that is mobile so that it can track the movement of the faces of the ingot 1 as it rotates and so that it can track the movement of the surface of the ingot 1 as its size is reduced by removing material.
Many variants of the method according to the invention can be obtained by combining the various embodiments described hereinabove.
In the embodiments described hereinabove, the implantation operation 100 is carried out by bombarding the surface of the ingot 1 either with a beam of atomic species or by immersion in a plasma. If a beam of atomic species is used, it can have a linear or rectangular shape or any other geometry. The ingot 1 can also be bombarded radially by more than one beam, simultaneously at several points on the surface, or even over the whole of its surface.
In the embodiments described hereinabove, a heating operation 200 can be carried out to encourage and/or cause detachment of the layer 2 from the ingot 1 . That operation can be complemented by the application of mechanical stresses to complete said detachment and separate the layer 2 from the remainder of the ingot 1 . However, the detachment of the layer 2 from the ingot 1 can be encouraged and/or caused entirely by the heating operation 200 . It can also be encouraged and/or caused entirely by mechanical stresses.
Similarly, in the embodiments described hereinabove, the atomic species implanted to create microcavities is hydrogen. Other atomic species can equally well be used. Examples are helium, boron, etc. Boron is advantageously used to dope the layer at the same time as encouraging or causing detachment. Boron can equally advantageously be used to reduce the doses of the atomic species implanted and/or the temperatures and/or the times of heating of the optional heating operation 200 (see U.S. Pat. No. 5,877,070, for example).
For some applications, and in particular if the surface of the ingot 1 exposed to implantation must be protected, a buffer layer can be deposited on the upstream side of the implantation 100 , relative to the direction of rotation of the ingot 1 .
Similarly, it can be beneficial to deposit a stiffener on the ingot 1 , even before the implantation operation 100 .
As a general rule, depending on the intended applications, it can be beneficial to deposit a support 6 (stiffener, reflecting layer, etc.) on one or both of its faces before or after the layer 2 is peeled off.
In a further variant of the method according to the invention, the layer 2 is transferred temporarily to a support 6 serving as a stiffener enabling a detachment operation 300 to be carried out, or even only a operation constituting a preliminary to the detachment operation, such as a heating operation 200 , preventing deformations such as those caused by the formation of blisters. The support 6 advantageously carries the layer 2 from the ingot 1 from which it has been obtained to storage means or carries the layer 2 before it is transferred to another support that confers the required mechanical strength on it. Thus one face of the layer 2 can adhere temporarily to the temporary support 6 , which possibly also serves as a stiffener, after which another support is caused to adhere to the other face, after which the temporary support 6 is finally removed.
A roller in contact with the ingot 1 downstream of the implantation means 110 can also serve as a temporary stiffener. This is advantageously combined with a heating operation 200 .
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The invention concerns a method for making substrates, in particular for optics, electronics or optoelectronics. The method includes an operation which consists in implanting ( 100 ) atomic species beneath the surface of a material in the form of a cylindrical ingot ( 1 ), at a depth of implantation distributed about a certain value by bombardment of the atomic species on a zone of the ingot ( 1 ) cylindrical surface, and an operation which consists in removing ( 300 ), at a separation depth located proximate to the depth of implantation, the layer ( 2 ) of material located between the surface and the separation depth, to remove the layer ( 2 ) from the rest of the cylindrical ingot ( 1 ).
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BACKGROUND AND SUMMARY OF THE INVENTION
The invention relates to a piezoelectric crystal with transversal effect. Such piezoelectric crystals have changes or reactions in different planes to applied forces. Those changes generally occur transverse to the direction of the applied force.
Piezoelectric crystals are employed in various sensors for measuring forces, pressures, accelerations, strains and moments. For this purpose, crystals with transversal effect are cut into thin plates or rods, for example. For metrological uses, these thin plates are exposed typically to a pressure on the small end surfaces of the plate, causing an electrical charge to appear on the two large side surfaces. By placing an electrically conductive layer on the two side surfaces, which however have no electrical contact with each other, this charge is measured with an appropriate device in the sensor so that information about the pressure is obtained and may be transmitted further. Such sensors are well known.
What is crucial, however, is that the crystal is fitted vertically and centered on the axis of the sensor. Any slight tilt will result in a false measurement or fracture of the crystal under the influence of the forces occurring subsequently. A contact of the crystal to the edge of the sensor may lead to a short circuit or hysteresis.
Since the sensitivity of the crystal is proportional to the ratio of the charge pickup surface to the pressure surface, these conventional crystal plates are very thin. Hence the handling, especially the centering and aligning in the sensor, are very difficult and laborious.
Often the sensor is fitted with centering aids which hold the crystal in position. However the various materials of these centering aids do not tolerate very high temperatures. Consequently the application areas of the known sensors as a whole are limited to a lower maximum temperature.
The present invention provides for a piezoelectric crystal which can be fitted easily into a sensor without laborious centering and aligning, and without restriction to a lower temperature range. Furthermore, the crystal of the present invention can be manufactured in large quantities, at low cost and fully automatically.
The present invention, then, is a piezoelectric crystal with transversal effect that has at least one plate and at least one base at an angle to the at least one plate. The at least one base projects laterally beyond a thickness of the at least one plate on at least one side of the at least one plate. An embodiment of the present invention may have two such identical crystals.
The present invention also includes a sensor for detecting one or more of force, pressure, acceleration, moments and strain signals by using at least one of the piezoelectric crystals with transversal effect discussed above.
The present invention also includes a method for producing the piezoelectric crystals with transversal effect.
Other aspects, advantages and novel features of the present invention will become apparent from the following detail description of the invention when considered in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 a is a side sectional view of a piezoelectric crystal fined in a sensor, according to the state of the art.
FIG. 1 b is a plan view of FIG. 1 a.
FIG. 2 a is a side sectional view of a piezoelectric crystal arrangement fitted in a sensor, according to the state of the art.
FIG. 2 b is a plan view of FIG. 2 a.
FIG. 3 is a perspective view of an embodiment of a piezoelectric crystal, according to the present invention.
FIG. 4 a is a sectional view of another embodiment of a crystal in a fitted position, according to the present invention.
FIG. 4 b is a plan view and partial cross-sectional view of the fitted crystal of FIG. 4 a.
FIG. 5 is a perspective view of the production process of wafer crystals, according to the present invention.
FIG. 6 is a sectional view of an embodiment of a double crystal, according to the present invention.
FIG. 7 is a sectional view of an embodiment of another double crystal, according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIGS. 1 a and 1 b show a piezoelectric crystal 11 with transversal effect in the form of a plate (not numbered), fitted in a sensor 10 , as is known from the state of the art. The crystal 11 is clamped at its ends by holding devices 12 , 1 , to retain it in a required position. FIG. 1 b shows the crystal 11 fitted in a sleeve 14 . The electrical charges (+, −) are taken off from two side surfaces 15 , 16 on electrically conductive layers or electrodes 17 , 18 , provided for this purpose. For example, one electrically conductive layer 17 leads to an upper holding device 12 that is negatively (−) charged, while the other conductive layer 18 leads to a lower holding device 13 on the opposite side that is positively charged (+). Accordingly, the two holding devices 12 , 13 have opposite electrical charges.
FIGS. 2 a and 2 b show another embodiment known from the state of the art. In this embodiment, typically three identical crystal rods 11 , their cross sections having the form of circular segments, are disposed in a circle as shown in FIG. 2 b . The charge on the outer surface 18 of each of the crystals 11 is picked up via a sleeve 14 at or through one end of the sensor 10 , for example. The other pole or polarity electrode 17 on the inside of the crystals 11 is picked up via an electrically conducting spiral 19 , as shown in FIG. 2 a . The spiral 19 also acts as a centering aid for the crystals 11 , which in turn are held from outside on or by the sleeve 14 .
FIG. 3 shows a crystal 20 with transversal effect according to the present invention. This crystal 20 comprises preferentially a monocrystalline material, whose symmetry of the piezoelectric constant d corresponds to that of the point group 32 . This crystal 20 includes a base 21 which has a plate 22 attached at one end of the crystal 20 . The base 21 projects laterally beyond the thickness of at least one side 15 , 16 of the plate 22 . The projection may be at right angles. According to the present invention, a transition surface (not identified) from an end of the plate 22 to the base 21 may have a curvature 23 to enhance the stability of the base 21 and plate 22 . Other types of transition surfaces are possible. At both an end face 24 of the plate 22 opposite from the end adjacent the base 21 and on the bottom of the base 25 , bevels 26 may be provided to prevent edges, sides and related surfaces of the crystal 20 from breaking.
The sides of the plate 15 , 16 are each coated with an electrically conductive layer 17 , 18 , making a charge transport possible. One layer 17 runs on one side 15 to the top end of the crystal plate 22 . The layer 18 on the opposite side 16 runs on over the edge of the base 28 to the bottom of the base 25 . If the crystal 20 is clamped by suitable holding devices 12 , 13 (see FIG. 4 a ), opposed charges can be picked up on the bottom of the base 25 and on the end face 24 of the plate 22 . At the end face 24 and the base 25 , it is essential that the electrically conductive layers 17 , 18 are insulated electrically from each other. To ensure this, an insulating bevel 29 may be provided at the end face 24 . Face 34 at the base 21 of the crystal plate 22 , may be insulated by removing all or part of its conductive layer 17 such that any connection between the electrically conductive layers 17 , 18 is interrupted.
FIG. 4 a shows a crystal 70 fitted in a sensor 10 . The bottom holding device 13 has a drilled area or recess 30 into which the base 21 can be fitted. This recess 30 must be less deep than the height of the edge of the base 28 , to ensure that the side 15 having the electrically conductive layer 17 leading upwards has no electrical contact with an edge of the recess 30 . Face 34 may be insulated by removing all or part of its conductive layer 17 . The other side 16 having the electrically conductive layer 18 must have a good electrical contact at the bottom of the recess 30 .
FIG. 4 b shows a plan view and partial cross sectional view of the crystal 70 fitted into recess 30 of holding device 13 . The edge of the base 28 may be circular, at least in part, and has partially rounded contours 31 formed on the base 21 . This ensures that the crystal 70 fits into the recess 30 of the holding device 13 (See FIG. 4 a ). The curvature or contours 31 may be continuous and extend over the side faces 32 of the crystal plate 22 . The curvature 31 on the base 21 should not be continuous on side 33 parallel to the crystal plate 22 . Otherwise, the forming of curvature 31 would remove the electrically conductive layer 18 completely, which would have to be restored again to assure contact with the bottom surface of the base 25 . By forgoing a complete curvature 31 on side of base 33 , the electrically conductive layer 18 is retained and contact with the electrically conductive layer 18 of the bottom of the base 25 is assured.
A method or process for the mass production of crystals, such as crystal 20 , according to the present invention, is shown in FIG. 5. A crystal wafer 40 may be in rectangular form, for example, (other geometric forms are possible). The wafer 40 may be cut in a first process stage or step so that a plate 41 of a desired thickness T is obtained, with a base ledge 42 running at least along one edge of the plate 41 . Here it is essential that the transition from the plate 41 to the base ledge 42 has a curvature 23 (shown as concave) in accordance with the present invention. In a further process stage the crystal wafer 40 is coated completely with an electrically conductive layer, except for end faces 43 . After this, the electrically conductive layer is broken through, preferentially at two areas. One of these areas is on or along one edge of base ledge 44 on one side of wafer 40 . The other area may be provided on or along end face 24 diametrically and on the other side of the crystal wafer 40 . At these areas, it is advisable to provide insulating bevels 29 , 45 . This results in two electrically conductive layers 17 , 18 isolated electrically from each other.
In a further process step, the crystal wafer 40 (See FIG. 5) may be divided into two or more smaller crystals 20 , all having a base 21 and electrically conductive layers 17 , 18 (see FIG. 3 ). Each base 21 of crystal 20 may have at least one partially rounded contour or curvature 31 on one or more of four comers of the base 21 which may extend over the sides 32 of the plate 22 without interruption (see FIG. 3 ).
In a further process step, each crystal 20 may be provided with bevels 26 on the bottom edge of the base 21 and along the edge of the end face 24 . However, the electrically conductive layer 17 on end face 24 must not be interrupted. The bevels 26 may be produced on the crystal wafer 40 before the electrically conductive layer is applied to the wafer 40 .
The crystal 20 is inserted into the recess 30 of the holding device 13 by inserting the base 21 first. Care must be taken to ensure that the recess 30 is large enough to have some play to allow insertion of the crystal 20 without breaking. The edge of the base 28 may be about twice as high as the depth of the recess 30 . The crystal 20 is not clamped in the recess 30 , but is held sufficiently rigid to allow the second holding device 12 to be fitted on the opposite end of crystal 20 without the crystal 20 being able to shift off-center or tilt.
The overall height of crystal 20 may be between approximately 1 and 40 mm, and preferably between 2 and 10 mm. The height of the base 21 , including the rounded contours 31 to the crystal plate 22 , may be approximately {fraction (1/10)} th to ⅓ rd of the overall height of the crystal 20 . The crystals 20 described herein are suited for use in metrology, and in particular, for measuring forces, pressures, accelerations, moments and strains.
Another embodiment of the present invention, crystal 50 , is shown in FIG. 6 . This double crystal 50 may have two or more crystal plates 22 , joined by a common base 21 . This arrangement provides approximately a double load capacity of the crystal 50 under pressure or force, with the same sensitivity and overall height as crystal 20 . This structure is formed by removing material from the center of wafer 40 (see FIG. 5) down to the base 21 . Other configurations with more than two plates 22 are also possible. With this double crystal 50 configuration or similar configurations, it must be ensured that each crystal plate 22 has an electrically conductive layer 17 , 18 on both sides, with the two layers 17 , 18 of a plate 22 having different holding devices 12 , 13 , respectively, in electrically conductive contact and insulated from the other. For this, the insulating surfaces or bevels 29 must be applied. A surface or surfaces of hole 59 may be provided with an electrically conductive layer 18 in order to conduct a charge from the interior conductive layer 18 to the bottom of the base 25 . Additionally, there may be other ways to electronically connect layer 18 with the bottom of base 25 , such as connecting another surface (not shown) of crystal 22 to the base 25 . To separate electrically charged layers 17 and 18 , surface 57 may be insulated by removing all or part of its conductive layer 17 adjacent hole 59 .
Another embodiment of the present invention, crystal 60 , is shown in FIG. 7 . This embodiment has two identical crystal plates 22 , each having a base 21 projecting beyond each of the crystal plates 22 at one side of the plate 22 only. The sides 16 of the crystals 20 having no base can thus be placed adjacent to each other or together. Since sides 16 have the same polarity, short-circuiting upon contact is ruled out. The production of this crystal 60 is analogous to the production of crystals 20 from wafer 40 already described except only one face of the wafer 40 is shaped. Placing two crystals together gives a configuration 60 similar but not identical to that of one crystal 20 in FIGS. 3 and 4 a . The difference is that generally, with equal geometrical conditions, the same force may be applied onto the crystal or crystals 20 , but the sensitivity of the configuration with the double crystal 60 should be approximately twice as high as a configuration with the single crystal 20 . That is because a surface area of the charge pickups, as shown but not identified in FIG. 7, is approximately double what is shown but not identified in FIG. 3 . When the width of the crystal plates 22 is doubled, load capacity is approximately doubled for the same sensitivity. With regard to a self-centering capability, the double crystal 60 in FIG. 7 is equal to that of the single crystal 20 in FIG. 3 .
In all the embodiments of the present invention, there is no need for ancillary or additional materials or aids to facilitate centering of the crystals 20 , 50 , 60 in a sensor 10 . Consequently, the application range of the crystals 20 , 50 , 60 in a sensor 10 is subject to no restrictions due to temperature.
Although the present invention has been described and illustrated in detail, it is to be clearly understood that this is done by way of illustration and example only and is not to be taken by way of limitation. The spirit and scope of the present invention are to be limited only by the terms of the appended claims.
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A piezoelectric crystal with transversal effect comprising: at least one plate; and, at least one base at an angle to the at least on plate, the at least one base projecting laterally beyond a thickness of the least one plate on at least one side of the at least one plate. A piezoelectric sensor, for detecting one or more of force, pressure, acceleration, moments and strain signals, comprising at least one of the piezoelectric crystals with transversal effects. A method for producing the piezoelectric crystals with transversal effect is disclosed.
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BACKGROUND OF THE INVENTION
[0001] A refrigerator is an appliance used to store food items at preset temperatures. A refrigerator appliance typically includes one or more temperature-controlled compartments into which food items may be placed to preserve the food items for later consumption. A refrigerator appliance also typically includes a plurality of shelves on which the food items may be arranged within the one or more temperature-controlled compartments. One problem with this type of refrigerator is that for certain types of containers, like wine bottles for instance, a refrigerator shelf may present space issues. The bottle may be too tall to fit within the space between the shelves. The shelves may not be convenient to lay a bottle down on its side, as the bottle may roll back and forth on the shelf. As such, a refrigerator may also include a rack for the storage of wine or other drinks with a suitable bottle for holding by the neck through an aperture. The rack may be attached to the shelves within the one or more temperature-controlled compartments.
SUMMARY OF THE PRESENT INVENTION
[0002] In one aspect, a refrigerator may include a cabinet, a liner, a fresh food compartment, a plurality of movable shelves, a plurality of shelf ladders, and a wine rack assembly, the wine rack assembly comprising a wine rack and a pair of wine rack brackets.
[0003] In another aspect, a refrigerator may include a cabinet, a liner, a fresh food compartment, a plurality of movable shelves, a plurality of shelf ladders, and a wine rack assembly, the wine rack assembly comprising a wine rack with a pair of pins, and a pair of wine rack brackets with holes corresponding to the pins on the wine rack.
[0004] In yet another aspect of the present invention a refrigerator may include a cabinet, a liner, a fresh food compartment, and a wine rack assembly, the wine rack assembly comprising a wine rack with at least four pins, and at least four liner grommets corresponding to the four rack pins.
[0005] In yet another aspect of the present invention a refrigerator may include a cabinet, a liner, a fresh food compartment, and a wine rack assembly, the wine rack assembly comprising a wine rack with at least two pins and at least two spring pin assemblies, and at least six liner grommets corresponding to the two rack pins and at least two spring pin assemblies in at least two different positions.
[0006] In another aspect, a refrigerator may include a cabinet, a liner, a fresh food compartment, a plurality of movable shelves, a plurality of shelf ladders, and a wine rack assembly, the wine rack assembly comprising a wine rack with a pair of pins, and a pair of wine rack brackets with corresponding attachments to the shelf ladders.
[0007] In still another aspect, a refrigerator may include a cabinet, a liner, a fresh food compartment, a plurality of movable shelves, a plurality of shelf ladders, and a wine rack assembly, the wine rack assembly comprising a wine rack and a pair of wine rack brackets, wherein the wine rack comprises a number of spaced round holes to hold bottles of wine substantially horizontal.
[0008] In still another aspect, a refrigerator may include a cabinet, a liner, a fresh food compartment, a plurality of movable shelves, a plurality of shelf ladders, and a wine rack assembly, the wine rack assembly comprising a wine rack and a pair of wine rack brackets, wherein the wine rack comprises a number of elongated holes to hold different sized bottles of wine substantially horizontal.
[0009] These and other aspects, objects, and features of the present invention will be understood and appreciated by those skilled in the art upon studying the following specification, claims, and appended drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] In the drawings:
[0011] FIG. 1 is a front elevation view of a refrigerator showing a number of adjustable shelves mounted on a number of shelf ladders within a fresh-food compartment of the refrigerator.
[0012] FIG. 2 is an exploded view of the adjustable shelf brackets and the shelf ladders within the fresh-food compartment of the refrigerator.
[0013] FIG. 3A is a plan view of a shelf with a wine rack installed.
[0014] FIG. 3B is a side elevation of a shelf with a wine rack installed.
[0015] FIG. 4A is a plan view of another embodiment with the shelf and wine rack installed.
[0016] FIG. 4B is a side elevation of another embodiment with the shelf and wine rack installed.
[0017] FIG. 4C is an isometric exploded view of a wine rack and the wine rack bracket in an embodiment.
[0018] FIG. 5A is an isometric view of an embodiment of the wine rack and the liner.
[0019] FIG. 5B is a section view of the liner, liner grommet, rack pin, and wine rack in an embodiment.
[0020] FIG. 5C . is a side elevation view of an embodiment with a wine rack, rack pins, liner, and liner grommets.
[0021] FIG. 5D is a section through a spring pin assembly in an embodiment.
[0022] FIG. 6 is an isometric view of the wine rack, wine rack brackets, shelf ladders, and liner in another embodiment.
[0023] FIG. 7A is an isometric view of a wine rack in a typical embodiment.
[0024] FIG. 7B is an isometric view of a wine rack in another embodiment.
[0025] FIG. 8 is an isometric view of an embodiment of a wine rack with an upstanding flange for logo or other information display.
DETAILED DESCRIPTION OF EMBODIMENTS
[0026] For purposes of description herein, the terms “upper,” “lower,” “right,” “left,” “rear,” “front,” “vertical,” “horizontal,” and derivatives thereof shall relate to the invention as oriented in FIG. 1 . However, it is to be understood that the invention may assume various alternative orientations, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification are simply exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise.
[0027] Referring to FIG. 1 , a home appliance is shown as a refrigerator appliance 10 (hereinafter, the refrigerator 10 ). The refrigerator 10 includes a lower frame 24 and a cabinet 12 extending upwardly from the lower frame 24 . The cabinet 12 of the refrigerator 10 includes a pair of inner liners 16 that define a pair of inner temperature-controlled compartments that are independently operable to maintain food items stored therein at one or more set temperatures.
[0028] The lower temperature-controlled compartment is a freezer compartment 22 , and the refrigerator 10 includes a drawer 108 that is positioned in the freezer compartment 22 . The drawer 108 is moveable relative to the cabinet 12 such that food items may be placed in the drawer 108 for storage in the freezer compartment 22 and retrieved from the drawer 108 when ready for use. A handle 28 is located on the drawer 108 so that a user may open and close the drawer 108 .
[0029] The upper temperature-controlled compartment is a fresh food compartment 20 into which a user may place and store food items such as milk, cheese, produce, etcetera. A pair of doors 14 are each hinged to the front of the cabinet 12 via a pair of hinge assemblies 30 . The doors 14 permit user access to the fresh food compartment 20 such that food items may be placed in and retrieved from the fresh food compartment 20 . A handle 26 is located on each of the doors 14 so that a user may open and close the doors 14 .
[0030] While the illustrative embodiment of the refrigerator 10 shown in FIG. 1 is a “french-door” model with a pair of doors 14 operable to permit access to the fresh food compartment 20 , it should be appreciated that other configurations are contemplated, such as, for example, configurations having only one door 14 operable to permit access to the fresh food compartment 20 . Additionally, it should also be appreciated that, in some embodiments, the freezer compartment 22 may be positioned above the fresh food compartment 20 and, in other embodiments, either one of the temperature-controlled compartments may be omitted. It should be further appreciated that, in some embodiments, the refrigerator 10 may include more than one freezer compartment 22 and/or more than one fresh food compartment 20 . Configurations of the refrigerator 10 are also contemplated in which the freezer compartment 22 is located on one side of the cabinet 12 and the fresh food compartment 20 is located on the opposite side of the cabinet 12 .
[0031] As shown in FIG. 1 , the refrigerator 10 may also include four adjustable shelves 100 removably mounted within the fresh food compartment 20 , upon which a user of the refrigerator 10 may arrange food items. It is contemplated that the refrigerator 10 may include any number of adjustable shelves 100 within the fresh food compartment 20 . As the adjustable shelves 100 are removably mounted within the fresh food compartment 20 , a user may remove any adjustable shelf 100 and relocate it to any available shelf mounting position within the fresh food compartment 20 . It will be appreciated that the refrigerator 10 may additionally or alternatively include other devices for supporting or storing food within the fresh food compartment 20 , such as, for example, drawers 32 or door bins 34 (as shown in FIG. 1 ). As used in the present disclosure, the term “shelf” is to be considered in its broadest sense as any device that will hold a food item, including shelves, drawers, bins, panels, racks, and the like.
[0032] The adjustable shelves 100 may be removably mounted within the fresh food compartment 20 using any suitable mechanism. In the illustrative embodiment of the refrigerator 10 shown in FIG. 1 , four shelf ladders 126 are disposed within the fresh food compartment 20 to provide a plurality of shelf mounting positions for the adjustable shelves 100 . It is contemplated that any number of shelf ladders 126 may be used for removably mounting the adjustable shelves 100 . In some embodiments, the shelf ladders 126 may be secured to one or more walls of the fresh food compartment 20 using screws, bolts, rivets, adhesive, or other fixation mechanisms. In other embodiments, the shelf ladders 126 may be integrally formed into one or more walls of the fresh food compartment 20 . It should also be appreciated that the adjustable shelves 100 may be removably mounted within the fresh food compartment 20 using any number of mechanisms other than the shelf ladders 126 . By way of example, the adjustable shelves 100 may be removably mounted within the fresh food compartment 20 using ledges, tracks, slides, glides, rollers, and the like.
[0033] As shown in more detail in FIG. 2 , each of the shelf ladders 126 in the illustrative embodiment of refrigerator 10 has a number of slots 128 defined therein. Each of the adjustable shelves 100 may illustratively include a pair of mounting brackets 102 that are spaced apart from one another the same distance as a pair of the shelf ladders 126 . The mounting brackets 102 of an adjustable shelf 100 may each engage one or more slots 128 defined in one of the shelf ladders 126 to cantilever the adjustable shelf 100 to a pair of shelf ladders 126 . As such, the slots 128 defined in the shelf ladders 126 provide a plurality of shelf mounting positions for the adjustable shelves 100 . In the illustrative embodiment, the slots 128 defined in the shelf ladders 126 (and, hence, the shelf mounting positions) are spaced approximately one inch apart. It will be appreciated that other configurations for the spacing of the slots 128 and the shelf mounting positions are possible.
[0034] As shown in FIG. 3A-3B , a refrigerator 10 may include a wine rack assembly 110 . The wine rack assembly 110 may have a wine rack 112 with a pair of wine rack brackets 114 on either end. The wine rack brackets 114 may be integrally formed to the ends of the wine rack 114 , forming the wine rack assembly 114 . It is also contemplated that the wine rack brackets may be attached using screws, bolts, rivets, adhesive, or other fixation mechanisms.
[0035] The wine rack assembly 110 may rest on a shelf 100 at the rear of the fresh food compartment 20 . The wine rack assembly 110 may be rotated up from underneath the shelf 100 such that the wine rack brackets 114 fit in a space between the shelf 100 and the liner 16 . The wine rack assembly 110 may rest loosely on the shelf 100 , held in place by the force of gravity on the wine rack 112 . The wine rack assembly 110 may also be fitted to specific refrigerator designs for the space between the shelf 100 and the rear wall of the cabinet 12 . The wine rack brackets 114 may also simply have a portion that extends out from the wine rack bracket 114 toward the rear wall of the cabinet 12 to prevent the wine rack assembly from rotating farther than desired. It is also contemplated that the wine rack assembly may be placed on the shelf 100 before the shelf 100 is located to the shelf ladders 126 .
[0036] The wine rack 112 may be a plate. The plate thickness may be within a range of 2 mm to 25 mm, preferably about 5 mm in thickness. The wine rack 112 may include a plurality of apertures 120 . The apertures 120 may be sized to allow the neck of a conventional wine bottle to pass through the aperture 120 and hold the bottle substantially horizontally in a cantilever fashion. The size of the aperture 120 necessary is a function of thickness of the plate and the angle of the wine rack 112 in its wine bottle storage position. As the thickness of the plate used in the wine rack 112 increases, the diameter D of aperture 120 may also increase to accommodate the neck of a conventional wine bottle. Similarly, as the thickness of the plate used in the wine rack 112 decreases, the diameter D of the aperture 120 may also decrease. The diameter D of the aperture 120 may be between 30 mm and 50 mm, preferably about 35 mm. As the angle α of the wine rack 112 increases, the diameter D of the aperture 120 may decrease. Similarly, as the angle α of the wine rack 112 decreases, the diameter D of the aperture 120 may increase. The angle α of the wine rack 112 may be between 90 and 45 degrees, preferably about 57 degrees.
[0037] As shown in FIG. 4A-4C , in another embodiment, the wine rack 112 may be rotatably connected to the wine rack brackets 114 . The wine rack 112 may be movable between a first position where it is stowed underneath the shelf 100 , and a second position where the wine rack 112 may hold bottles in a preferred position. The wine rack brackets 114 may include round holes 212 and the wine rack 112 may include corresponding round pins 210 . The pins 210 and holes 212 may be sized as an interference fit such that the rack 112 stays in the first stowed position when not in use. It is further contemplated that other shapes may be used other than round to act as hard stops for the rack in the first and second positions. It is also contemplated that hinges of a type known in the art may be used between the wine rack 112 and the brackets 114 .
[0038] In a further embodiment as shown in FIGS. 5A-5B , a wine rack attaches directly to the liner 16 . The wine rack 312 may include at least 4 rack pins 310 sized to fit within liner grommets 320 located in the liner 16 . The liner grommets 320 are spaced such that the wine rack 312 holds the conventional wine bottle substantially horizontal.
[0039] It is also contemplated as shown in FIGS. 5C-5D that the wine rack 312 be rotatable about the upper pin 310 between a first stowed position and a second wine bottle storage position. In this embodiment, the lower pin 310 would be a spring loaded pin assembly 330 . The spring loaded spring assembly 330 may include a spring 332 , a pin ball 334 , and a rack grommet 336 . When in the first or second position, the force of the spring 332 may push the pin ball 334 outward from the rack 312 . The rack grommet 336 would have a shape to allow the pin ball 334 to extend beyond the end of the rack grommet 336 , but remain contained within the rack grommet 336 . The portion of the pin ball 334 that extends beyond the end of the rack grommet 336 would extend into the corresponding liner grommet 320 , preventing the rack 312 from any undesired movement. While the spring loaded pin assembly 330 prevents undesired movement, it is also deisgned to be easily moved by a user from one of the first or second position to the other using hand forces only. It has also been contemplated that the refrigerator 10 include a spring loaded wine rack 312 such that the wine rack 312 spring back to the first stowed position when there is no load on the wine rack 312 , i.e. when no bottles are being stored.
[0040] In another embodiment, as shown in FIG. 6 , the wine rack assembly 410 includes a wine rack 412 and a pair of wine rack brackets 414 . The wine rack brackets 414 are shaped similarly to the shelf brackets 102 as described in detail above. The wine rack brackets 414 attach to the shelf ladders 126 in the same way as the shelf brackets 102 described above.
[0041] As shown in FIG. 7A , in order to accommodate standard wine bottles, the spacing of the apertures 120 on the wine rack 112 should be a minimum of 62 mm, and preferably greater than or about 87 mm. It has been contemplated in order to accommodate many different sized bottles, both standard and non-standard, that the wine rack have one or more non-circle apertures with a width equal to the diameter D as contemplated above. This could be one single rectangle aperture as shown in FIG. 7B , or more apertures either rectangle or oval in shape with a width equal to the diameter D as contemplated above. It has also been contemplated that the wine rack could extend along the entire width of the fresh food compartment in any of the above embodiments. It has further been contemplated that other types of bottles such as bottles of soda or juice, or anything else in a bottle with a neck that may fit into the apertures may be suitable for this rack.
[0042] As shown in FIG. 8 , in another embodiment, the wine rack 112 also has an upstanding flange 160 upon which a logo or other information could be displayed when the wine rack 112 is in a first position.
[0043] It will be understood by one having ordinary skill in the art that construction of the described invention and other components is not limited to any specific material. Other exemplary embodiments of the invention disclosed herein may be formed from a wide variety of materials, unless described otherwise herein.
[0044] For purposes of this disclosure, the term “coupled” (in all of its forms, couple, coupling, coupled, etc.) generally means the joining of two components (electrical or mechanical) directly or indirectly to one another. Such joining may be stationary in nature or movable in nature. Such joining may be achieved with the two components (electrical or mechanical) and any additional intermediate members being integrally formed as a single unitary body with one another or with the two components. Such joining may be permanent in nature or may be removable or releasable in nature unless otherwise stated.
[0045] It is also important to note that the construction and arrangement of the elements of the invention as shown in the exemplary embodiments is illustrative only. Although only a few embodiments of the present innovations have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited. For example, elements shown as integrally formed may be constructed of multiple parts or elements shown as multiple parts may be integrally formed, the operation of the interfaces may be reversed or otherwise varied, the length or width of the structures and/or members or connector or other elements of the system may be varied, the nature or number of adjustment positions provided between the elements may be varied. It should be noted that the elements and/or assemblies of the system may be constructed from any of a wide variety of materials that provide sufficient strength or durability, in any of a wide variety of colors, textures, and combinations. Accordingly, all such modifications are intended to be included within the scope of the present innovations. Other substitutions, modifications, changes, and omissions may be made in the design, operating conditions, and arrangement of the desired and other exemplary embodiments without departing from the spirit of the present innovations.
[0046] It will be understood that any described processes or steps within described processes may be combined with other disclosed processes or steps to form structures within the scope of the present invention. The exemplary structures and processes disclosed herein are for illustrative purposes and are not to be construed as limiting.
[0047] It is also to be understood that variations and modifications can be made on the aforementioned structures and methods without departing from the concepts of the present invention, and further it is to be understood that such concepts are intended to be covered by the following claims unless these claims by their language expressly state otherwise.
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A refrigerator comprising a cabinet, a liner disposed within the cabinet and defining an interior fresh food compartment, a wine rack rotatably mounted within the fresh food compartment, the wine rack comprising a substantially planar plate having a first end and a second end with at least one aperture sized to receive a neck portion of a bottle to hold the bottle substantially horizontally in a cantilever fashion; a pair of attachment elements disposed on the first end and second end of the substantially planar plate to support the substantially planar plate and configured to secure the substantially plate to the refrigerator.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation application of United States Non-Provisional patent application Ser. No. 13/300,537, filed Nov. 18, 2011, which claims the benefit of U.S. Provisional Application Ser. No. 61/416,081 filed Nov. 22, 2010, which is hereby incorporated by reference in its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to novel derivatives, processes for preparing them, pharmaceutical compositions containing them and their use as pharmaceuticals, as modulators of sphingosine-1-phosphate receptors. The invention relates specifically to the use of these compounds and their pharmaceutical compositions to treat disorders associated with sphingosine-1-phosphate (S1P) receptor modulation.
BACKGROUND OF THE INVENTION
[0003] Sphingosine-1 phosphate is stored in relatively high concentrations in human platelets, which lack the enzymes responsible for its catabolism, and it is released into the blood stream upon activation of physiological stimuli, such as growth factors, cytokines, and receptor agonists and antigens. It may also have a critical role in platelet aggregation and thrombosis and could aggravate cardiovascular diseases. On the other hand the relatively high concentration of the metabolite in high-density lipoproteins (HDL) may have beneficial implications for atherogenesis. For example, there are recent suggestions that sphingosine-1-phosphate, together with other lysolipids such as sphingosylphosphorylcholine and lysosulfatide, are responsible for the beneficial clinical effects of HDL by stimulating the production of the potent antiatherogenic signaling molecule nitric oxide by the vascular endothelium. In addition, like lysophosphatidic acid, it is a marker for certain types of cancer, and there is evidence that its role in cell division or proliferation may have an influence on the development of cancers. These are currently topics that are attracting great interest amongst medical researchers, and the potential for therapeutic intervention in sphingosine-1-phosphate metabolism is under active investigation.
SUMMARY OF THE INVENTION
[0004] We have now discovered a group of novel compounds which are potent and selective sphingosine-1-phosphate modulators. As such, the compounds described herein are useful in treating a wide variety of disorders associated with modulation of sphingosine-1-phosphate receptors. The term “modulator” as used herein, includes but is not limited to: receptor agonist, antagonist, inverse agonist, inverse antagonist, partial agonist, partial antagonist.
[0005] This invention describes compounds of Formula I, which have sphingosine-1-phosphate receptor biological activity. The compounds in accordance with the present invention are thus of use in medicine, for example in the treatment of humans with diseases and conditions that are alleviated by S1P modulation.
[0006] In one aspect, the invention provides a compound having Formula I or a pharmaceutically acceptable salt thereof or stereoisomeric forms thereof, or the geometrical isomers, enantiomers, diastereoisomers, tautomers, zwitterions and pharmaceutically acceptable salts thereof:
[0007] In one embodiment of the invention, there are provided compounds having the Formula I below and pharmaceutically accepted salts thereof, its enantiomers, diastereoisomers, hydrates, solvates, crystal forms and individual isomers, tautomers or a pharmaceutically acceptable salt thereof,
[0000]
[0000] wherein:
R 1 is N or C—R 9 ;
[0008] R 2 is substituted or unsubstituted aromatic heterocycle, C 5-8 cycloalkenyl or C 8-10 aryl;
R 3 is O, N—R 10 , CH—R 11 , S, —CR 12 ═CR 13 —, —C═C— or —C(O)—;
[0009] R 4 is H, C 5-8 cycloalkenyl, C 3-8 cycloalkyl or substituted or unsubstituted C 6-10 aryl;
R 5 is H, halogen, —OC 1-3 alkyl, C 1-3 alkyl or hydroxyl;
R 6 is H, halogen, —OC 1-3 alkyl, C 1-3 alkyl or hydroxyl;
a is 0, 1, 2, 3 or 4;
b is 0, 1, 2, 3 or 4;
L is CHR 7 , O, S, NR 8 or —C(O)—;
[0010] R 7 is H, C 1-3 alkyl, —OC 1-3 alkyl, halogen, hydroxyl or NR 9 R 10 ;
R 8 is H or C 1-3 alkyl;
R 9 is H, halogen or C 1-3 alkyl;
R 10 is H or C 1-3 alkyl;
R 11 is H or C 1-3 alkyl;
R 12 is H or C 1-3 alkyl;
R 13 is H or C 1-3 alkyl;
Q 1 is —CR 14 R 15 —;
[0011] R 14 is H, halogen, or C 1-3 alkyl;
R 15 is H, halogen, or C 1-3 alkyl;
m is 0, 1, 2 or 3;
T is —NH-Q 2 ,
[0012]
“*” represents the point of attachment to the rest of the molecule;
R 18 is NR 9 , O, or S;
[0014] Q 2 is the same or independently —OPO 3 H 2 , carboxylic acid, —PO 3 H 2 , —C 1-6 alkyl, H, —S(O) 2 OH, —P(O)MeOH, —P(O)(H)OH, —OH
[0000]
[0000] with the proviso that when R 3 is O, N—R 10 , S, —CR 12 ═CR 13 —, —C═C— or —C(O)— and b is 0 or 1 then L is not O, S, NR 8 or —C(O)—.
[0015] In another aspect, the invention provides a compound having Formula I wherein:
R 1 is N or C—R 9 ;
[0016] R 2 is a five-membered aromatic substituted or unsubstituted heterocycle or C 5-8 cycloalkenyl;
R 3 is O, N—R 10 , CH—R 11 , S;
[0017] R 4 is substituted or unsubstituted C 6-10 aryl;
R 5 is H, or halogen;
R 6 is H or halogen;
R 8 is H or C 1-3 alkyl;
R 9 is H or C 1-3 alkyl;
R 10 is H or C 1-3 alkyl;
R 11 is H or C 1-3 alkyl;
a is 0, 1, 2, 3 or 4;
b is 0, 1, 2, 3 or 4;
L is CH 2 ;
[0018] m is 0;
T is —NH-Q 2 ;
[0019] Q 2 is —C 1-6 alkyl,
[0000]
[0000] “*” represents the point of attachment to the rest of the molecule.
[0020] In another aspect, the invention provides a compound having Formula I wherein:
R 1 is N or C—R 9 ;
[0021] R 2 is furan, 2-furyl and 3-furyl derivatives; thiophene, 2-thienyl and 3-thienyl derivatives; pyrrole, oxazole, thiazole, pyrrolidine, pyrroline, imidazole, pyrazole, pyrazoline, isoxazole, isothiazole, pyrazolidine, imidazoline, thiazoline, oxazoline, dihydrothiophene, dihydrofuran, tetrazole, triazole, oxadiazole, 1,2,5-oxadiazole, thiadiazole, 1,2,3-triazole, 1,2,4-triazole, pyrrolidinone, pyrrol-2(3H)-one, imidazolidin-2-one, or 1,2,4-triazol-5(4H)-one and the like 5-membered heterocyclic rings;
R 3 is O, N—R 10 , CH—R 11 , S;
[0022] R 4 is phenyl with ortho, meta and para substitution with groups such as: halogens fluoro, chloro and bromo; short chain alkyls methyl, ethyl, propyl, isopropyl and other, methoxy, trifluoromethoxy, trifluoromethyl and perfluorinated short chain alkyl groups;
R 5 is H, or halogen;
R 6 is H or halogen;
R 8 is H or C 1-3 alkyl;
R 9 is H or C 1-3 alkyl;
R 10 is H or C 1-3 alkyl;
R 11 is H or C 1-3 alkyl;
a is 0, 1, 2, 3 or 4;
b is 0, 1, 2, 3 or 4;
L is CH 2 ;
[0023] m is 0;
T is —NH-Q 2 ;
[0024] Q 2 is —C 1-6 alkyl,
[0000]
“*” represents the point of attachment to the rest of the molecule.
[0026] In another aspect, the invention provides a compound having Formula I wherein:
R 1 is C—R 9 ;
[0027] R 2 is a five-membered aromatic substituted or unsubstituted heterocycle or C 5-8 cycloalkenyl;
R 3 is O, N—R 10 , CH—R 11 , S;
[0028] R 4 is substituted or unsubstituted C 6-10 aryl;
R 5 is H, or halogen;
R 6 is H or halogen;
R 8 is H or C 1-3 alkyl;
R 9 is H or C 1-3 alkyl;
R 10 is H or C 1-3 alkyl;
R 11 is H or C 1-3 alkyl;
a is 0, 1, 2, 3 or 4;
b is 0, 1, 2, 3 or 4;
L is CH 2 ;
[0029] m is 0;
T is —NH-Q 2 ;
[0030] Q 2 is —C 1-6 alkyl,
[0000]
[0000] “*” represents the point of attachment to the rest of the molecule.
[0031] In another aspect, the invention provides a compound having Formula I wherein:
R 1 is C—R 9 ;
[0032] R 2 is a five-membered aromatic substituted or unsubstituted heterocycle;
R 3 is O;
[0033] R 4 is substituted or unsubstituted phenyl;
R 5 is H, Cl, Br or F;
R 6 is H, Cl, Br or F;
[0034] a is 1, 2, or 3;
b is 1, 2, or 3;
L is CHR 7 ;
[0035] R 7 is H or C 1-3 alkyl;
m is 0;
T is —NH-Q 2 ;
[0036] Q 2 is —C 1-6 alkyl or
[0000]
[0000] “*” represents the point of attachment to the rest of the molecule.
[0037] In another aspect, the invention provides a compound having Formula I wherein:
R 1 is C—R 9 ;
[0038] R 2 is a five-membered aromatic substituted or unsubstituted heterocycle;
R 3 is O;
[0039] R 4 is substituted or unsubstituted phenyl;
R 5 is H, Cl, Br or F;
R 6 is H, Cl, Br or F;
[0040] a is 1, 2, or 3;
b is 1, 2, or 3;
L is CHR 7 ;
[0041] R 7 is H or C 1-3 alkyl;
m is 0;
T is —NH-Q 2 ;
[0042] Q 2 is —C 1-6 alkyl or
[0000]
[0000] “*” represents the point of attachment to the rest of the molecule.
[0043] In another aspect, the invention provides a compound having Formula I wherein:
R 1 is C—R 9 ;
[0044] R 2 is a five-membered aromatic substituted or unsubstituted heterocycle;
R 3 is O;
[0045] R 4 is substituted or unsubstituted phenyl;
R 5 is H or F;
R 6 is H or F;
[0046] R 8 is H or C 1-3 alkyl;
R 9 is H or C 1-3 alkyl;
a is 1, 2, or 3;
b is 1, 2, or 3;
L is CH 2 ;
[0047] m is 0;
T is —NH-Q 2 ;
[0048] Q 2 is —C 1-6 alkyl or
[0000]
[0000] “*” represents the point of attachment to the rest of the molecule.
[0049] In another aspect, the invention provides a compound having Formula I wherein:
R 1 is C—R 9 ;
[0050] R 2 is a five-membered aromatic substituted or unsubstituted heterocycle;
R 3 is O;
[0051] R 4 is substituted or unsubstituted phenyl;
R 5 is H or F;
R 6 is H or F;
R 9 is H;
[0052] a is 2;
b is 2;
L is CH 2 ;
[0053] m is 0;
T is —NH-Q 2 ;
[0054] Q 2 is —C 1-6 alkyl,
[0000]
[0000] “*” represents the point of attachment to the rest of the molecule.
[0055] In another aspect, the invention provides a compound having Formula I wherein:
R 1 is C—R 9 or N;
[0056] R 2 is a five-membered aromatic substituted or unsubstituted heterocycle;
R 3 is O;
[0057] R 4 is substituted or unsubstituted C 6-10 aryl;
a is 0, 1, 2, 3 or 4;
b is 0, 1, 2, 3 or 4;
R 5 is H, or F,
R 6 is H, or F,
[0058] R 9 is H or C 1-3 alkyl;
L is CH 2 ;
Q 1 is —CR 14 R 15 —;
R 14 is H;
R 15 is H;
[0059] m is 2;
T is
[0060]
“*” represents the point of attachment to the rest of the molecule;
R 18 is NR 9 ;
[0062] Q 2 is —OPO 3 H 2 , —OH, carboxylic acid, —PO 3 H 2 , H, —C 1-6 alkyl, —P(O)MeOH or —P(O)(H)OH.
[0063] In another aspect, the invention provides a compound having Formula I wherein:
R 1 is C—R 9 or N;
[0064] R 2 is a five-membered substituted or unsubstituted heterocycle;
R 3 is O;
[0065] R 4 is substituted or unsubstituted phenyl;
R 5 is H, or F;
R 6 is H or F;
[0066] a is 1, 2, or 3;
b is 1, 2, or 3;
R 9 is H or C 1-3 alkyl;
L is CH 2 ;
Q 1 is —CR 14 R 15 —;
R 15 is H;
R 15 is H;
[0067] m is 2;
T is
[0068]
“*” represents the point of attachment to the rest of the molecule;
Q 2 is —OPO 3 H 2 , —OH, carboxylic acid, —PO 3 H 2 , H, —C 1-6 alkyl, —P(O)MeOH or —P(O)(H)OH.
[0070] In another aspect, the invention provides a compound having Formula I wherein:
R 1 is C—R 9 ;
[0071] R 2 is a five-membered aromatic substituted or unsubstituted heterocycle;
R 3 is O;
[0072] R 4 is substituted or unsubstituted phenyl;
R 5 is H or F;
R 6 is H or F;
R 9 is H;
[0073] a is 2;
b is 2;
L is CH 2 ;
Q 1 is —CR 14 R 15 —;
R 14 is H;
R 15 is H;
[0074] m is 2;
T is
[0075]
“*” represents the point of attachment to the rest of the molecule;
Q 2 is —OPO 3 H 2 , —OH, carboxylic acid, —PO 3 H 2 , H, —C 1-6 alkyl, —P(O)MeOH or —P(O)(H)OH.
[0077] In another aspect, the invention provides a compound having Formula I wherein:
R 1 is N or C—R 9 ;
[0078] R 2 is a five-membered aromatic substituted or unsubstituted heterocycle;
R 3 is O;
[0079] R 4 is substituted or unsubstituted phenyl;
R 5 is H, or F;
R 6 is H, or F;
[0080] a is 1, 2, or 3;
b is 1, 2, or 3;
L is CH 2 ;
[0081] R 9 is H or C 1-3 alkyl;
m is 0;
T is
[0082]
“*” represents the point of attachment to the rest of the molecule;
R 18 is NR 9 ;
[0084] Q 2 is —OPO 3 H 2 , —OH, carboxylic acid, —PO 3 H 2 , H, —C 1-6 alkyl, —P(O)MeOH or —P(O)(H)OH.
[0085] In another aspect, the invention provides a compound having Formula I wherein:
R 1 is C—R 6
[0086] R 2 is a five-membered aromatic substituted or unsubstituted heterocycle;
R 3 is O;
[0087] R 4 is substituted or unsubstituted phenyl;
R 5 is H, or F;
R 6 is H, or F;
R 9 is H;
[0088] a is 2;
b is 2;
L is CH 2 ;
[0089] m is 0;
T is
[0090]
“*” represents the point of attachment to the rest of the molecule;
R 18 is NR 9 ;
[0092] Q 2 is —OPO 3 H 2 , —OH, carboxylic acid, —PO 3 H 2 , H, —C 1-6 alkyl, —P(O)MeOH or —P(O)(H)OH.
[0093] In another aspect, the invention provides a compound having Formula I wherein:
R 1 is N or C—R 9 ; R 2 is substituted or unsubstituted heterocycle, C 6 -8 cycloalkenyl or C 6-10 aryl; R 3 is O, N—R 10 , CH—R 11 , S, —CR 12 ═CR 13 —, —C═C— or —C(O)—; R 4 is H, C 6-8 cycloalkenyl, C 3-8 cycloalkyl or substituted or unsubstituted C 6-10 aryl; R 5 is H, halogen, —OC 1-3 alkyl, C 1-3 alkyl or hydroxyl; R 6 is H, halogen, —OC 1-3 alkyl, C 1-3 alkyl or hydroxyl; a is 0, 1, 2, 3 or 4; b is 0, 1, 2, 3 or 4; L is CHR 7 , O, S, NR 8 or —C(O)—; R 7 is H, C 1-3 alkyl, —OC 1-3 alkyl, halogen, hydroxyl or NR 9 R 10 ; R 8 is H or C 1-3 alkyl; R 9 is H, halogen or C 1-3 alkyl; R 10 is H or C 1-3 alkyl; R 11 is H or C 1-3 alkyl; R 12 is H or C 1-3 alkyl; R 13 is H or C 1-3 alkyl; Q 1 is —CR 14 R 15 —; R 14 is H, halogen, or C 1-3 alkyl; R 15 is H, halogen, or C 1-3 alkyl; m is 0, 1, 2 or 3; T is —NH-Q 2 ,
[0000]
“*” represents the point of attachment to the rest of the molecule;
R 18 is NR 9 , O, or S;
Q 2 is the same or independently —OPO 3 H 2 , carboxylic acid, —PO 3 H 2 , —C 1-6 alkyl,
[0000]
H, —S(O) 2 OH, —P(O)MeOH, —P(O)(H)OH, —OH with the proviso that when R 3 is O, N—R 10 , S, —CR 12 ═CR 13 —, —C═C— or —C(O)— and
b is 0 or 1 then L is not O, S, NR 8 or —C(O)—.
[0120] In another aspect, the invention provides a compound having Formula I wherein:
R 1 is C—R 9 ; R 2 is a five-membered substituted or unsubstituted heterocycle; R 3 is O; R 4 is substituted or unsubstituted C 6-10 aryl; R 5 is H or halogen; R 6 is H or halogen; a is 1 or 2; b is 1 or 2; L is CHR 7 ; R 7 is H; R 9 is H or C 1-3 alkyl; Q 1 is —CR 14 R 15 —; R 15 is H; m is 2; T is —NH-Q 2 ,
[0000]
“*” represents the point of attachment to the rest of the molecule;
R 18 is NR 9 ;
Q 2 is the same or independently —OPO 3 H 2 , carboxylic acid, —PO 3 H 2 , —C 1-6 alkyl, H, —P(O)MeOH, —P(O)(H)OH, —OH.
[0139] In another aspect, the invention provides a compound having Formula I wherein:
R 1 is C—R 9 ; R 2 is a five-membered substituted or unsubstituted heterocycle; R 3 is O; R 4 is substituted or unsubstituted C 6-10 aryl; R 5 is H or halogen; R 6 is H or halogen; a is 1 or 2; b is 1 or 2; L is CHR 7 ; R 7 is H; R 9 is H or C 1-3 alkyl; Q 1 is —CR 14 R 15 —; R 15 is H; m is 2; T is —NH-Q 2 ,
[0000]
“*” represents the point of attachment to the rest of the molecule;
R 18 is NR 9 ;
Q 2 is the same or independently —OPO 3 H 2 , carboxylic acid, —PO 3 H 2 , —C 1-6 alkyl, H, —P(O)MeOH, —P(O)(H)OH, —OH.
[0158] In another aspect, the invention provides a compound having Formula I wherein:
R 1 is C—R 9 ; R 2 is a five-membered substituted or unsubstituted heterocycle; R 3 is O; R 4 is substituted or unsubstituted C 6-10 aryl; R 5 is H or halogen; R 6 is H or halogen; a is 1 or 2; b is 1 or 2; L is CHR 7 ; R 7 is H; R 9 is H or C 1-3 alkyl; Q 1 is —CR 14 R 15 —; R 14 is H; R 15 is H; m is 2;
[0000]
T is —NH-Q 2 ,
“*” represents the point of attachment to the rest of the molecule;
Q 2 is the same or independently —OPO 3 H 2 , carboxylic acid, —PO 3 H 2 , —C 1-6 alkyl, H, —P(O)MeOH, —P(O)(H)OH, —OH.
[0177] In another aspect, the invention provides a compound having Formula I wherein:
R 1 is C—R 9 ; R 2 is substituted or unsubstituted heterocycle; R 3 is O; R 4 is substituted or unsubstituted phenyl; R 5 is H or halogen; R 6 is H or halogen; a is 2; b is 2; L is CHR 7 ; R 7 is H; R 9 is H; m is 0;
T is —NH-Q 2 ,
[0000]
“*” represents the point of attachment to the rest of the molecule;
Q 2 is the same or independently —OPO 3 H 2 , carboxylic acid, —PO 3 H 2 , —C 1-6 alkyl,
[0000]
H, —S(O) 2 OH, —P(O)MeOH, —P(O)(H)OH, —OH
[0193] In another aspect, the invention provides a compound having Formula I wherein:
R 1 is C—R 9 ; R 2 is substituted or unsubstituted heterocycle; R 3 is O; R 4 is substituted or unsubstituted phenyl; R 5 is H or halogen; R 6 is H or halogen; a is 2; b is 2; L is CHR 7 ; R 7 is H; R 9 is H; m is 0; T is —NH-Q 2 ,
“*” represents the point of attachment to the rest of the molecule;
Q 2 is the same or independently —OPO 3 H 2 , carboxylic acid, —PO 3 H 2 , —C 1-6 alkyl, H, —S(O) 2 OH, —P(O)MeOH, —P(O)(H)OH, —OH
[0000]
[0210] In another aspect, the invention provides a compound having Formula I wherein:
R 1 is C—R 9 ; R 2 is substituted or unsubstituted heterocycle; R 3 is O; R 4 is substituted or unsubstituted phenyl; R 5 is H or halogen; R 6 is H or halogen; a is 2; b is 2; L is CHR 7 ; R 7 is H; R 9 is H; m is 0; T is —NH-Q 2 ,
“*” represents the point of attachment to the rest of the molecule;
Q 2 is the same or independently —OPO 3 H 2 , carboxylic acid, —PO 3 H 2 , —C 1-6 alkyl,
[0000]
H, —S(O) 2 OH, —P(O)MeOH, —P(O)(H)OH, —OH
[0227] In another aspect, the invention provides a compound having Formula I wherein:
R 1 is C—R 9 ; R 2 is substituted or unsubstituted heterocycle; R 3 is O; R 4 is substituted or unsubstituted phenyl; R 5 is H or halogen; R 6 is H or halogen; a is 2; b is 2; L is CHR 7 ; R 7 is H; R 9 is H; m is 0; T is —NH-Q 2 ,
“*” represents the point of attachment to the rest of the molecule;
Q 2 is the same or independently —OPO 3 H 2 , carboxylic acid, —PO 3 H 2 , —C 1-6 alkyl, H, —S(O) 2 OH, —P(O)MeOH, —P(O)(H)OH, —OH
[0000]
[0244] In another aspect, the invention provides a compound having Formula I wherein:
R 1 is C—R 9 ; R 2 is substituted or unsubstituted heterocycle; R 3 is O; R 4 is substituted or unsubstituted phenyl; R 5 is H or halogen; R 6 is H or halogen; a is 2; b is 2; L is CHR 7 ; R 7 is H; R 9 is H; m is 0; T is —NH-Q 2 ,
“*” represents the point of attachment to the rest of the molecule;
Q 2 is the same or independently —OPO 3 H 2 , carboxylic acid, —PO 3 H 2 , —C 1-6 alkyl, H, —S(O) 2 OH, —P(O)MeOH, —P(O)(H)OH, —OH,
[0000]
[0261] The term “alkyl”, as used herein, refers to saturated, monovalent hydrocarbon moieties having linear or branched moieties or combinations thereof and containing 1 to 6 carbon atoms. One methylene (—CH 2 —) group, of the alkyl can be replaced by oxygen, sulfur, sulfoxide, nitrogen, carbonyl, carboxyl, sulfonyl, or by a divalent C 3-6 cycloalkyl. Alkyl groups can be substituted by halogen, amino, hydroxyl, cycloalkyl, amino, non-aromatic heterocycles, carboxylic acid, phosphonic acid groups, sulphonic acid groups, phosphoric acid.
[0262] The term “short chain alkyl” as used herein, refers to saturated monovalent linear or branched moieties containing 1 to 3 carbon atoms.
[0263] The term perfluorinated short chain alkyl groups as used herein, refers to but CF 3 —CF 2 —, CF 3 , (CF 3 ) 2 —CH—, CF 3 -(CF 3 ) 2 —.
[0264] The term “alkylene”, as used herein, refers to saturated, divalent hydrocarbon moieties having linear or branched moieties or combinations thereof and containing 1 to 6 carbon atoms. One methylene (—CH 2 —) group of the alkylene can be replaced by oxygen, sulfur, sulfoxide, nitrogen, carbonyl, carboxyl, sulfonyl.
[0265] The term “cycloalkyl”, as used herein, refers to a monovalent or divalent group of 3 to 8 carbon atoms, derived from a saturated cyclic hydrocarbon. Cycloalkyl groups can be monocyclic or polycyclic. Cycloalkyl can be substituted by 1 to 3 C 1-3 alkyl groups or 1 or 2 halogens.
[0266] The term “cycloalkenyl”, as used herein, refers to a monovalent or divalent group of 5 to 8 carbon atoms, derived from a saturated cycloalkyl having one double bond.
[0267] Cycloalkenyl groups can be monocyclic or polycyclic. Cycloalkenyl groups can be substituted by C 1-3 alkyl groups or halogens.
[0268] The term “halogen”, as used herein, refers to an atom of chlorine, bromine, fluorine, iodine.
[0269] The term “alkenyl”, as used herein, refers to a monovalent or divalent hydrocarbon radical having 2 to 6 carbon atoms, derived from a saturated alkyl, having at least one double bond. C 2 -6 alkenyl can be in the E or Z configuration. Alkenyl groups can be substituted by C 1-3 alkyl.
[0270] The term “alkynyl”, as used herein, refers to a monovalent or divalent hydrocarbon radical having 2 to 6 carbon atoms, derived from a saturated alkyl, having at least one triple bond.
[0271] The term “heterocycle” as used herein, refers to a 3 to 10 membered ring, which is aromatic or non-aromatic, saturated or non-saturated and containing at least one heteroatom selected form O or N or S or combinations of at least two thereof, interrupting the carbocyclic ring structure. The heterocyclic ring can be interrupted by a C═O; the S heteroatom can be oxidized. Heterocycles can be monocyclic or polycyclic. Heterocyclic ring moieties can be substituted by hydroxyl, C 1-3 alkyl or halogens. Examples of aromatic heterocycles are, but not limited to: furan, 2-furyl and 3-furyl derivatives; thiophene, 2-thienyl, 3-thienyl derivatives; pyrrole, oxazole, thiazole, imidazole, pyrazole, isoxazole, isothiazole, tetrazole, triazole, oxadiazole, 1,2,5-oxadiazole, thiadiazole, 1,2,3-triazole, 1,2,4-triazole.
[0272] Examples of non-aromatic heterocycles are, but not limited to: pyrrolidine, pyrroline, pyrazoline, pyrazolidine, imidazoline, thiazoline, oxazoline, dihydrothiophene, dihydrofuran, pyrrolidinone, pyrrol-2(3H)-one, imidazolidin-2-one, or 1,2,4-triazol-5(4H)-one.
[0273] Usually, in the present case, heterocyclic groups are 5 or 6 membered rings including but not limited to: 1-substituted-1H-1,2,4-triazole, 1-substituted-azetidine-3-CO 2 H, 4-linked-indole, 6-methyl-5-linked-indazole or 6-hydro-5-linked-indazole.
[0274] Some preferred heterocycles at the R 2 position include the following: furan, 2-furyl and 3-furyl derivatives; thiophene, 2-thienyl and 3-thienyl derivatives; pyrrole, oxazole, thiazole, pyrrolidine, pyrroline, imidazole, pyrazole, pyrazoline, isoxazole, isothiazole, pyrazolidine, imidazoline, thiazoline, oxazoline, dihydrothiophene, dihydrofuran, tetrazole, triazole, oxadiazole, 1,2,5-oxadiazole, thiadiazole, 1,2,3-triazole, 1,2,4-triazole, pyrrolidinone, pyrrol-2(3H)-one, imidazolidin-2-one, or 1,2,4-triazol-5(4H)-one and the like 5-membered heterocyclic rings.
[0275] The term “aryl” as used herein, refers to an organic moiety derived from an aromatic hydrocarbon consisting of a ring containing 6 to 10 carbon atoms by removal of one hydrogen. Aryl is optionally substituted by halogen atoms or by C 1-3 alkyl groups. Preferred aryl groups at the R 4 position include: phenyl with ortho, meta and para substitution with groups such as: halogens fluoro, chloro and bromo; short chain alkyls methyl, ethyl, propyl, isopropyl and other, methoxy, trifluoromethoxy, trifluoromethyl and perfluorinated short chain alkyl groups.
[0276] The group of formula “—CR 12 ═CR 13 —”, as used herein, represents an alkenyl radical.
[0277] The group of formula “—C═C-”, as used herein, represents an alkynyl radical.
[0278] The term “hydroxyl” as used herein, represents a group of formula “—OH”.
[0279] The term “carbonyl” as used herein, represents a group of formula “—C(O)”.
[0280] The term “carboxyl” as used herein, represents a group of formula “—C(O)O—”.
[0281] The term “sulfonyl” as used herein, represents a group of formula “—SO 2 ”.
[0282] The term “sulfate” as used herein, represents a group of formula “—O—S(O) 2 —O—”.
[0283] The term “carboxylic acid” as used herein, represents a group of formula “—C(O)OH”.
[0284] The term “sulfoxide” as used herein, represents a group of formula “—S═O”. The term “phosphonic acid” as used herein, represents a group of formula “—P(O)(OH) 2 ”.
[0285] The term “phosphoric acid” as used herein, represents a group of formula “—(O)P(O)(OH) 2 ”.
[0286] The term “boronic acid”, as used herein, represents a group of formula “—B(OH) 2 ”.
[0287] The term “sulphonic acid” as used herein, represents a group of formula “—S(O) 2 OH”.
[0288] The formula “H”, as used herein, represents a hydrogen atom.
[0289] The formula “O”, as used herein, represents an oxygen atom.
[0290] The formula “N”, as used herein, represents a nitrogen atom.
[0291] The formula “S”, as used herein, represents a sulfur atom.
[0292] Some compounds of the invention are:
(2R)-2-amino-2-methyl-3-oxo-3-({4-[(5-phenylpentyl)oxy]-3-(2-thienyl)phenyl}amino)propyl dihydrogen phosphate; (2S)-2-amino-2-methyl-3-oxo-3-({4-[(5-phenylpentyl)oxy]-3-(2-thienyl)phenyl}amino)propyl dihydrogen phosphate; 2-amino-3-hydroxy-2-methyl-N-{4-[(5-phenyl pentyl)oxy]-3-(2-thienyl)phenyl}propanamide; 2-amino-3-hydroxy-2-methyl-N-{4-[(5-phenyl pentyl)oxy]-3-(2-thienyl)phenyl}propanamide; (2S)-2-amino-3-({3-(2-furyl)-4-[(5-phenylpentyl)oxy]phenyl}amino)-3-oxopropyl dihydrogen phosphate;
(2S)-2-amino-3-oxo-3-({4-[(5-phenylpentyl)oxy]-3-(2-thienyl)phenyl}amino)propyl dihydrogen phosphate;
2-amino-N-{3-(2-furyl)-4-[(5-phenylpentyl)oxy]phenyl}-3-hydroxypropanamide; 2-amino-3-hydroxy-N-{4-[(5-phenylpentyl)oxy]-3-(2-thienyl)phenyl}propanamide; 2-amino-3-({3-(5-fluoro-2-furyl)-4-[(5-phenylpentyl)oxy]phenyl}amino)-3-oxopropyl dihydrogen phosphate; 2-amino-3-{[4-{[5-(4-fluorophenyl)pentyl]oxy}-3-(2-furyl)phenyl]amino}-3-oxopropyl dihydrogen phosphate; 2-amino-3-({3-(3-furyl)-4-[(5-phenylpentyl)oxy]phenyl}amino)-3-oxopropyl dihydrogen phosphate; 2-amino-3-oxo-3-({4-[(5-phenylpentyl)oxy]-3-(3-thienyl)phenyl}amino)propyl dihydrogen phosphate; 2-amino-3-({6-(2-furyl)-5-[(5-phenylpentyl)oxy]pyridin-2-yl}amino)-3-oxopropyl dihydrogen phosphate; 2-amino-N-{3-(5-fluoro-2-furyl)-4-[(5-phenylpentyl)oxy]phenyl}-3-hydroxypropanamide; 2-amino-N-{3-(5-fluoro-2-furyl)-4-[(5-phenylpentyl)oxy]phenyl}-3-hydroxypropanamide; 2-amino-N-{3-(3-furyl)-4-[(5-phenylpentyl)oxy]phenyl}-3-hydroxypropanamide; 2-amino-3-hydroxy-N-{4-[(5-phenylpentyl)oxy]-3-(3-thienyl)phenyl}propanamide; 2-amino-N-{6-(2-furyl)-5-[(5-phenylpentyl)oxy]pyridin-2-yl}-3-hydroxypropanamide; 2-amino-4-{3-(2-furyl)-4-[(5-phenylpentyl)oxy]phenyl}-2-(hydroxymethyl)butyl dihydrogen phosphate; 2-amino-2-(hydroxymethyl)-4-{4-[(5-phenylpentyl)oxy]-3-(2-thienyl)phenyl}butyl dihydrogen phosphate; 2-amino-4-{3-(5-fluoro-2-furyl)-4-[(5-phenylpentyl)oxy]phenyl}-2-(hydroxymethyl)butyl dihydrogen phosphate; 2-amino-4-[4-{[5-(4-fluorophenyl)pentyl]oxy}-3-(2-furyl)phenyl]-2-(hydroxymethyl)butyl dihydrogen phosphate; 2-amino-4-{3-(3-furyl)-4-[(5-phenylpentyl)oxy]phenyl}-2-(hydroxymethyl)butyl dihydrogen phosphate; 2-amino-2-(hydroxymethyl)-4-{4-[(5-phenylpentyl)oxy]-3-(3-thienyl)phenyl}butyl dihydrogen phosphate; 2-amino-4-{6-(2-furyl)-5-[(5-phenylpentyl)oxy]pyridin-2-yl}-2-(hydroxymethyl)butyl dihydrogen phosphate; 2-amino-2-(2-{3-(2-furyl)-4-[(5-phenylpentyl)oxy]phenyl}ethyl)propane-1,3-diol; 2-amino-2-(2-{4-[(5-phenylpentyl)oxy]-3-(2-thienyl)phenyl}ethyl)propane-1,3-diol; 2-amino-2-(2-{3-(5-fluoro-2-furyl)-4-[(5-phenylpentyl)oxy]phenyl}ethyl)propane-1,3-diol; 2-amino-2-{2-[4-{[5-(4-fluorophenyl)pentyl]oxy}-3-(2-furyl)phenyl]ethyl}propane-1,3-diol; 2-amino-2-(2-{3-(3-furyl)-4-[(5-phenylpentyl)oxy]phenyl}ethyl)propane-1,3-diol; 2-amino-2-(2-{4-[(5-phenylpentyl)oxy]-3-(3-thienyl)phenyl}ethyl)propane-1,3-diol; 2-amino-2-(2-{6-(2-furyl)-5-[(5-phenylpentyl)oxy]pyridin-2-yl}ethyl)propane-1,3-diol; 2-amino-2-(4-{3-(2-furyl)-4-[(5-phenylpentyl)oxy]phenyl}-1H-imidazol-2-yl)ethyl dihydrogen phosphate; 2-amino-2-(4-{4-[(5-phenylpentyl)oxy]-3-(2-thienyl)phenyl}-1H-imidazol-2-yl)ethyl dihydrogen phosphate; 2-amino-2-(4-{3-(5-fluoro-2-furyl)-4-[(5-phenylpentyl)oxy]phenyl}-1H-imidazol-2-yl)ethyl dihydrogen phosphate; 2-amino-2-{4-[4-{[5-(4-fluorophenyl)pentyl]oxy}-3-(2-furyl)phenyl]-1H-imidazol-2-yl}ethyl dihydrogen phosphate; 2-amino-2-(4-{3-(3-furyl)-4-[(5-phenylpentyl)oxy]phenyl}-1H-imidazol-2-yl)ethyl dihydrogen phosphate; 2-amino-2-(4-{4-[(5-phenylpentyl)oxy]-3-(3-thienyl)phenyl}-1H-imidazol-2-yl)ethyl dihydrogen phosphate; 2-amino-2-(4-{6-(2-furyl)-5-[(5-phenylpentyl)oxy]pyridin-2-yl}-1H-imidazol-2-yl)ethyl dihydrogen phosphate; 2-amino-2-(4-{3-(2-furyl)-4-[(5-phenylpentyl)oxy]phenyl}-1H-imidazol-2-yl) ethanol; 2-amino-2-(4-{4-[(5-phenylpentyl)oxy]-3-(2-thienyl)phenyl}-1H-imidazol-2-yl) ethanol; 2-amino-2-(4-{3-(5-fluoro-2-furyl)-4-[(5-phenylpentyl)oxy]phenyl}-1H-imidazol-2-yl)ethanol; 2-amino-2-{4-[4-{[5-(4-fluorophenyl)pentyl]oxy}-3-(2-furyl)phenyl]-1H-imidazol-2-yl}ethanol; 2-amino-2-(4-{3-(3-furyl)-4-[(5-phenylpentyl)oxy]phenyl}-1H-imidazol-2-yl) ethanol; 2-amino-2-(4-{4-[(5-phenylpentyl)oxy]-3-(3-thienyl)phenyl}-1H-imidazol-2-yl) ethanol; 2-amino-2-(4-{6-(2-furyl)-5-[(5-phenylpentyl)oxy]pyridin-2-yl}-1H-imidazol-2-yl)ethanol.
[0338] Some compounds of Formula I and some of their intermediates have at least one stereogenic center in their structure. This stereogenic center may be present in an R or S configuration, said R and S notation is used in correspondence with the rules described in Pure Appli. Chem. (1976), 45, 11-13.
[0339] The term “pharmaceutically acceptable salts” refers to salts or complexes that retain the desired biological activity of the above identified compounds and exhibit minimal or no undesired toxicological effects. The “pharmaceutically acceptable salts” according to the invention include therapeutically active, non-toxic base or acid salt forms, which the compounds of Formula I are able to form.
[0340] The acid addition salt form of a compound of Formula I that occurs in its free form as a base can be obtained by treating the free base with an appropriate acid such as an inorganic acid, for example, a hydrohalic acid, such as hydrochloric acid, hydrobromic acid, sulfuric acid, phosphoric acid, nitric acid and the like; or an organic acid such as for example, acetic, hydroxyacetic, propanoic, lactic, pyruvic, malonic, fumaric acid, maleic acid, oxalic acid, tartaric acid, succinic acid, malic acid, ascorbic acid, benzoic acid, tannic acid, pamoic acid, citric, methylsulfonic, ethanesulfonic, benzenesulfonic, formic and the like (Handbook of Pharmaceutical Salts, P. Heinrich Stahal & Camille G. Wermuth (Eds), Verlag Helvetica Chemica Acta-Zürich, 2002, 329-345).
[0341] Compounds of Formula I and their salts can be in the form of a solvate, which is included within the scope of the present invention. Such solvates include for example hydrates, alcoholates and the like.
[0342] With respect to the present invention reference to a compound or compounds, is intended to encompass that compound in each of its possible isomeric forms and mixtures thereof unless the particular isomeric form is referred to specifically. Compounds according to the present invention may exist in different polymorphic forms. Although not explicitly indicated in the above formula, such forms are intended to be included within the scope of the present invention.
[0343] The compounds of the invention are indicated for use in treating or preventing conditions in which there is likely to be a component involving the sphingosine-1-phosphate receptors.
[0344] In another embodiment, there are provided pharmaceutical compositions including at least one compound of the invention in a pharmaceutically acceptable carrier.
[0345] In a further embodiment of the invention, there are provided methods for treating disorders associated with modulation of sphingosine-1-phosphate receptors. Such methods can be performed, for example, by administering to a subject in need thereof a pharmaceutical composition containing a therapeutically effective amount of at least one compound of the invention.
[0346] These compounds are useful for the treatment of mammals, including humans, with a range of conditions and diseases that are alleviated by S1P modulation: not limited to the treatment of diabetic retinopathy, other retinal degenerative conditions, dry eye, angiogenesis and wounds.
[0347] Therapeutic utilities of S1P modulators are ocular diseases, such as but not limited to: wet and dry age-related macular degeneration, diabetic retinopathy, retinopathy of prematurity, retinal edema, geographic atrophy, glaucomatous optic neuropathy, chorioretinopathy, hypertensive retinopathy, ocular ischemic syndrome, prevention of inflammation-induced fibrosis in the back of the eye, various ocular inflammatory diseases including uveitis, scleritis, keratitis, and retinal vasculitis; or systemic vascular barrier related diseases such as but not limited to: various inflammatory diseases, including acute lung injury, its prevention, sepsis, tumor metastasis, atherosclerosis, pulmonary edemas, and ventilation-induced lung injury; or autoimmune diseases and immunosuppression such as but not limited to: rheumatoid arthritis, Crohn's disease, Graves' disease, inflammatory bowel disease, multiple sclerosis, Myasthenia gravis, Psoriasis, ulcerative colitis, antoimmune uveitis, renal ischemia/perfusion injury, contact hypersensitivity, atopic dermititis, and organ transplantation; or allergies and other inflammatory diseases such as but not limited to: urticaria, bronchial asthma, and other airway inflammations including pulmonary emphysema and chronic obstructive pulmonary diseases; or cardiac protection such as but not limited to: ischemia reperfusion injury and atherosclerosis; or wound healing such as but not limited to: scar-free healing of wounds from cosmetic skin surgery, ocular surgery, GI surgery, general surgery, oral injuries, various mechanical, heat and burn injuries, prevention and treatment of photoaging and skin ageing, and prevention of radiation-induced injuries; or bone formation such as but not limited to: treatment of osteoporosis and various bone fractures including hip and ankles; or anti-nociceptive activity such as but not limited to: visceral pain, pain associated with diabetic neuropathy, rheumatoid arthritis, chronic knee and joint pain, tendonitis, osteoarthritis, neuropathic pains; or central nervous system neuronal activity in Alzheimer's disease, age-related neuronal injuries; or in organ transplant such as renal, corneal, cardiac or adipose tissue transplant; inflammatory skin diseases, scleroderma, dermatomyositis, atopic dermatitis, lupus erythematosus, epidermolysis bullosa, and bullous pemphigold. Topical use of S1P (sphingosine) compounds is of use in the treatment of various acne diseases, acne vulgaris, and rosacea.
[0348] In still another embodiment of the invention, there are provided methods for treating disorders associated with modulation of sphingosine-1-phosphate receptors. Such methods can be performed, for example, by administering to a subject in need thereof a therapeutically effective amount of at least one compound of the invention, or any combination thereof, or pharmaceutically acceptable salts, hydrates, solvates, crystal forms and individual isomers, enantiomers, and diastereomers thereof.
[0349] The present invention concerns the use of a compound of Formula I or a pharmaceutically acceptable salt thereof, for the manufacture of a medicament for the treatment of ocular disease, wet and dry age-related macular degeneration, diabetic retinopathy, retinopathy of prematurity, retinal edema, geographic atrophy, glaucomatous optic neuropathy, chorioretinopathy, hypertensive retinopathy, ocular ischemic syndrome, prevention of inflammation-induced fibrosis in the back of the eye, various ocular inflammatory diseases including uveitis, scleritis, keratitis, and retinal vasculitis; or systemic vascular barrier related diseases, various inflammatory diseases, including acute lung injury, its prevention, sepsis, tumor metastasis, atherosclerosis, pulmonary edemas, and ventilation-induced lung injury; or autoimmune diseases and immunosuppression, rheumatoid arthritis, Crohn's disease, Graves' disease, inflammatory bowel disease, multiple sclerosis, Myasthenia gravis, Psoriasis, ulcerative colitis, antoimmune uveitis, renal ischemia/perfusion injury, contact hypersensitivity, atopic dermititis, and organ transplantation; or allergies and other inflammatory diseases, urticaria, bronchial asthma, and other airway inflammations including pulmonary emphysema and chronic obstructive pulmonary diseases; or cardiac protection, ischemia reperfusion injury and atherosclerosis; or wound healing, scar-free healing of wounds from cosmetic skin surgery, ocular surgery, GI surgery, general surgery, oral injuries, various mechanical, heat and burn injuries, prevention and treatment of photoaging and skin ageing, and prevention of radiation-induced injuries; or bone formation, treatment of osteoporosis and various bone fractures including hip and ankles; or anti-nociceptive activity, visceral pain, pain associated with diabetic neuropathy, rheumatoid arthritis, chronic knee and joint pain, tendonitis, osteoarthritis, neuropathic pains; or central nervous system neuronal activity in Alzheimer's disease, age-related neuronal injuries; or in organ transplant such as renal, corneal, cardiac or adipose tissue transplant; inflammatory skin diseases, scleroderma, dermatomyositis, atopic dermatitis, lupus erythematosus, epidermolysis bullosa, and bullous pemphigold.
[0350] The actual amount of the compound to be administered in any given case will be determined by a physician taking into account the relevant circumstances, such as the severity of the condition, the age and weight of the patient, the patient's general physical condition, the cause of the condition, and the route of administration.
[0351] The patient will be administered the compound orally in any acceptable form, such as a tablet, liquid, capsule, powder and the like, or other routes may be desirable or necessary, particularly if the patient suffers from nausea. Such other routes may include, without exception, transdermal, parenteral, subcutaneous, intranasal, via an implant stent, intrathecal, intravitreal, topical to the eye, back to the eye, intramuscular, intravenous, and intrarectal modes of delivery. Additionally, the formulations may be designed to delay release of the active compound over a given period of time, or to carefully control the amount of drug released at a given time during the course of therapy.
[0352] In another embodiment of the invention, there are provided pharmaceutical compositions including at least one compound of the invention in a pharmaceutically acceptable carrier thereof. The phrase “pharmaceutically acceptable” means the carrier, diluent or excipient must be compatible with the other ingredients of the formulation and not deleterious to the recipient thereof.
[0353] Pharmaceutical compositions of the present invention can be used in the form of a solid, a solution, an emulsion, a dispersion, a patch, a micelle, a liposome, and the like, wherein the resulting composition contains one or more compounds of the present invention, as an active ingredient, in admixture with an organic or inorganic carrier or excipient suitable for enteral or parenteral applications. Invention compounds may be combined, for example, with the usual non-toxic, pharmaceutically acceptable carriers for tablets, pellets, capsules, suppositories, solutions, emulsions, suspensions, and any other form suitable for use. The carriers which can be used include glucose, lactose, gum acacia, gelatin, mannitol, starch paste, magnesium trisilicate, talc, corn starch, keratin, colloidal silica, potato starch, urea, medium chain length triglycerides, dextrans, and other carriers suitable for use in manufacturing preparations, in solid, semisolid, or liquid form. In addition auxiliary, stabilizing, thickening and coloring agents and perfumes may be used. Invention compounds are included in the pharmaceutical composition in an amount sufficient to produce the desired effect upon the process or disease condition.
[0354] Pharmaceutical compositions containing invention compounds may be in a form suitable for oral use, for example, as tablets, troches, lozenges, aqueous or oily suspensions, dispersible powders or granules, emulsions, hard or soft capsules, or syrups or elixirs. Compositions intended for oral use may be prepared according to any method known in the art for the manufacture of pharmaceutical compositions and such compositions may contain one or more agents selected from the group consisting of a sweetening agent such as sucrose, lactose, or saccharin, flavoring agents such as peppermint, oil of wintergreen or cherry, coloring agents and preserving agents in order to provide pharmaceutically elegant and palatable preparations. Tablets containing invention compounds in admixture with non-toxic pharmaceutically acceptable excipients may also be manufactured by known methods. The excipients used may be, for example, (1) inert diluents such as calcium carbonate, lactose, calcium phosphate or sodium phosphate; (2) granulating and disintegrating agents such as corn starch, potato starch or alginic acid; (3) binding agents such as gum tragacanth, corn starch, gelatin or acacia, and (4) lubricating agents such as magnesium stearate, stearic acid or talc. The tablets may be uncoated or they may be coated by known techniques to delay disintegration and absorption in the gastrointestinal tract and thereby provide a sustained action over a longer period. For example, a time delay material such as glyceryl monostearate or glyceryl distearate may be employed.
[0355] In some cases, formulations for oral use may be in the form of hard gelatin capsules wherein the invention compounds are mixed with an inert solid diluent, for example, calcium carbonate, calcium phosphate or kaolin. They may also be in the form of soft gelatin capsules wherein the invention compounds are mixed with water or an oil medium, for example, peanut oil, liquid paraffin or olive oil.
[0356] The pharmaceutical compositions may be in the form of a sterile injectable suspension. This suspension may be formulated according to known methods using suitable dispersing or wetting agents and suspending agents. The sterile injectable preparation may also be a sterile injectable solution or suspension in a non-toxic parenterally-acceptable diluent or solvent, for example, as a solution in 1,3-butanediol. Sterile, fixed oils are conventionally employed as a solvent or suspending medium. For this purpose any bland fixed oil may be employed including synthetic mono- or diglycerides, fatty acids (including oleic acid), naturally occurring vegetable oils like sesame oil, coconut oil, peanut oil, cottonseed oil, etc., or synthetic fatty vehicles like ethyl oleate or the like. Buffers, preservatives, antioxidants, and the like can be incorporated as required.
[0357] Invention compounds may also be administered in the form of suppositories for rectal administration of the drug. These compositions may be prepared by mixing the invention compounds with a suitable non-irritating excipient, such as cocoa butter, synthetic glyceride esters of polyethylene glycols, which are solid at ordinary temperatures, but liquefy and/or dissolve in the rectal cavity to release the drug.
[0358] Since individual subjects may present a wide variation in severity of symptoms and each drug has its unique therapeutic characteristics, the precise mode of administration and dosage employed for each subject is left to the discretion of the practitioner.
[0359] The compounds and pharmaceutical compositions described herein are useful as medicaments in mammals, including humans, for treatment of diseases and/or alleviations of conditions which are responsive to treatment by agonists or functional antagonists of sphingosine-1-phosphate receptors. Thus, in further embodiments of the invention, there are provided methods for treating a disorder associated with modulation of sphingosine-1-phosphate receptors. Such methods can be performed, for example, by administering to a subject in need thereof a pharmaceutical composition containing a therapeutically effective amount of at least one invention compound. As used herein, the term “therapeutically effective amount” means the amount of the pharmaceutical composition that will elicit the biological or medical response of a subject in need thereof that is being sought by the researcher, veterinarian, medical doctor or other clinician. In some embodiments, the subject in need thereof is a mammal. In some embodiments, the mammal is human.
[0360] The present invention concerns also processes for preparing the compounds of Formula I. The compounds of formula I according to the invention can be prepared analogously to conventional methods as understood by the person skilled in the art of synthetic organic chemistry. The synthetic schemes set forth below, illustrate how compounds according to the invention can be made. Those skilled in the art will be able to routinely modify and/or adapt the following schemes to synthesize any compounds of the invention covered by Formula I.
[0361] In Scheme 1, aryl amines or aryl amine derivatives or precursors react with functionalized compounds such as halogenated or hydroxylated compounds in the presence of reagents that promote alkylation as known to synthetic chemists to give the corresponding ether intermediate. This intermediate from the last step is coupled with the boronic acid or the stannate, generally involving a metal catalyst under appropriate conditions with an R 2 group to give the corresponding intermediate. The previous intermediate from the coupling procedure may be converted to an aryl amine as required for the next step by deprotection or reduction methods. The intermediate from the previous step reacts to form an amide under conditions that may employ carboxylic acids and the like to give an intermediate of Formula I. This intermediate from the last step is reacted with appropriate reagents to promote phosphorylation and yield a derivative of Formula I as a Compound of the invention upon removal of any required protecting groups.
[0000]
[0362] In Scheme II, aryl amines/amine precursors that may contain a halogen such as a bromine atom, react with functionalized compounds such as a halogenated or hydroxylated compound, in the presence of reagents that promote alkylation well known to synthetic chemists to give the corresponding ether intermediate. This intermediate from the last step is coupled with the boronic acid or the stannate involving a metal catalyst under appropriate conditions with an R 2 group (shown as a 2-furyl derivative below) to give the corresponding intermediate. The intermediate from the previous step may be converted to an aryl amine as required for the next step by deprotection or reduction methods. This aryl amine from the last step reacts to form an amide under conditions that may employ carboxylic acids and the like to give an intermediate of Formula I. This intermediate is reacted with appropriate reagents to promote phosphorylation and yield a derivative of Formula I as a Compound of the invention upon removal of any required protecting groups.
[0000]
[0363] In Scheme III, elaborated aryl bromides, are obtained according to application of appropriate synthetic preparation, may react with compounds in the presence of reagents that promote alkylation. This intermediate from the last step that contains the R 3 group (representing an —O—, —S— —NH—, —CH 2 —) or other group is coupled with the boronic acid or the stannate under appropriate conditions with an R 2 group to give the corresponding intermediate. This intermediate from the previous step is reacted with appropriate reagents to promote phosphorylation and yield a derivative of Formula I as a Compound of the invention upon removal of any required protecting groups.
[0000]
BRIEF DESCRIPTION OF THE DRAWINGS
[0364] FIG. 1 depicts lowered lymphocyte count after 24 hours (<1 number of lymphocytes 10 3 /μL blood) by Compound 4.
DETAILED DESCRIPTION OF THE INVENTION
[0365] It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention claimed. As used herein, the use of the singular includes the plural unless specifically stated otherwise.
[0366] It will be readily apparent to those skilled in the art that some of the compounds of the invention may contain one or more asymmetric centers, such that the compounds may exist in enantiomeric as well as in diastereomeric forms. Unless it is specifically noted otherwise, the scope of the present invention includes all enantiomers, diastereomers and racemic mixtures. Some of the compounds of the invention may form salts with pharmaceutically acceptable acids or bases, and such pharmaceutically acceptable salts of the compounds described herein are also within the scope of the invention.
[0367] The present invention includes all pharmaceutically acceptable isotopically enriched compounds. Any compound of the invention may contain one or more isotopic atoms enriched or different than the natural ratio such as deuterium 2 H (or D) in place of protium 1 H (or H) or use of 13 C enriched material in place of 12 C and the like. Similar substitutions can be employed for N, O and S. The use of isotopes may assist in analytical as well as therapeutic aspects of the invention. For example, use of deuterium may increase the in vivo half-life by altering the metabolism (rate) of the compounds of the invention. These compounds can be prepared in accord with the preparations described by use of isotopically enriched reagents.
[0368] The following examples are for illustrative purposes only and are not intended, nor should they be construed as limiting the invention in any manner. Those skilled in the art will appreciate that variations and modifications of the following examples can be made without exceeding the spirit or scope of the invention.
[0369] As will be evident to those skilled in the art, individual isomeric forms can be obtained by separation of mixtures thereof in conventional manner. For example, in the case of diasteroisomeric isomers, chromatographic separation may be employed.
[0370] Compound names were generated with ACD version 8, and some intermediates' and reagents' names used in the examples were generated with software such as Chem Bio Draw Ultra version 12.0 or Auto Nom 2000 from MDL ISIS Draw 2.5 SP1 or from a commercial supplier catalog such as Sigma-Aldrich.
[0371] In general, characterization of the compounds is performed using NMR spectra which were recorded on 300 and/or 600 MHz Varian and acquired at room temperature. Chemical shifts were given in ppm referenced either to internal TMS or to the solvent signal. Coupling constant J reported in Hz, hertz.
[0372] All the reagents, solvents, catalysts for which the synthesis is not described are purchased from chemical vendors such as Sigma Aldrich, Fluka, Bio-Blocks, Combi-blocks, TCI, VWR, Lancaster, Oakwood, Trans World Chemical, Alfa, Fisher, Maybridge, Frontier, Matrix, Ukrorgsynth, Toronto, Ryan Scientific, SiliCycle, Anaspec, Syn Chem, Chem-Impex, MIC-scientific, Ltd; however some known intermediates, were prepared according to published procedures.
[0373] Usually the compounds of the invention were purified by column chromatography (Auto-column) on a Teledyne-ISCO CombiFlash with a silica gel column, unless noted otherwise.
[0374] The following abbreviations are used in the examples:
s, m, h, d second, minute, hour, day CH 3 CN acetonitrile PSI pound per square inch DCM dichloromethane DMF N,N-dimethylformamide NaOH sodium hydroxide MeOH methanol CD 3 OD deuterated methanol NH 3 ammonia HCl hydrochloric acid Na 2 SO 4 sodium sulfate RT or rt room temperature MgSO 4 magnesium sulfate EtOAc ethyl acetate CDCl 3 deuterated chloroform DMSO-d 6 deuterated dimethyl sulfoxide Auto-column automated flash liquid chromatography TFA trifluoroacetic acid THF tetrahydrofuran M molar PdCl 2 (PPh 3 ) 2 bis(triphenylphosphine)palladium(II) chloride AcOH acetic acid K 2 CO 3 potassium carbonate NaCl sodium chloride CHCl 3 chloroform HATU (O-(7-azabenzotriazol-1-yl)-N,N,N′,N′-tetramethyluronium hexafluorophosphate)
[0401] Those skilled in the art will be routinely able to modify and/or adapt the following procedures to synthesize any compound of the invention covered by Formula I.
Example 1
Intermediate 1
2-bromo-4-nitro-1-((5-phenylpentyl)oxy)benzene
[0402]
[0403] A mixture of 2-bromo-4-nitrophenol (CAS 5847-59-6) (2.05 g, 9.4 mmol), (5-bromopentyl)benzene (CAS 14469-83-1) (2.41 g, 10.6 mmol) and K 2 CO 3 (3.5 g, 19.1 mmol) was dissolved in DMF (20 mL). The reaction mixture was heated at 100° C. for ˜18 h. The mixture was diluted with hexanes:EtOAc (1:1) (˜200 mL) and washed with H 2 O (3×). The organic solution was dried over MgSO 4 , filtered, and concentrated onto silica gel under vacuum. Auto-column (9.5 hexanes: 0.5 EtOAc) gave Intermediate 1 as a white solid 1.91 g (56%).
Example 2
Intermediate 2
2-[5-nitro-2-(5-phenyl-pentyloxy)-phenyl]-thiophene
[0404]
[0405] A mixture of Intermediate 1 (1.91 g, 5.25 mmol), tributyl-thiophen-2-yl-stannane (CAS 54663-78-4) (3.4 mL, 10.7 mmol) and PdCl 2 (PPh 3 ) 2 (0.55 g, 15 mol %) in DMF (12 mL) was reacted under MWI at 160° C. for 15 m. The mixture was cooled to rt and diluted with hexanes:EtOAc (1:1, 200 mL). The mixture was washed with water (3×), dried over MgSO 4 , filtered and concentrated onto silica gel under vacuum. Auto-column (9.5 hexanes: 0.5 EtOAc) produced Intermediate 2 as an orange solid, 1.10 g (57%).
Example 3
Intermediate 3
4-(5-phenyl-pentyloxy)-3-thiophen-2-yl-phenylamine
[0406]
[0407] A mixture of iron chips (0.62 g, 11.1 mmol), NH 4 Cl (0.88 g, 16.4 mmol), water (3.3 mL), and ethanol (10 mL) were heated to reflux for 15 m. This mixture was transferred into a solution of Intermediate 2 (1.0 g, 2.72 mmol) in EtOH (8 mL). The resulting mixture was heated to reflux for 5 h. The mixture was filtered, washed with EtOAc and partitioned between EtOAc and water. The organic layers were dried over MgSO 4 , filtered and concentrated onto silica gel. Auto-column (7 hexane: 3 EtOAc) gave Intermediate 3, as a tan solid 0.55 g (60%).
Example 4
Intermediate 4
(R)-tert-butyl (3-hydroxy-2-methyl-1-oxo-1-((4-((5-phenylpentyl)oxy)-3-(thiophen-2-yl)phenyl)amino)propan-2-yl)carbamate
[0408]
[0409] Intermediate 3 (0.30 g, 0.89 mmol), Boc-D-serine (CAS 84311-18-2) (0.25 g, 1.11 mmol), HATU (CAS 148893-10-1) (0.51 g, 1.34 mmol), diisopropylethylamine (CAS 7087-68-5) (0.46 mL) in DMF (20 mL) was reacted at rt for ˜18 h. After an aqueous workup and extraction with (hexanes: EtOAc) the organic layers were combined and concentrated onto silica gel. Auto-column (3% MeOH in CH 2 Cl 2 ) gave Intermediate 4 0.28 g, (58%).
Example 5
Intermediate 5
2-amino-2-methyl-3-oxo-3-({4-[(5-phenylpentyl)oxy]-3-(2-thienyl)phenyl}amino)propyl dihydrogen phosphate
[0410]
[0411] Intermediate 4 (0.28 g, 5.20 mmol), tetrazole (7.0 mL, 3.15 mmol; 0.45 M in CH 3 CN), and di-tert-butyl diisopropyl-phosphoramidite (0.65 mL, 2.06 mmol) in DMF (5 mL) were stirred at RT for ˜18 h. Hydrogen peroxide 35% (0.19 mL, 2.2 mmol) excess was added at 0° C. and the mixture was warmed to RT and stirred for 1 h. The solvent was removed under vacuum and the residue was quenched with sat. Na 2 S 2 O 3 (10% aq) and extracted with EtOAc. The organic layers were dried over MgSO 4 , filtered, concentrated onto silica gel under vacuum. Auto-column (6 hexanes: 4 EtOAc) gave Intermediate 5 as a white solid 0.27 g (71%).
Example 6
Compound 1
(2R)-2-amino-2-methyl-3-oxo-3-({4-[(5-phenylpentyl)oxy]-3-(2-thienyl)phenyl}amino)propyl dihydrogen phosphate
[0412]
[0413] Intermediate 5 was dissolved in CH 2 Cl 2 and reacted with HCl in dioxane. The mixture was reacted for ˜18 h at rt. The solvent was removed under vacuum and the crude material was titurated several times with diethyl ether to give Compound 1 as a solid, ˜160 mg.
[0414] (300 MHz, CD 3 OD): δ 7.89 (d, J=2.4, 1H), 7.50-7.44 (m, 2H), 7.37 (d, J=5.4, 1H), 7.26-7.21 (m, 2H), 7.17-7.13 (m, 3H), 7.06-7.00 (m, 2H), 4.42 (dd, J=5.1, 11.4, 1H), 4.20 (dd, J=4.8, 11.7, 1H), 4.08 (t, J=6.3, 2H), 2.63 (t, J=7.2, 2H), 1.91-1.84 (m, 2H), 1.74-1.65 (m, 2H), 1.68 (s, 3H), 1.62-1.53 (m, 2H).
[0415] Compound 2 prepared from the corresponding starting materials in a similar manner to the procedure described for Compound 1. The results are tabulated below in Table 1.
[0000]
TABLE 1
Compound 2
IUPAC Name
(2S)-2-amino-2-methyl-3-oxo-3-({4-[(5-phenylpentyl)oxy]-3-(2-
thienyl)phenyl}amino)propyl dihydrogen phosphate
Structure
1 H NMR δ (ppm)
(600 MHz, CD 3 OD/CDCl 3 ) δ: 7.91 (d, J = 2.4, 1 H), 7.51 (d, J = 3.0,
1H), 7.45 (dd, J = 2.4, 9.0, 1H), 7.33 (d, J = 4.8, 1H), 7.25 (t, J = 7.8,
2H), 7.18-7.14 (m, 3H), 7.06 (t, J = 4.8, 1H), 6.95 (d, J = 9.0, 1H),
4.27 (dd, J = 5.4, 10.8, 1H), 4.07 (t, J = 6.6, 2H), 3.96 (dd, J = 5.4,
9.6, 1H), 2.65 (t, J = 7.8, 2H), 1.93-1.89 (m, 2H), 1.74-1.68 (m, 2H),
1.61-1.57 (m, 2H), 1.50 (s, 3H).
Intermediate(s)
1, 2 and 3
starting
Boc-L-serine
material(s)
Example 7
Intermediate 7
2-(2-(benzyloxy)-5-nitrophenylfuran
[0416]
[0417] Intermediate 7 was prepared from Intermediate 1 and tributyl-2-furanyl-stannane, in a similar manner to the procedure described in Example 2 for Intermediate 2.
Example 8
Intermediate 8
3-furan-2-yl-4-(5-phenyl-pentyloxy)-phenylamine
[0418]
[0419] Intermediate 8 was prepared from Intermediate 7 in a similar manner to the procedure described in Example 3 for Intermediate 3.
Example 9
Intermediate 9
{(S)-1-[3-furan-2-yl-4-(5-phenyl-pentyloxy)-phenylcarbamoyl]-2-hydroxy-ethyl}-carbamic acid benzyl ester
[0420]
[0421] Intermediate 8 (0.98 g, 3.05 mmol), N-carbobenzoxy-L-serine (0.82 g, 3.36 mmol), HATU (2.0 g, 5.1 mmol), and diisopropylethylamine (1.8 mL, 10.3 mmol) in DMF (30 mL) was allowed to react for ˜18 h at RT. Auto column (6 hexanes:4 EtOAc) gave a crude Intermediate 9 as a yellow solid, 1.32 g (80%).
Example 10
Intermediate 10
benzyl [2-({3-(2-furyl)-4-[(5-phenylpentyl)oxy]phenyl}amino)-1-{[(3-oxido-1,5-dihydro-2,4,3-benzodioxaphosphepin-3-yl)oxy]methyl}-2-oxoethyl]carbamate
[0422]
[0423] Intermediate 9 (1.32 g, 2.43 mmol), tetrazole (16.2 mL, 7.29 mmol; 0.45 M in CH 3 CN), and 3-(diethylamino)-1,5-dihydro-2,4,3-benzodioxaphosphepine (CAS 82372-35-8) (0.88 mL, 3.67 mmol) in THF (25 mL) were stirred at RT for ˜24 h. Hydrogen peroxide 35% (4.7 mL, 54.6 mmol) excess was added and the mixture was stirred for 1 h. The solvent was removed under vacuum and the residue was quenched with sat. Na 2 S 2 O 3 and extracted with EtOAc. The organic layers were dried over MgSO 4 . Auto-column (5 hexanes: 5 EtOAc) gave a crude Intermediate 10 as a yellow oil ˜0.86 g.
Example 11
Compound 3
(2S)-2-amino-3-({3-(2-furyl)-4-[(5-phenylpentyl)oxy]phenyl}amino)-3-oxopropyl dihydrogen phosphate
[0424]
[0425] Intermediate 10 (0.86 g, 1.19 mmol) was treated with 10% Pd on C (0.30 g) and hydrogen at 50 psi for 3 h. The mixture was filtered through celite. The filtrate was concentrated onto silica gel and purified with auto-column (gradient 0→100% MeOH in CH 2 Cl 2 ) to give Compound 3 as a solid ˜50 mg.
[0426] (300 MHz, DMSO-d 6 ) δ: 8.10 (d, J=2.7, 1H), 7.70 (s, 1H), 7.47 (dd, J=2.1, 8.7, 1H), 7.27-7.14 (m, 6H), 6.99 (d, J=8.7, 1H), 6.85 (d, J=3.0, 1H), 6.54 (dd, J=1.8, 3.6, 1H), 4.02 (t, J=6.3, 2H), 3.98-3.90 (m, 3H), 2.58 (t, J=7.5, 2H), 1.84-1.78 (m, 2H), 1.67-1.62 (m, 2H), 1.52-1.44 (m, 2H).
[0427] Compound 4 prepared from Intermediate 3 and the corresponding procedure(s) as described for preparation of Intermediate 10 and in Example 11 for Compound 3. The results are tabulated below in Table 2.
[0000]
TABLE 2
Compound 4
IUPAC Name
(2S)-2-amino-3-oxo-3-({4-[(5-phenylpentyl)oxy]-3-(2-
thienyl)phenyl}amino)propyl dihydrogen phosphate
Structure
1 H NMR δ (ppm)
(600 MHz, CF 3 C(O)OD) δ: 7.68 (d, J = 3.0, 1H), 7.30-7.28 (m, 1H),
7.25-7.22 (m, 3H), 7.20-7.16 (m, 3H), 7.14 (t, J = 7.2, 1H), 7.10 (d, J =
9.0, 1H), 7.06 (d, J = 3.0, 1H), 5.02-4.97 (m, 2H), 4.80-4.77 (m, 1H),
4.17 (t, J = 6.6, 2H), 2.65 (t, J = 7.2, 2H), 1.96-1.92 (m, 2H), 1.75-1.70
(m, 2H), 1.59-1.56 (m, 2H).
Intermediate
3
BIOLOGICAL EXAMPLES
In Vitro Assay
[0428] Compounds were tested for S1P1 activity using the GTP γ 35 S binding assay. These compounds may be assessed for their ability to activate or block activation of the human S1P1 receptor in cells stably expressing the S1P1 receptor. GTP γ 35 S binding was measured in the medium containing (mM) HEPES 25, pH 7.4, MgCl 2 10, NaCl 100, dithitothreitol 0.5, digitonin 0.003%, 0.2 nM GTP γ 35 S, and 5 μg membrane protein in a volume of 150 μl. Test compounds were included in the concentration range from 0.08 to 5,000 nM unless indicated otherwise. Membranes were incubated with 100 μM 5′-adenylylimmidodiphosphate for 30 min, and subsequently with 10 μM GDP for 10 min on ice. Drug solutions and membrane were mixed, and then reactions were initiated by adding GTP γ 35 S and continued for 30 min at 25° C. Reaction mixtures were filtered over Whatman GF/B filters under vacuum, and washed three times with 3 mL of ice-cold buffer (HEPES 25, pH7.4, MgCl 2 10 and NaCl 100). Filters were dried and mixed with scintillant, and counted for 35 S activity using a β-counter. Agonist-induced GTP γ 35 S binding was obtained by subtracting that in the absence of agonist. Binding data were analyzed using a non-linear regression method. In case of antagonist assay, the reaction mixture contained 10 nM S1P in the presence of test antagonist at concentrations ranging from 0.08 to 5000 nM.
Activity Potency:
[0429] S1P1 receptor from GTP γ 35 S: nM, (EC 50 ),
[0000]
TABLE 3
S1P1
EC 50
IUPAC name
(nM)
(2R)-2-amino-2-methyl-3-oxo-3-({4-[(5-phenylpentyl)oxy]-3-(2-
96
thienyl)phenyl}amino)propyl dihydrogen phosphate
(2S)-2-amino-2-methyl-3-oxo-3-({4-[(5-phenylpentyl)oxy]-3-(2-
34
thienyl)phenyl}amino)propyl dihydrogen phosphate
(2S)-2-amino-3-({3-(2-furyl)-4-[(5-
8
phenylpentyl)oxy]phenyl}amino)-3-oxopropyl dihydrogen
phosphate
(2S)-2-amino-3-oxo-3-({4-[(5-phenylpentyl)oxy]-3-(2-
3
thienyl)phenyl}amino)propyl dihydrogen phosphate
Lymphopenia Assay in Mice
[0430] Test drugs are prepared in a solution containing 3% (w/v) 2-hydroxy propyl β-cyclodextrin (HPBCD) and 1% DMSO to a final concentration of 1 mg/ml, and subcutaneously injected to female C57BL6 mice (CHARLES RIVERS) weighing 20-25 g at the dose of 10 mg/Kg. Blood samples are obtained by puncturing the submandibular skin with a Goldenrod animal lancet at 24, 48, 72, and 96 hrs post drug application. Blood is collected into microvettes (SARSTEDT) containing EDTA tripotassium salt. Lymphocytes in blood samples are counted using a HEMAVET Multispecies Hematology System, HEMAVET HV950FS (Drew Scientific Inc.). (Hale, J. et al Bioorg. & Med. Chem. Lett. 14 (2004) 3351).
[0431] A lymphopenia assay in mice; as previously described, was employed to measure the in vivo blood lymphocyte depletion after dosing with (2S)-2-amino-3-oxo-3-({4-[(5-phenylpentyl)oxy]-3-(2-thienyl)phenyl}amino)propyl dihydrogen phosphate. This S1P1 agonist is useful for S1P-related diseases and exemplified by the lymphopenia in vivo response. Test drug, (2S)-2-amino-3-oxo-3-({4-[(5-phenylpentyl)oxy]-3-(2-thienyl)phenyl}amino)propyl dihydrogen phosphate was prepared in a solution containing 3% (w/v) 2-hydroxy propyl β-cyclodextrin (HPBCD) and 1% DMSO to a final concentration of 1 mg/ml, and subcutaneously injected to female C57BL6 mice (CHARLES RIVERS) weighing 20-25 g at the dose of 10 mg/Kg. Blood samples were obtained by puncturing the submandibular skin with a Goldenrod animal lancet at different time intervals such as: 24, 48, 72, and 96 h post drug application. Blood was collected into microvettes (SARSTEDT) containing EDTA tripotassium salt. Lymphocytes in blood samples were counted using a HEMAVET Multispecies Hematology System, HEMAVET HV950FS (Drew Scientific Inc.). Results are shown in FIG. 1 that depicts lowered lymphocyte count after 24 hours (<1 number of lymphocytes 10 3 /μL blood).
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The present invention relates to novel derivatives, processes for preparing them, pharmaceutical compositions containing them and their use as pharmaceuticals as modulators of sphingosine-1-phosphate receptors.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Not applicable.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to improvements in the construction and manufacture of polymeric bags. In particular, the present invention relates to improvements to trash bags.
[0004] 2. Description of the Related Art
[0005] Polymeric bags are ubiquitous in modern society and are available in countless combinations of varying capacities, thicknesses, dimensions and colors. The bags are available for numerous applications including typical consumer applications such as long-term storage, food storage, and trash collection. Like many other consumer products, increased demand and new technology have driven innovations in polymeric bags improving the utility and performance of such bags. The present invention is an innovation of particular relevance to polymeric bags used for trash collection.
[0006] Polymeric bags are manufactured from polymeric film produced using one of several manufacturing techniques that are well-known in the art. However, the two most common manufacturing methods for creating polymeric film are blown-film extrusion and cast-film extrusion. Both blown-film extrusion and cast-film extrusion offer certain advantages versus the other. The ultimate selection of a method of manufacture is often driven by considerations such as the desired properties for the final product as well as by financial considerations.
[0007] In both blown-film extrusion and cast-film extrusion, an extruder is used to push molten polymeric material through a die. In the case of blown-film extrusion, the film during processing is tubular in shape. In cast-film extrusion, the film during processing is substantially flat. Certain dies also allow for the manufacture of polymeric films having multiple layers co-extruded through a single die. An early die designed to produce multi-layer blown-film tubes is described in U.S. Pat. No. 4,185,954 entitled Die for Extruding Tubes Composed of Plurality of Layers. Furthermore, other types of co-extrusion dies are available which allow for different polymer blends to be extruded through a single die to provide distinct sections across the width, or circumference, of the extruded film. Such dies, for example, may be used with polymer blends having different color additives to provide stripes in the extruded blown-film.
[0008] As previously stated, the present invention relates to polymeric trash bags, which are available in several popular configurations such as drawstring trash bags and wave-cut trash bags, the latter of which have two or more flaps extending from the top of the bag. Both drawstring and wave-cut trash bags are popular among consumers and, given their popularity, recent innovations have attempted to improve the bags' performance.
[0009] One common complaint, which is applicable to many different types of trash bags, revolves around the tendency of the trash bag to fall into the trash can during use. Specifically, the top of the trash bag, which is placed over the top of the can, often has a tendency to fall into the trash can as the weight of the trash pulls the bag downward into the can.
[0010] To address this issue, certain trash bags now provide features intended to enhance the ability of the bag to “grip” the outside of the trash can near the top of the trash can. With respect to drawstring trash bags, elastic drawstrings have been introduced which stretch outward and retract in order to grip the outside of a trash receptacle. However, the physical properties and strength of the panels comprising the trash bags, specifically the area near the top of the bag at or around the hem area, can make it difficult to stretch the mouth of the bag over the perimeter of the trash receptacle.
[0011] One prior art attempt to address this problem is to provide perforations or notches near the upper corners of the bag thereby allowing the ends of an elastic drawstring to be separated from the bag proper and stretched over and around the upper opening of a trash receptacle. However, the perforations or notches result in large openings at the top of the bag when it is closed. Additionally, when compared with traditional drawstring trash bags, the perforations and/or notches in the bag can increase the risk that tears will propagate away from the cutouts when stress is placed on the bag.
[0012] In view of the foregoing, it would be desirable to provide a trash bag that is easier to extend over the upper opening of a trash can, keeps the structural integrity of the bag intact, and overcomes challenges of the prior art. Additionally, it would also be desirable to provide a trash bag that effectively grips trash cans. The present invention addresses these and other needs.
SUMMARY OF THE INVENTION
[0013] In one embodiment of the present invention, a trash bag is comprised of a first panel and a second panel joined along a first side edge, a second side edge, and a bottom edge. The top edge of the first panel and second panel defines an upper opening of the bag. The first panel has a normal thickness and further comprises a reduced gauge portion. The reduced gauge portion of the first panel has a thickness that is less than the normal thickness of the first panel. In some embodiments of the present invention, the reduced gauge portion of the first panel extends substantially across a width of the first panel. Additionally, the reduced gauge portion of the first panel may have a substantially uniform height.
[0014] In certain embodiments of the present invention, the thickness of the reduced gauge portion may be less than or approximately equal to 80% of the normal thickness of the first panel. Furthermore, in some embodiments of the present invention, the thickness of the reduced gauge portion may be less than or approximately equal to 50% of the normal thickness of the first panel. Additionally, the second panel may also have a normal thickness with a reduced gauge portion of the second panel having a thickness that is less than the normal thickness of the second panel.
[0015] In some embodiments of the present invention, a first hem is provided in the first panel with a first drawstring contained within the first hem. Additionally, a second hem may be provided in the second panel with a second drawstring contained within the second hem. In some embodiments, the first drawstring may be elastic or both the first and second drawstring may be elastic. Furthermore, in such embodiments, a reduced gauge portion of the first panel may be provided that includes substantially all of the first hem and may further include an area of the first panel below the first hem. Similarly, a reduced gauge portion of the second panel may be provided that includes substantially all of the second hem and may further include an area of the second panel below the second hem.
BRIEF DESCRIPTION OF THE RELATED DRAWINGS
[0016] A full and complete understanding of the present invention may be obtained by reference to the detailed description of the present invention and certain embodiments when viewed with reference to the accompanying drawings. The drawings can be briefly described as follows.
[0017] FIG. 1 provides a perspective view of a first embodiment of the present invention.
[0018] FIG. 2 provides an elevation view of a panel used to construct the first embodiment of the present invention.
[0019] FIG. 3 provides a perspective view of a second embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0020] The present disclosure illustrates several embodiments of the present invention. It is not intended to provide an illustration or encompass all embodiments contemplated by the present invention. In view of the disclosure of the present invention contained herein, a person having ordinary skill in the art will recognize that innumerable modifications and insubstantial changes may be incorporated or otherwise included within the present invention without diverging from the spirit of the invention. Therefore, it is understood that the present invention is not limited to those embodiments disclosed herein. The appended claims are intended to more fully and accurately encompass the invention to the fullest extent possible, but it is fully appreciated that certain limitations on the use of particular terms are not intended to conclusively limit the scope of protection.
[0021] Referring initially to FIG. 1 , a perspective view of drawstring trash bag 100 is shown according to one embodiment of the present invention. The drawstring trash bag comprises a first panel 102 and a second panel 104 , each panel being substantially rectangular in shape. The first panel 102 and second panel 104 are coupled along a first side edge 106 , a second side edge 108 , and a bottom edge 110 of the respective panels 102 and 104 . In some embodiments, the first panel 102 and second panel 104 may be formed from a single piece of polymeric film, folded to define a bottom edge 110 and sealed along the first side edge 106 and second side edge 108 .
[0022] The unsealed top edge 112 of the respective panels 102 and 104 defines the upper opening of the drawstring trash bag. A pair of drawstrings 140 are disposed within hems 142 located proximate the top edge 112 of the respective first panel 102 and second panel 104 . The drawstrings 140 may be traditional high-density polyethylene drawstrings or, in some embodiments, may be elastic drawstrings. The drawstrings are generally loose within the hems 142 and sealed near the upper corners of the drawstring trash bag 100 by short seals 120 and 122 . Therefore, when the drawstrings 140 are pulled through the drawstring cutouts 144 of the bag 100 , the respective upper corners of the bag 100 are pulled together, facilitating closure of the bag.
[0023] In the depicted embodiment of FIG. 1 , the panels 102 and 104 of the drawstring trash bag 100 are primarily comprised of a polymer blend which generally comprises linear low density polyethylene (LLDPE) although other polyethylenes may be utilized as the primary component such as high density polyethylene (HDPE) or low density polyethylene (LDPE). Typically, the LLDPE comprises at least 80% of the polymer blend. The remaining 20% of the polymer blend may comprise additives to provide color for the final product, increased resistance to blocking, odor control, or other properties.
[0024] To facilitate the drawstrings 140 in being stretched over certain trash receptacles while still keeping the structural integrity of the bag intact, a reduced gauge portion 150 generally extends across the width of the drawstring trash bag 100 and may generally encompass the hems 142 and may also encompass a small area below the hems 142 as well. The reduced gauge portion 150 has a thickness, or gauge, that is less than the remainder of the trash bag panels 102 and 104 . The thickness of the remainder of the trash bag panels 102 and 104 may be referred to herein as the normal gauge or normal thickness of the respective trash bag panels 102 and 104 . However, it is understood that the thickness of thin polymeric films may vary and that certain variations in thickness may be expected. Therefore, the gauge and thickness of a polymeric film is usually expressed in terms of an average thickness across a certain area.
[0025] In a typical embodiment of the present invention as shown in FIG. 1 , the reduced gauge portion 150 may have a thickness that is less than or equal to 80% of the normal thickness of the trash bag panels 102 and 104 . As an example, in a certain embodiment, the trash bag panels 102 and 104 may have a normal thickness of 1.0 mil while the thinner portion 150 may have a thickness of approximately 0.8 mil. Furthermore, it is contemplated that in certain other embodiments, the reduced gauge portion 150 may have a thickness equal to or less than 50% of the normal thickness of the trash bag panels 102 and 104 . Compared to a similar trash bag known in the prior art which has substantially uniform thickness, the reduced thickness of the reduced gauge portion 150 provides less resistance when stretching the mouth of the trash bag 100 over certain trash receptacles.
[0026] In some embodiments of the present invention, the reduced gauge portion 150 may be comprised of the same polymer blend as the remainder of the trash bag panels 102 and 104 . For example, in many embodiments of the present invention the trash bag panels 102 and 104 may be comprised primarily of linear-low density polyethylene (LLDPE), which typically makes up over 80% of the polymer blend used for the trash bag panels 102 and 104 . IN certain embodiments, the reduced gauge portion 150 may comprise the same polymer blend, comprising at least 80% of LLDPE. However, in other embodiments of the present invention, the polymer blend of the reduced gauge portion 150 may be a modified polymer blend, different from the polymer blend used for the trash bag panels 102 and 104 . The modified polymer blend may have a lower modulus of elasticity than the remainder of the panels 102 and 104 facilitating the reduced gauge portion 150 of the drawstring trash bag 100 to be stretched over the outside of a trash receptacle. Additionally, the modified polymer blend may provide greater elastic recovery improving the grip of the drawstring trash bag 100 on the outside of the trash receptacle after being placed over it. It is contemplated that several different polymers may be used in the modified polymer blend, including but not limited to, linear low density polyethylene (LLDPE), low density polyethylene (LDPE), ethylene-vinyl acetate (EVA), ethylene-acrylic acid (EAA), very low density polyethylene (VLDPE), and ultra low density polyethylene (ULDPE). As an example, in some embodiments of the present invention, a modified polymer blend of the reduced gauge portion 150 may comprise at least 20% ULDPE or VLDPE. However, in certain preferred embodiments, the modified polymer blend may have at least 50% ULDPE or VLDPE.
[0027] Referring now to FIG. 2 , the first panel 102 is depicted to better illustrate the first panel 102 made with a reduced gauge portion 150 . The reduced gauge portion 150 is shaded to illustrate the portion of the first panel 102 which is thinner than the normal thickness for the remainder of the first panel 102 . In the depicted embodiment, the reduced gauge portion 150 of the first panel 102 encompasses the entire area of the hems 142 and extends slightly below the hem 142 as well. A person of ordinary skill in the art would understand that FIG. 2 illustrates the first panel 102 wherein the drawstring cutout 144 has been provided but before providing a drawstring 140 . After providing the drawstring 140 , the upper portion of the first panel 102 would be folded downward over the drawstring 140 to form the hem 142 as shown in FIG. 1 .
[0028] Referring now to FIG. 3 , another embodiment of the present invention is depicted. The embodiment depicted in FIG. 3 is an improved drawstring bag 300 similar to the drawstring trash bag 100 of FIG. 1 . Like the embodiment of FIG. 1 , the reduced gauge portion 150 includes the hems 142 and extends slightly below the hems 142 . However, in this improved drawstring trash bag 300 , a first inner short seal 320 and a second inner short seal 322 are additionally provided to seal the drawstrings 140 and panels 102 and 104 together. The first inner short seal 320 and second inner short seal 322 effectively reduce the width of the upper opening of the improved drawstring bag 300 .
[0029] As previously noted, the specific embodiments depicted herein are not intended to limit the scope of the present invention. Indeed, it is contemplated that any number of different embodiments may be utilized without diverging from the spirit of the invention. Therefore, the appended claims are intended to more fully encompass the full scope of the present invention.
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The present invention is directed to a polymeric bag having a reduced gauge portion extending generally across the width of the bag, wherein the reduced gauge portion allows that area of the polymeric bag to be stretched more easily. This invention is especially advantageous in the context of drawstring trash bags wherein the reduced gauge portion encompasses the hems.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No. 60/176,355, filed Jan. 14, 2000.
FIELD OF THE INVENTION
[0002] The present invention relates generally to filter-fan products including a filter monitoring system and more particularly relates to a filter monitoring system using a counter that works in conjunction with the fan motor speed. The system will provide a display for remaining filter life for filter-fan products.
BACKGROUND OF THE INVENTION
[0003] Filter-fan products such as some types of portable fans, air purifiers, humidifiers and dehumidifiers include filters for removing airborne particles from the homes or offices in which they operate. Such filters include fine particle high efficiency particulate air (HEPA) filters, filters for trapping relatively large particles and carbon filters to remove odors.
[0004] Typically, a fan is positioned adjacent a removable filter to force air through the filter thereby trapping airborne particles therein. As the efficiency of these types of products depends upon the replacement of the filter when spent, the ability to easily determine when the filter is spent is important. With conventional filter-fan products, the filter is typically replaced only when a visual inspection reveals a spent filter. However, this requires periodic inspection and by the time a filter shows signs of needing replacement, its efficiency has already been drastically reduced. Another option for maintaining the efficiency of the filter-fan product is to follow the manufacturer's filter replacement schedule. However, this requires the user to somehow keep track of the filter-fan product's use. Neither of these options are particularly convenient for the user of the filter-fan product.
[0005] Accordingly, it is desirable to provide such fan-filter products with a system to monitor the remaining life of a filter and to indicate when the filter should be replaced. What is needed is an easily viewable display on the filter-fan product alerting the user to the status of the filter.
SUMMARY OF THE INVENTION
[0006] The present invention is a method and circuit for monitoring the useful life of a filter for a filter-fan product. The method according to the present invention generally includes the steps of detecting use of a fan of the filter-fan product with a microprocessor, counting from a predetermined initial counter value a duration of usage of the fan with a counter of the microprocessor to determine a present counter value, calculating by the microprocessor a percentage of filter life remaining based on the present counter value, sending a signal representing the percentage of filter life remaining from the microprocessor to a display and displaying the remaining useful life of the filter based on the signal received from the micro processor.
[0007] Preferably, use of the fan is detected by detecting a position of a fan speed switch such that the microprocessor detects the speed of the fan and adjusts the rate of counting by the counter based on the detected speed of the fan. The method further preferably includes the steps of storing the present counter value in a memory device upon termination of fan use, retrieving the stored present counter value from the memory device upon reactivation of the fan and resetting the present counter value to the predetermined initial counter value upon replacement of the filter. The remaining useful life of the filter is preferably displayed by illuminating one of a plurality of light emitting devices, each light emitting device representing a level of remaining useful life of the filter.
[0008] The circuit according to the present invention generally includes a microprocessor electrically connected to a power circuit for a fan assembly of the filter-fan product for detecting use of the fan and a display electrically connected to the microprocessor for displaying the remaining useful life of the filter. The microprocessor includes a counter, having a predetermined initial counter value, and an algorithm. The counter counts from the predetermined initial counter value a duration of usage of the fan to determine a present counter value and the algorithm calculates a percentage of filter life remaining based on the present counter value. The microprocessor sends a signal representing the percentage of filter life remaining to the display which uses the signal to display the remaining useful life of the filter.
[0009] Preferably, the microprocessor is electrically connected to a fan speed selection switch so that the microprocessor detects a selected fan speed and adjusts the rate of counting by the counter based on the detected fan speed. The fan speed selection switch is positionable to one of a plurality of positions, each position being electrically connected to an input of the microprocessor, wherein the microprocessor detects the selected fan speed by sampling each microprocessor input. The display preferably comprises a plurality of light emitting devices, one of the light emitting devices being illuminated to display a level of remaining useful life of the filter.
[0010] The circuit further preferably includes a memory device for storing the present counter value upon termination of fan use and for retrieving the present counter value by the microprocessor upon reactivation of the fan. Additionally, the circuit preferably includes a reset switch for resetting the present counter value to the predetermined initial counter value upon replacement of the filter.
[0011] For a better understanding of the present invention, reference is made to the following detailed description to be read in conjunction with the accompanying drawings and its scope will be defined in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] [0012]FIG. 1 is a cross-sectional view of a filter-fan product having a filter monitoring system in accordance with the present invention.
[0013] [0013]FIG. 2 is a simplified circuit diagram showing a preferred embodiment of the filter monitoring system in accordance with the present invention.
[0014] [0014]FIG. 3 is a simplified circuit diagram showing an alternate embodiment of the filter monitoring system in accordance with the present invention.
[0015] [0015]FIG. 4 is a simplified circuit diagram showing another alternate embodiment of the filter monitoring system in accordance with the present invention.
[0016] [0016]FIG. 5 is a block circuit diagram of the preferred embodiment of the filter monitoring system in accordance with the present invention.
[0017] [0017]FIG. 6 is a detailed schematic diagram of the preferred embodiment of the filter monitoring system in accordance with the present invention.
[0018] [0018]FIG. 7 is a schematic diagram of a printed circuit board of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0019] [0019]FIG. 1 illustrates a cross-section through an air purifier 10 having the present invention incorporated therein. Although an air purifier is shown, the present invention can be used with any type of fan product utilizing a filter including, but not limited to fans, air conditioners, humidifiers and dehumidifiers. The air purifier 10 , shown in FIG. 1, generally includes a housing 11 , a fan 12 , a fan motor 13 , one or more filter assemblies 14 and electronic power circuitry 15 for operating the air purifier. The housing 11 may include a door 16 , to facilitate replacement of the filter assemblies 14 , and a perforated intake grille 17 and a perforated outlet grille 18 , to allow the flow of air through the air purifier 10 . The electronic power circuitry 15 , which will be discussed in further detail below, generally includes a fan motor switch 19 , for selecting the speed of the fan motor 13 , a display 20 and a microprocessor 21 . In operation, the rotation of the fan 12 causes air to be drawn through the intake grille 17 and into the filter assemblies 14 where the airborne particles are removed before the air exits through the outlet grille 18 . This exemplifies the basic operation of a typical filter-fan device that uses replaceable filter assemblies.
[0020] However, to monitor the remaining life of the filter assemblies 14 , and to thus determine when they need replacement, the present invention includes unique electronic circuitry 15 to monitor and “count” the use of the fan motor 13 . Generally, each position of the fan switch 19 is connected to an input of the microprocessor 21 which “counts” usage of the fan motor based on fan motor speed. The fan switch 19 discussed hereinafter includes positions for “off”, “low”, “medium”, “high” and “sleep” (intermittent), however, switches having fewer or more positions may be utilized with the present invention. FIGS. 2 - 4 are simplified circuit diagrams illustrating alternate approaches for detecting present fan speed.
[0021] In the preferred embodiment, as shown in FIG. 2, each position of the fan switch 19 is wired to an input of the microprocessor 21 through a similar circuit including diodes 22 and an RC network. As a result, AC voltage present at the fan switch positions results in an AC waveform at the microprocessor inputs. The microprocessor 21 is programmed to determine which inputs are active and, from the lack of activity at one input, determines which position the fan speed switch 19 is in. The diodes 22 are used to clamp the voltage at the microprocessor input (i.e., to prevent the input from exceeding the power supply voltage or becoming more negative than ground).
[0022] In an alternate embodiment, as shown in FIG. 3, each position of the fan switch 19 is wired to an input of the microprocessor 21 through a similar circuit. AC voltage present at the fan switch positions is detected by a series diode and R/C network. This detector creates a dc voltage at the microprocessor input. In normal operation, the inactive inputs of the microprocessor 21 will have voltage, and the input corresponding to the selected speed will not. The additional diode is used to clamp the voltage at the microprocessor input (i.e., to prevent the input from exceeding the power supply voltage).
[0023] In another alternate embodiment, as shown in FIG. 4, the same circuit topology (with somewhat different values) is used. Unlike FIGS. 2 and 3 however, only one circuit is required to be connected to one of the fan switch positions. In this circuit, the capacitor is increased in value so that it requires many milliseconds for it to charge from the filter switch input. The additional resistor between the microprocessor input and the capacitor allows the microprocessor to change its input to output mode. In output mode, the microprocessor can discharge the capacitor. Then, if the microprocessor switches back to input mode, and by measuring the time that is required for the input to reach a logic ‘1’ level, a measurement of the voltage at the fan switch position may be ascertained. Then, by comparing the measured voltage against a table of expected voltages for different fan switch positions, the fan switch position may be ascertained.
[0024] Referring now to FIG. 5, the preferred embodiment of the present invention as shown in FIG. 2 is shown in further detail. The fan switch 19 allows for manual selection of the speed of the fan motor 13 . The positions are designated “L 1 ” for off, “L” for low, “M” for medium, “H” for high and “S” for sleep in FIG. 5. As described above, each position of the fan switch 19 is connected to an input of the microprocessor 21 designated J 2 , J 3 , J 4 , J 5 and J 6 , respectively, in FIG. 5. FIG. 5 also shows microprocessor inputs J 1 and J 2 connected to an optional door switch 23 to terminate power to the motor 13 when the device's filter door 16 is ajar. As will be described in further detail below, the microprocessor 21 includes a counter 24 which “counts” usage of the fan motor based on the selected fan motor speed.
[0025] [0025]FIG. 6 is a detailed schematic diagram showing the electronic circuitry 15 in accordance with the preferred embodiment of the present invention as shown in FIGS. 2 and 5. The circuitry 15 generally includes the fan motor switch 19 , the display 20 , the microprocessor 21 , a power supply 25 , a filter time reset switch 26 and a non-volatile memory storage (NOVRAM) 27 . The circuitry 15 is preferably incorporated into a PCB 28 as shown in FIG. 6. The PCB 28 is preferably a single-sided design (i.e. tracks on etch side only, no plated-through holes), with the components mounted to the board using through-hole technology. This board design will allow for panelization.
[0026] The power supply 25 uses a capacitive dropping design since general experience has shown that the capacitive type of supply is more reliable. This design provides fifteen milliamperes of current required to operate the microprocessor 21 , the memory 27 and the display 20 . The power supply 25 has an operating voltage of 115 VAC, 60 hertz and 230 VAC, 50 Hertz. (At the required current level, a resistive dropping design would have required the dissipation of multiple watts of power in the 230 VAC model.)
[0027] The non-volatile memory storage 27 preferably has the capability for running up to 30,000 hours before 100% usage is reached. Design life of the memory should exceed 10 years in continuous use and, preferably, no battery of any type is used. A suitable memory device is Part No. 24C00 (available in 8 pin DIP) manufactured by Microchip and other sources. This device uses an I 2 C interface, requiring only clock and data lines from the microprocessor 21 . The device is specified for 1,000,000 write cycles. As described below, the present program writes the device every 770 seconds. Thus, at this frequency, the memory will be written 410,000 times in ten years.
[0028] A number of microprocessors from different suppliers can be used in the present invention. Table 1 below lists several alternatives:
TABLE 1 MFR PART NOTES Atmel Atiny 11 1K Flash, 8 Pin DIP Atmel Atiny 12 1K Flash, 64 byte Nov, 8 Pin DIP Microchip 16CR54 512 Mask ROM, 18 pin DIP Microchip 12CR509 1024 Mask ROM, 8 pin DIP Microchip 16CR620 512w Mask ROM, 18 pin DIP Motorola MC68HC05K0 512b Mask ROM, 16 pin DIP Zilog Z86C02 512b Mask ROM, 18 pin DIP Zilog Z8E000 512b OTP ROM, 18 pin DIP
[0029] However, it has been found that the preferred microprocessor is the Microchip PIC16CR54C device. This device allows for minimal external support componentry while providing adequate RAM and Program Memory for the filter check application. For example, the Microchip device includes internal diodes for clamping the voltage at the microprocessor input (diodes 22 shown in FIG. 2). Additionally, the Microchip microprocessor provides an external RC oscillator and external reset circuitry components. Development for the microprocessor 21 is performed using OTP parts in the Microchip MPLAB environment using assembly and/or C Language.
[0030] The display 20 comprises six LEDs D 3 , D 4 , D 5 , D 6 , D 7 and D 8 . Preferably, the LEDs are six discrete T 1 {fraction ( 3 / 4 )} LEDs including four green, one amber, one red only one of which are illuminated at one time. The LEDs are controlled by the microprocessor to indicate “Filter Life Remaining” in a vertical bar. Initially this display is lit at a 100% level. As the fan is run, the lit level drops over time until the 0% LED is lit. The following Table 2 defines which LED is lit as a function of percentage of “Filter Life Remaining”:
TABLE 2 LED Color % Life Remaining 3 (top) GRN >80% to 100% 4 GRN >60% to 80% 5 GRN >40% to 60% 6 GRN >20% to 40% 7 YEL >0.0% to 20% 8 (bottom) RED 0.0%
[0031] The percentage of filter life remaining is determined by a program in the microprocessor 21 that is based on a straight-line linear relationship between total time of fan use and filter life remaining. Predetermined values for total filter life relative to fan speed are programmed into the microprocessor 21 and are used as baseline variables by the microprocessor program to determine filter life remaining. For example, it may be known that a particular filter has a life of 8,760 hours with a fan running at full speed. Inputting this value into the microprocessor's program will result in the microprocessor illuminating the red LCD D 8 , indicating 0%, after the fan has run at full speed for 8,760 hours. Accordingly, values for total filter life relative to other fan speeds can be calculated based on this value. Table 3 below shows exemplary predetermined baseline variables for programming the microprocessor.
TABLE 3 Fan Speed Filter Life H (Fastest) 8,760 hours (1 yr) M 10,950 hours L (Slowest) 14,600 hours S (Sleep) 21,900 hours (2.5 yr)
[0032] The microprocessor 21 then “counts” down based on these starting values and on actual fan use at the detected fan speed. In operation, the microprocessor functions in the following manner. The microprocessor 21 includes a RC clock that runs the microprocessor at 800 kHz. The processor divides this rate by four to achieve a 200 kHz nominal instruction speed (5 μsec per instruction). This frequency may be as low as 180 kHz or as high as 220 kHz depending on component tolerances and regulated voltage. Whenever the processor is reset, or the processor detects the fan turning on, the unit is initialized, and a display test is run. This test lights each of the display LEDs in order for ⅓ second starting at the top (green) LED and finishing with the bottom (red) LED. The display then blanks for one second. Finally, normal operation starts, and the LED associated with the present filter life remaining is lit.
[0033] Fan speed detection is implemented in the microprocessor firmware by continuously sampling the four fan speed switch inputs for transitions. Transitions are counted for each input using individual 8 bit counters. When the largest count is greater than the selected line frequency, then the sampling counters are serviced. Any counter that is less than ½ the value of the largest counter is set to be zero. The counters are reviewed in order, from the counter associated with the highest speed input to that associated with the slowest. The first zero counter detected establishes the present fan speed. If no zero counter is detected, the fan is assumed to be off. If the fan is detected as off twice in succession (for two seconds), the unit blanks the display. If the display is blanked, and a fan position is detected, the unit proceeds to the power-up test and display. After detecting fan speed in normal operation, the input counters are then decremented by 60 or 50 (the selected line frequency). Counters are zeroed if their value is less than line frequency. At this point, fan speed has been detected, and one second of filter life has been measured. From this point the filter life calculation proceeds.
[0034] At the time that the input counters are decremented (and one second of life has been measured), a prescaler is decremented. The amount the prescaler is decremented depends on the detected fan speed. At the fastest fan speed, the prescaler reaches zero every five seconds (12.5 seconds at the slowest speed). When this prescaler rolls, another following prescaler is decremented. This following prescaler reaches zero every 770 seconds at the fastest fan speed. The following prescaler decrements the filter life counter. This counter is a two byte value. Whenever this counter is decremented, it is re-written in triplicate to NOVRAM 27 . The top three bits of this counter are displayed on the LED bar-graph. This counter is initially loaded to a predetermined initial counter value. The following Table 4, illustrates exemplary predetermined counter values for a given filter.
TABLE 4 % Life Life Counter Span LED # Color Initially Initial Final Init-Final Days 6 Grn 100 57343 49152 8192 73.01 5 Grn 80 49151 40960 8192 73.01 4 Grn 60 40959 32768 8192 73.01 3 Grn 40 32767 24576 8192 73.01 2 Yel 20 24575 16384 8192 73.01 1 Red 0 16383 8192 40960 365.04
[0035] As shown in Table 4, the value 57,343 will light the 6 th LED (top green LED). With the prescaler arrangement described, the life counter will decrement to 49,151 after 73.01 days of fan use at the highest speed. At this point, the 6 th LED will turn off, and the 5 th LED will light. As the counter continues to decrement, the LEDs are lit as indicated in Table 4.
[0036] After a filter has been changed, the filter life display 20 may be reset by depressing the filter life reset switch 26 . Preferably, the reset switch 26 is located below the LED display, as shown in FIG. 6, and is accessible through a small hole (⅛″ diameter) in the housing 11 of the air purifier 10 . To achieve reset, the user must depress and hold the switch for several seconds. When the user depresses this switch, the time remaining display shall return to 100% (i.e. the top green LED will light) and the filter life counter is reset to 57343.
[0037] Provided below in Table 5 is a complete bill-of-materials for each electronic component illustrated in FIG. 6, including a preferred value of resistance, capacitance, and component types. It will be understood by those skilled in the art that similar components with varying values may be used to accomplish the objectives of the invention without departing from the spirit of the invention.
TABLE 5 Designator Description C1 Capacitor, Metallized Polyester Film, 1.0 μF, 250 V C2 Capacitor, Aluminum Electrolytic, Radial, 470 μF, 10 V C3 Capacitor, Ceramic Disk, 0.001 μF, 1KV C4,C5,C6,C7 Capacitor, Ceramic Disk, 100 pF, 500 V C8 Capacitor, Ceramic, Axial, Z5U, 0.1 μF, 50 V C9 Capacitor, Ceramic, Axial, NPO, 220 pF, 100 V C10 Capacitor, Aluminum Electrolytic, Radial, 10 μF, 16 V D1 Diode, Rectifier, 200 V, 1A, DO41 D2 Diode, Zener, 1.0 W, 5.8 V, DO41 D8 LED, T1-¾, , Red, Diffused D7 LED, T1-¾, , Yellow, Diffused D3,D4,D5,D6 LED, T1-¾, , Green, Diffused D9 Diode, Rectifier, GP, D035 R1 Resistor, CF, 220 ohms, 1/2 W, 5% R2,R10 Resistor, CF, 10 K ohms, 1/4 W, 5% R3,R5,R6,R8 Resistor, CF, 4.7 M ohms, 1/2 W, 5% R7 Resistor, CF, 330 ohms, 1/4 W, 5% R4,R9 Resistor, CF, 100 K ohms, 1/4 W, 5% R11 Resistor, CF, 3.3 K ohms, 1/4 W, 5% S1 Switch, Pushbutton, 6X6 mm U1 IC, CMOS, Serial Eeprom, 16 × 8 U2 IC, CMOS, Micro, 8 Bit, 512 × 12, OTP PCB1 Printed Circuit Board, 2″ × 3″, Single Sided
[0038] While there has been described what is presently believed to be the preferred embodiments of the invention, those skilled in the art will realize that various changes and modifications may be made to the invention without the parting from the spirit of the invention and it is intended to claim all such changes and modifications as fall within the true scope of the invention.
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A method and circuit for monitoring the useful life of a filter for a filter-fan product. The method includes the steps of detecting use of a fan of the filter-fan product with a microprocessor, counting from a predetermined initial counter value a duration of usage of the fan with a counter of the microprocessor to determine a present counter value, sending a signal representing the present counter value from the microprocessor to a display and displaying the remaining useful life of the filter based on the signal received from the micro processor. Use of the fan is preferably detected by detecting a position of a fan speed switch such that the microprocessor detects the speed of the fan and adjusts the rate of counting by the counter based on the detected speed of the fan. The circuit includes a microprocessor electrically connected to a fan of the filter-fan product for detecting use of the fan and a display electrically connected to the microprocessor for displaying the remaining useful life of the filter. The microprocessor includes a counter, having a predetermined initial counter value, which counts from the predetermined initial counter value a duration of usage of the fan to determine a present counter value. The microprocessor sends a signal representing the present counter value to the display which uses the signal to display the remaining useful life of the filter.
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This application claims priority to U.S. Provisional Application Ser. Nos. 60/204,774 and 60/204,775, both filed May 17, 2000, whose entire disclosure is incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to electro-optic devices, and in particular, to polarization independent broadband optical modulators and switches for wideband fiberoptic networks.
2. Background of the Related Art
A balanced bridge optical switch has two input and two output waveguides. Two ½l c (half a coupling length) 3-dB (i.e., 50:50 power splitter) directional couplers and a phase modulated interferometer waveguide pair are used. Note that “l c ” is the characteristic coupling length of a directional coupler, which is the length of the directional coupler necessary to transfer substantially all the power from a first waveguide to a second waveguide. The input 3-dB coupler is used to equally divide an input signal received by an upper input waveguide into both the upper and lower waveguides prior to entering an interferometer section of the balanced bridge optical switch. An output ½l c directional coupler rejoins the electro-optical phase modulated signal from the interferometer section back into the upper output waveguide for a “straight-thru” path (i.e., “on” or (=) bar state) or the lower output waveguide in the “cross-over” path (i.e., “off” or switched (×) state). If the optical path lengths of the two waveguides are identical in the middle interferometer section, the two optical waves arrive at the output (½l c ) 3-dB coupler section and recombined coherently producing an optical signal that transfers all into the lower waveguide or crossover path. However, if there is a 180° phase difference between the two optical path lengths in the interferometer section, the two optical waves will recombine and transfer back to upper waveguides or the straight through path. Thus, electro-optical phase modulation of the two optical waves in the interferometer section results in an amplitude modulation at each of the output waveguides and the device can be used as a 1×2 or a 2×2 optical switch.
FIG. 1 illustrates a related art polarization-independent 2×2 electro-optic switch 100 based on a balanced-bridge interferometric waveguide structure. As shown in FIG. 1 , the related art switch 100 includes upper and lower waveguide patterns 120 , 130 formed in a X-cut Z-propagation lithium niobate (LiNbO 3 ) electro-optic substrate 110 . The switch 100 includes a 3 dB-directional coupler section 142 (50:50 power splitter) having an interaction length of L B =½L dc , an interferometer section of length L e , and an output 3 dB-directional coupler section 146 having an interaction length of L B =½L dc , where L B =½L dc , L dc equals combined length of the two couplers, and l c equals characteristic coupling length of the directional coupler. Note that “interaction length” and “effective coupling length” are used interchangeably to describe the actual length of the waveguides in a directional coupler over which a signal may couple from a first waveguide to a second waveguide. Also note that the effective coupling length may be described in terms or units of characteristic coupling length l c . Thus a range of effective coupling lengths or interaction lengths for a directional coupler can be indicated as 0.75l c to 1.1l c . The input and output 3 dB-directional coupler sections operate as 50:50 power splitters and are preferably identical with a combined length where l c is the characteristic coupling length of the switch 100 . As shown in FIG. 1 , the upper waveguide 120 receives an input optical signal I in . Under straight-thru switch operations, the input signal I in received by the upper waveguide 120 exits from the waveguide 120 as an output signal I upper (=), and in cross-over switch operations, the input signal I in enters the upper waveguide 120 but exits through the lower waveguide 130 as I lower (×).
For the related art switch 100 , the upper and lower waveguides 120 , 130 are single mode for each of two polarizations (TE, TM), and therefore support one TE mode and one TM mode each, where the “TE mode” is the transverse electric field mode, and the “TM mode” is the transverse magnetic field mode. A normalized applied voltage V applied in the interferometer section 144 is applied with an electric field in the Y-direction (E y ) that induces a differential propagation constant Δβ (“Δβ”) between the two interferometric sections of the upper and lower waveguides 120 , 130 of length L e via the linear electro-optic effect. The length L e is the length of the electrodes 150 , 152 , 154 . Electrodes 150 , 152 , 154 are arranged in a push-pull configuration to maximize the electro-optically induced Δβ between the upper and lower waveguides 120 , 130 in the interferometer section 144 . Thus, the electrode 152 receives the normalized applied voltage V and the electrodes 150 and 154 receive a ground potential. As shown in FIG. 1 , the placement of the electrodes 150 , 152 , 154 maximizes the E-field along the Y-axis inside the waveguides.
For the X-cut substrate 110 , when the waveguide propagation direction in the waveguides 120 , 130 is along the Z-axis (optic axis), both the TE and TM modes see the same ordinary index (n o ). Thus, both the TE and TM polarization modes are nearly degenerated and will behave in approximately the same way. The electro-optic (“EO”) interaction for the TE and TM modes with the E y field in the interferometer section are via EO coefficients that are equal but opposite in sign (i.e., r 22 , −r 22 ) in the lithium niobate substrate 110 . Therefore, the magnitudes of the Δβ i for both the TM and TE modes are the same in the interferometer section 144 where Δβ i is the difference in the propagation constants between the two waveguide pair in the middle “interference” section, and Δβ dc is the difference in the propagation constants between the waveguide pair in the “input” and “output” directional coupler sections. In other words, the EO interactions in the interferometer section 144 in the TE mode is proportional to +r 22 (E y ) and the TM mode is proportional to −r 22 (E y ) as the corresponding change in the propagation constants is via the electric field in the Y-axis direction.
In FIG. 2A , I cross-over and I straight-thru conditions are illustrated for the related art switch 100 , where optical power is a vertical axis and the ratio of normalized applied voltage to V π , which is the voltage required to cause a 180° phase shift between the two arms of the interferometer V/V π , is a horizontal axis. As shown in FIG. 2A , the input signal I in is output as I cross when V/V π is equal to −4, −2, 0, 2, 4 and I in is output as I upper (I straight-thru ) when V/V π is equal to −3, −1, 1, 3.
In FIG. 2A , the optical power is illustrated from 0 to 1 corresponding to an on (=) or off (×) state of the switch 100 . For a high performance, low-crosstalk switching device, the input and output directional couplers 142 , 146 of the switch 100 must behave as 3 dB-couplers for both the TE and TM modes simultaneously. In this case of zero (0) voltage, both the TE and TM modes entering an input port of the upper waveguide 120 will exit a lower output “cross-over” port (×) of the lower waveguide 130 . When voltage is applied to the interferometer section 144 of the switch 100 with an electric field in the Y-axis direction, the EO induced change in the waveguide indices for the TE and TM modes are exactly equal, but with opposite sign because of the r 22 , −r 22 linear EO coefficients. Because of the symmetric nature of the switching characteristics of the balanced bridge interferometer with respect to voltage, both the TE and TM modes would be switched to the upper output port as shown in FIG. 2A when a normalized applied voltage V=V π (or V =−V π ) is applied. Thus, the related art optical switch 100 provides polarization independent switching. However, as shown in FIG. 2B , for effective operation of the related art switch 100 , the length of each of the directional coupler sections 142 , 144 L B (=½L dc ) must be very precisely manufactured to be equal to ½l c , which is the coupling length of the switch 100 . When L dc (=2 L B ) does not equal l c , light entering the upper input channel cannot be switched completely from the output port (=) of the waveguide 120 to the output port (×) of the other waveguide 130 . Note that L dc equals 2×(L B ), and L B =length of each 3 dB coupler (input and output). Thus, L B must precisely equal ½l c for a low crosstalk switch. When L dc does not equal l c , the crosstalk of the switch increases rapidly as L dc deviates from l c . This is shown in FIG. 2B , for L dc= 0.6l c , 0.8l c , 1.0l c and 1.4l c . Accordingly, when L dc does not equal 1.0l c precisely, the high crosstalk can make the switch 100 a non-working switch.
As described above, the related art polarization independent optical switches have various disadvantages. Crosstalk of the switch depends on fabricating optimal 3 dB couplers. L dc precision is limited by fabrication tolerances, and a precise length for the 3 dB couplers is hard to achieve. For example, a 10% variation in coupler length can render an optical switch defective. Thus, a low crosstalk (<−25dB) switch is difficult to achieve. Further, an optimal fabrication parameter to achieve a 3 dB-coupler for the TE mode is often somewhat different than the optimal fabrication parameter required for a 3 dB-coupler for the TM mode. Thus, it is difficult to achieve an exact 3 dB coupling for both TE and TM modes simultaneously. This will result in an undesirable high crosstalk for either TE or TM modes or both.
The above references are incorporated by reference herein where appropriate for appropriate teachings of additional or alternative details, features and/or technical background.
SUMMARY OF THE INVENTION
An object of the invention is to solve at least the above problems and/or disadvantages and to provide at least the advantages described hereinafter.
Another object of the present invention is to provide an optical switch and method for operating same that substantially obviates one or more problems caused by disadvantages and limitations of the related art.
Another object of the present invention is to provide a polarization independent balanced-bridge interferometric waveguide switch and method for operating same that is a low crosstalk switch (less than −20 dB).
Another object of the present invention is to provide a polarization independent 1×2 or 2×2 electro-optic switch and method for operating same that provides polarization-independent switch operation over a broad wavelength.
Another object of the present invention is to provide a polarization independent 2×2 electro-optic switch and method for operating same that provides a reduced polarization mode dispersion.
Another object of the present invention is to provide a polarization independent 2×2 electro-optic switch and method for operating same that provides a reduced polarization dependent loss switch.
Another object of the present invention is to provide a polarization independent 2×2 electro-optic switch and method for operating same that uses differential propagation constant Δβ dc coupling in the input and output couplers.
Another object of the present invention is to provide a polarization independent 2×2 electro-optic switch and method for operating same that uses tunable Δβ dc directional couplers in the input and output power splitters.
Another object of the present invention is to provide a polarization independent 2×2 electro-optic switch and method for operating same that uses voltage induced linear electro-optic effect to induce Δβ dc in the input and output directional couplers.
Another object of the present invention is to provide a polarization independent 2×2 electro-optic switch and method for operating same that uses asymmetric-waveguide widths to achieve the proper Δβ dc .
Another object of the present invention is to provide a polarization independent 2×2 electro-optic switch and method for operating same that uses directional couplers having different waveguide indices between the upper and lower waveguides that result in a Δβ dc between the upper and lower waveguides.
In order to achieve at least the above-described objects of the present invention in whole or in part, there is provided a device including an optical input, a first coupler optically coupled to the optical input having a first +Δβ dc mismatch, an optical interferometer optically coupled to the first coupler and having a first optical path and a second optical path, the interferometer having an input that receives a signal voltage, wherein an optical path length difference between the first and second optical paths is induced in response to the signal voltage, and a second coupler optically coupled to the optical interferometer and capable of having a second −Δβ dc mismatch.
To further achieve the above-described objects of the present invention in whole or in parts, there is provided a device including an optical input a first coupler optically coupled to the optical input having a first +Δβ dc mismatch, a first optical waveguide optically coupled to the first coupler and having a first path length, a second optical waveguide optically coupled to the first coupler and having a second path length, a control signal electrically coupled to at least one of the first and second optical waveguides, whereby an optical path length difference between the first and second optical paths is controlled in response to the control signal, and a second coupler optically coupled to the first and second optical waveguides and capable of having a second −Δβ dc mismatch.
To further achieve the above-described objects of the present invention in whole or in parts, there is provided a device including at least one optical input, a first coupler optically coupled to the optical input having a first optical propagation constant Δβ mismatch, an optical interferometer optically coupled to the first coupler and having a first optical path and a second optical path, the interferometer having an input that receives a signal voltage, wherein an optical path length difference between the first and second optical paths is induced in response to the signal voltage, second coupler optically coupled to the optical interferometer and capable of having a second optical propagation constant Δβ mismatch, and at least one optical output optically coupled to the second coupler.
To further achieve the above-described objects of the present invention in whole or in parts, there is provided a device including at least one optical input, an input directional coupler optically coupled to the at least one optical input having a first optical propagation constant Δβ mismatch, a first optical waveguide optically coupled to the input directional coupler and having a first optical path length, a second optical waveguide optically coupled to the input directional coupler and having a second optical path length, a control signal electrically coupled to at least one of the first and second optical waveguides, whereby an optical path length difference between the first and second optical paths is controllable variable in response to the control signal, and an output directional coupler optically coupled to the first and second optical waveguides and capable of having a second optical propagation constant Δβ mismatch.
To further achieve the above-described objects of the present invention in whole or in parts, there is provided a balanced bridge optical switch including at least one input port, an input directional coupler having a first optical propagation constant Δβ mismatch coupled to the at least one input port, an interferometer optically coupled to the input directional coupler, an output directional coupler having a second optical propagation constant Δβ mismatch optically coupled to the interferometer, at least one output port optically coupled to the output directional coupler, whereby a first optical propagation constant Δβ mismatch is adjusted to provide an approximate 50% power split at the input directional coupler for a range of effective coupling lengths from approximately 0.75l c to approximately 1.1l c , and a second optical propagation constant Δβ mismatch is adjusted to provide an approximate 50% power split at the output directional coupler for a range of effective coupling lengths from approximately 0.75l c to approximately 1.1l c .
To further achieve the above-described objects of the present invention in whole or in parts, there is provided a balanced bridge optical switch including at least one input port, an input directional coupler having a first optical propagation constant Δβ mismatch coupled to the at least one input port, an interferometer optically coupled to the input directional coupler, an output directional coupler having a second optical propagation constant Δβ mismatch optically coupled to the interferometer, at least two output ports optically coupled to the output directional coupler, whereby the effective coupling length of the input directional coupler combined with the effective coupling length of the output directional coupler has a range from approximately 1.5l c to approximately 2.2l c , and a first optical propagation constant Δβ mismatch is determined and a second optical propagation constant Δβ mismatch is determined such that crosstalk between the at least two output ports is below a desired amount.
Additional advantages, objects, and features of the invention will be set forth in part in the description which follows and in part will become apparent to those having ordinary skill in the art upon examination of the following or may be learned from practice of the invention. The objects and advantages of the invention may be realized and attained as particularly pointed out in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be described in detail with reference to the following drawings in which like reference numerals refer to like elements wherein:
FIG. 1 is a diagram that illustrates a related art polarization-independent 2×2 electro-optic switch based on a balanced-bridge interferometric waveguide;
FIG. 2A is a diagram that illustrates optical output plotted against applied voltage for the related art optical switch of FIG. 1 ;
FIG. 2B is a diagram that illustrates normalized optical output plotted against normalized applied voltage for various ratios of length of the directional coupler over characteristic coupling length of the directional coupler (L dc /l c );
FIG. 2C is a diagram that illustrates a plot of optical output versus normalized applied voltage for an optical switch as shown in FIG. 1 ;
FIGS. 3A and 3B are diagrams that illustrates a schematic plan view of a preferred embodiment of a polarization-independent 2×2 electro-optic switch according to the present invention, and its output;
FIG. 4 is a diagram that illustrates a plot of optical output versus normalized applied voltage for the optical switch shown in FIGS. 3A and 3B ;
FIGS. 5A-5C are diagrams that illustrate plots of normalized optical output versus normalized applied voltage in the switch of FIGS. 3A and 3B ;
FIGS. 6A-6G are diagrams that illustrate output power contours of −10 dB, −20 dB and −30 dB for normalized optical output plotted against normalized applied voltage in a range of input/output bias voltages;
FIGS. 7A and 7B are diagrams that illustrate a schematic plan view of another preferred embodiment of an optical switch according to the present invention, with an associated output signal;
FIGS. 8 and 9 are diagrams that illustrate a schematic plan view of another preferred embodiment of an optical switch according to the present invention, with a graph of its associated output signal;
FIG. 10 is a diagram that illustrates a schematic plan view of another preferred embodiment of an optical switch according to the present invention;
FIGS. 11A and 11B are diagrams correlating the output port of a related art switch with the output signal;
FIGS. 12A-12E shows the output of a related art switch for various coupling lengths of the directional couplers;
FIGS. 13A-13B show a schematic of the invention with bias-able directional couplers, and contour plot showing the output power for both outputs of a single bias-able directional coupler;
FIGS. 14A through 14H show optical outputs vs applied voltage for the present invention; and,
FIG. 15 shows contour plots of straight-thru and cross-over switch states for a related art balance bridge interferometer.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
FIG. 3A is a diagram that illustrates a first preferred embodiment of a broad wavelength band polarization independent optical switch, in accordance with the present invention. “Broad wavelength band” includes the range of wavelengths from at least approximately 1530 nm (nanometer) to at least approximately 1610 nm. The switch's functioning wavelength range includes the C and L bands, where the C band spans approximately 1530 nm to 1565 nm, and the L band spans approximately 1565 nm to 1610 nm. However, the switch's functioning is not limited to the wavelength range encompassing the L and C band, and the switch will function substantially below and substantially above both those bands, inclusively. “Polarization independent” means that the switch may effectively switch any polarization or all components of an optical signal. The first preferred embodiment of the optical switch is a polarization-independent, broad-wavelength band 2×2 switch using a balanced-bridge interferometer with asymmetrically-biased (±Δβ dc ) directional couplers.
As shown in FIG. 3A , an optical switch 300 includes upper and lower waveguide patterns 320 , 330 preferably formed in an X-axis cut, Z-axis propagation electro-optic substrate 310 . The electro-optic substrate is preferably lithium niobate (LiNbO 3 ). The switch 300 includes a first directional coupler section 342 , an interferometer section 344 and a second directional coupler section 346 . The first directional coupler 342 has an electrode length of L B , the interferometer section 344 has an electrode length L e and the second directional coupler section 346 has an electrode length of L B . The first and second directional coupler sections 342 , 346 preferably operate the same with opposite directivities and respectively couple an input and output of the interferometer section 344 . The first and second directional coupler sections 342 , 346 have equal magnitude but opposite in sign differential propagation constants Δβ dc , i.e., the input coupler is +Δβ dc biased and the output coupler is −Δβ dc biased and vice versa. While it is perferable that the signs of the differential propagation Δβ dc mismatches for the directional couplers are opposite, such a sign difference is not necessary. Additionally, when there is a sign difference between the differential propagation Δβ dc mismatches for the directional couplers, either order will work. That is, the first directional coupler's differential propagation Δβ dc mismatch may have a positive sign and the second directional coupler's differential propagation Δβ dc mismatch may have a negative sign, or the first directional coupler's differential propagation Δβ dc mismatch may have a negative sign and the second directional coupler's differential propagation Δβ dc mismatch may have a positive sign. The first and second waveguide pair sections 342 , 346 experience evanescent coupling while the interferometer section 344 does not.
Both the first and second directional couplers may have a differential propagation Δβ mismatch, and the interferometer may have Δβ mismatch. The differential propagation Δβ mismatch for the couplers may be referred to as either Δβ or Δβ dc , and the Δβ mismatch of the interferometer may be referred to as Δβ or Δβ E . When the mismatch is simply referred to as Δβ, whether it is the Δβ mismatch of a coupler or Δβ mismatch of an interferometer is determined by the context of the reference. “Coupler” refers to either directional coupler of the switch. “First coupler,” “first directional coupler,” “input coupler,” and “input directional coupler” and the like are synonymous. “Second coupler,” “second directional coupler,” “output coupler,” “output directional coupler,” and the like are also synonymous. Similarly, a “first optical propagation constant Δβ mismatch” refers to the Δβ in the first or input coupler, and “second optical propagation constant Δβ mismatch” refers to the Δβ mismatch in the second or output coupler.
The optical propagation Δβ dc mismatch in a coupler may be achieved by having the propagation constant in the first waveguide of the coupler be a first value β 1 , and the optical propagation constant in the second waveguide of the coupler be a second value β 2 . Thus, β 1 −β 2 =+Δβ dc , and β 2 −β 1 =−Δβ dc . A coupler with an optical propagation Δβ dc mismatch has a value of β 1 for one of its waveguides and a value of β 2 for another of its waveguides.
As shown in FIG. 3A , the upper waveguide 320 of the switch 300 receives an input optical signal I in that exits entirely from the waveguide 320 as an output signal I upper in a “straight-thru” path or “bar (=)” state, and the input signal I in enters the upper waveguide 320 but entirely exits through the lower waveguide 330 as I lower in a “cross-over” path or “(×)” state. For the optical switch 300 , the upper and lower waveguides 320 , 330 are single moded for both TE and TM polarizations, and therefore support one TE mode and one TM mode each.
A signal voltage V S applied as a switching voltage in the interferometer section 344 is applied with an electric field in the Y-direction (E y ) that induces Δβ e between the two interferometer arms of the upper and lower waveguides 320 , 330 via the linear electro-optic effect. The electrode length of the two interferometer arms is L e . The signal voltage can have various waveforms such as sinusoidal, stepped, chirped, sawtooth, DC, off/on, etc. Electrodes generating the electric fields are preferably arranged in a push-pull configuration to increase the electro-optically induced phase difference between the upper and lower waveguides 320 , 330 in the interferometer section 344 . Thus, in the X-axis cut, Z-axis propagation substrate 310 , an electrode 352 receives the signal voltage V S and electrodes 350 and 354 receives a ground potential.
As shown in FIG. 3A , electrodes are placed to maximize an electric field in the Y-axis direction of the lithium niobate crystal 310 . In the X-axis cut substrate shown in FIG. 3A , the electrodes are placed along side the waveguide so as to increase or maximize horizontal electric field (E y ) inside the optical waveguide. Alternatively, tor Y-axis cut Z-axis propagation substrates, the electrodes are preferably placed on top of the waveguides so as to increase or maximize the vertical electric field (E y ) inside the optical waveguide (as shown in FIG. 10 ).
To be polarization independent, the optical switch 300 orients the propagation direction of the waveguides 320 , 330 along the Z-axis (optic axis) so that both the TE and TM modes see the same ordinary index (n o ). The EO interaction for the TE and TM modes with the E y field are via electro-optic coefficients that are equal but opposite in sign (i.e., r 22 , −r 22 in a lithium niobate substrate). Thus, the EO interactions in the interferometer section 344 in the TE mode is +r 22 (E y ) and the TM mode is −r 22 (E y ) as the corresponding change in the propagation constants is via the electric field in the Y-axis direction. Thus, magnitudes of Δβ e for both the TM and TE modes are the same, but opposite in sign in the interferometer section 344 . As shown in FIGS. 5A-5C , optical power for the switch 300 is illustrated as a vertical axis and the ratio of voltages V/V π is a horizontal axis. The optical power is measured by a ratio of an output optical power over an input optical power (e.g., I upper /I input ) Accordingly, the input signal I in launched via the upper input channel is transmitted as I lower (I cross-over ) via the waveguide 330 when V/V π is equal to −4, −2, 0, 2, 4 and I in , launched via the upper input channel, is transmitted as I upper (I straight-thru ) when the V/V π is equal to −3, −1, 1, 3.
FIG. 3B shows the same embodiment of the switch as shown in FIG. 3A , with like numbers referring to like elements. The graph shows the output of the straight-thru port 320 , as a function of applied switching voltage. The maximums of the output labeled “=” correspond to when substantially all the signal exits the interferometer switch 300 , through the straight-thru port 320 , and the minimum labeled “×” corresponds to when substantially all the signal exits the interferometer through the cross-over port 330 .
FIG. 4 is a vertical two-dimensional slice of a three-dimensional plot of the power output of the upper waveguide 320 as a function of normalized applied voltage V/V π . When light is launched into the upper input channel of the switch 300 , where the X-axis is the ratio between L dc /l c and the Y-axis is the ratio of the normalized applied voltage V/V π in the interferometer section 344 . As shown in FIG. 4 , crosstalk contour A, crosstalk contour B, and crosstalk contour C represent −10 dB, −20 dB and −30 dB crosstalk contour lines respectively. FIGS. 5A-5C show a particular case where electrodes 360 , 362 , 364 on the input and output couplers 342 , 346 receive the normalized applied voltage bias of V dc =Δβ dc L dc /π of approximately ±1.6 (where Δβ dc =difference in the propagation constant of the two waveguides in the directional coupler). The characteristic coupling length of the switch 300 is represented as l c , and the combined length of the two directional coupler is L dc .
FIGS. 5A-5C are two-dimensional plots that are horizontal slices through the three-dimensional plot of FIG. 4 . FIGS. 5A-5C each represent optical power output by the upper waveguide 320 while the ratio V/V π varies for a fixed ratio of L dc /l c . FIG. 5A illustrates where L dc is 2.2l c , FIG. 5B illustrates the case where L dc is 1.8l c , and FIG. 5C illustrates the case where L dc is approximately 1.6l c . (L dc is the total length of the two input and output directional couplers.)
In FIGS. 5A-5C , the optical power is illustrated from 1 to 0, which correspond to an “ON” or “OFF” state of the switch 300 , respectively. The Δβ dc (propagation difference between the directional waveguide pair) of the first and second directional couplers 342 , 346 must be equal but opposite in sign. This means that the Δβ dc of the second directional coupler 346 must be in the opposite direction of the Δβ dc of the first input coupler 342 but of the same magnitude. This asymmetric Δβ dc is achieved in the first preferred embodiment of the switch 300 by having an equal but opposite bias to the central electrodes 362 of the first and second directional couplers 342 , 346 while the outer electrodes 360 , 364 are coupled to the ground voltage. Further, the central electrodes 362 preferably have a length L E . The outer electrodes 360 , 364 preferably have an equal length being L B .
When the signal voltage V S is applied to the interferometer section 344 with an electric field in the Y-axis direction, the EO induced change in the waveguide indices for the TE and TM modes are exactly equal, but with opposite sign via the r 22 , −r 22 linear EO coefficients. Thus, because of the symmetric nature of the switching characteristics of the balanced bridge interferometer with respect to voltage, both the TE and TM modes of the input optical signal I in would be switched to the upper output port as shown when a V S =V π (or V S =−V π ) is applied. The dark band in the center of each contour on FIG. 4 graphically shows an expanded “cross-over” switch region with very low (−30 dB) crosstalk for the switch when the input and output directional couplers are properly asymmetrically biased V dc =Δβ dc L dc /π of approximately ±1.6. FIG. 4 also shows that an expanded −30 dB crosstalk contour (e.g., vertical slot) is achieved for an expanded range of L dc /l c value from 1.5 to 2.2. This particular family of crosstalk contours illustrated by FIG. 4 is achieved by applying a normalized bias voltage V dc =Δβ dc L dc /π of approximately ±1.6 to the first and second (input and output) directional couplers 342 , 346 .
FIG. 5A is a two-dimensional plot showing the output of the upper waveguide 320 when L dc =2.2l c . Again, the X-axis illustrates power of the signal coming out of the upper waveguide 320 , and the Y-axis shows the ratio of the switching voltage V/V π . FIG. 4B shows that even though L dc is not equal to l c and in fact is 2.2l c , the output of the upper waveguide 320 ranges from 0 to 1 thereby exhibiting very low crosstalk being <−30 dB between the ON (upper) and the OFF (lower) outputs of the switch 300 . FIG. 5B is a two-dimensional graph for the special case of L dc =1.8l c .
FIG. 5B shows that when L dc =1.8l c the output from the upper waveguide 320 ranges from 0 to 1 through the range of normalized applied voltages even though L dc does not equal l c and in fact FIG. 4C shows that the switch 300 functions as well when L dc =1.8l c as it does when L dc =2.2l c . Thus, FIG. 5B shows the switch 300 exhibits crosstalk being <−30 dB for the ratio L dc =2.2l c .
FIG. 5C is another two-dimensional plot showing the output of the upper waveguide 320 for the values of L dc ≈1.6l c for a range of switching voltages. Once again FIG. 5C shows that the output of the upper waveguide ranges 320 from 0 to 1 for the range of normalized applied voltages V when L dc is not equal to l c but L dc ≈1.6l c .
Taken together, FIGS. 5A-5C graphically illustrate that the directional couplers 342 , 346 can have a range of L dc (or a range of ratios 1.5<L dc /l c <2.2) and the switch 300 still operates as a low −30 dB crosstalk switch. This is what is meant by the switch having expanded cross-over region and a −30 dB crosstalk contour (e.g., slot) for both the TE and TM modes. The switch 300 differs from the related art because the related art does not exhibit an expanded −30 dB crosstalk contour but merely has a −30 dB point when L dc =l c as shown in FIG. 2 C.
According to the first preferred embodiment of the switch 300 , l dc is the total length of the combined directional couplers, l c is the characteristic coupling length for the directional coupler sections 342 and 346 . L B is the electrode length of each directional coupler that is preferably equal to {fraction (1/2 )}L dc . The signal voltage V S is preferably a normalized applied voltage, and is equal to Δβ e L e /π where L e is the electrode length for the interferometer section 344 , and Δβ e is the electron optically induced propagation difference between the two interferometric waveguide pair. Thus, normalized directional coupler bias voltage V dc =Δβ dc L dc /π where L B (=½L dc ) is the electrode length for each of the input and output directional couplers, and Δβ dc is the electro-optically induced Δβ dc between the waveguide pair in the directional coupler region.
Thus, the first preferred embodiment of the optical switch 300 uses a balanced bridge interferometer waveguide structure with asymmetrically-bias Δβ dc -directional coupler structures 342 and 346 , with an equal magnitude, but an opposite sign for the directivity. The directional couplers 342 and 346 , are preferably designed such that the effective Δβ dc L dc /π is approximately equal to 1.6, which provides the favorable extinction ratios with an extended −30 dB crosstalk contour for a given coupling length ratio L dc /l c . Accordingly, to maintain a −30 dB optical switch, the total (including the input and output) directional coupler effective length (L dc ) can be in the range of ˜1.5 to 2.2 times the characteristic coupling length l c of the directional coupler. Evanescent coupling occurs in the input and output directional couplers but not in the interferometer section. Light for both TE and TM polarizations is switched between the two outputs (e.g., I upper , I lower ) by applying a signal voltage V S to the interferometer section equivalent to V π , which is the voltage required to electro-optically induce a phase mismatch of π (180°) between the two waveguides.
The first preferred embodiment generates the asymmetrically-biased Δβ dc input and output directional couplers using an applied voltage to induce the Δβ dc change using the linear electro-optic effect. However, the present invention is not intended to be so limited.
As shown in FIGS. 6A-6G , the crosstalk contour plots of −10 dB, −20 dB and −30 dB for a vertical axis in units of L dc /l c and a horizontal axis of a normalized applied voltage V/V π are provided for a progressive directional coupler bias voltage V dc applied to the switch 300 . A center of a bullseye is a low point in the optical power output of the waveguide, and represents low (−30 dB) crosstalk, and is shown being a cross-over (×) state 502 for the upper waveguide 320 (in FIG. 3A ) in FIG. 5 A. For example, a cut on this contour plot along the line of L dc /l c =1 would be a horizontal cut through the center of the bullseye on V/V π =0. The bullseye is a low point and one can move horizontally to the right to where V/V π =1, which is a high point shown being the bar (=) state 504 , for the upper waveguide 320 (in FIG. 3A ) in FIG. 5A occurs at V/V π =1. Moving horizontally, the next bullseye at V/V π =2 is a low point. Accordingly, a horizontal line cut along the L dc /l c =1 horizontal line would produce a sinusoidal varying linear switch line. Similar sinusoids are shown in FIGS. 5A-5C . As another example, if a horizontal cut was taken along the L dc /l c =0 line along a bottom edge of the crosstalk contour plot in FIG. 4 , there is no variation in the optical power as V/V π goes from 0 to 2. Thus, there is no coupling to the lower waveguide and all the optical power remains in the upper waveguide output 320 of switch 300 . As V/V π is varied there is no switching effect because there is no coupling in the interferometer section 344 . Similarly, at the L dc /l c =2 horizontal line in FIG. 6A , each one of the directional couplers is 100% coupling in the bar (=) state. Thus, the first directional coupler 320 couples a portion of the input signal I in to the bottom waveguide 320 and the first directional coupler 320 is exactly one coupling length l c so all the input signal I in power in the upper waveguide 320 will couple down to the lower waveguide 330 at V/V π =−2, 0, 2, etc. In the interferometer section 344 , a phase shift would be applied, but since there is no signal in the upper waveguide 320 all power is phase shifted to the bottom waveguide 330 . Upon passage through the output directional coupler 346 , which is again one coupling length l c , the input signal I in is coupled back to the upper waveguide 320 and output as I upper . Thus, the result is similar. All the input power signal is transmitted out the upper waveguide output 320 independent of V/V π . As shown in the description of the related art, the bar state can generally be achieved by optical switches, but a −30 dB crosstalk cross-over (×) state is generally difficult to achieve.
When the cross-over (×) state (e.g., as indicated by a bullseye, peanut shape or slot in FIGS. 6A-6G ) in the crosstalk contour plots cannot be reached, complete switching from 0 to 1 cannot be achieved by the optical switch and the switch would exhibit high crosstalk (e.g., greater than −20 dB, −30 dB outside the corresponding contours). As shown in FIGS. 6A-6G , a −10 dB cross-over (×) state 610 is larger than a −20 dB cross-over (×) state 620 , which is larger than a −30 dB cross-over (×) state 630 . In fact, as shown in FIG. 6A , where V dc =0, a −30 dB state can rarely be achieved since L dc must be precisely 1l c and such manufacturing tolerances are rarely achieved. However, as shown in FIG. 6F , where V dc ≈±1.6, a −30 dB crosstalk contour extends from approximately from L dc /l c =1.5 to 2.2. Thus, a horizontal line across the crosstalk contour plot shown in FIG. 6F indicates that a −30 dB switch can achieve 100% switching from 0 to 1 for a large tolerance of L dc /l c ratios and accordingly a very large tolerance of L dc lengths.
The contour plots of FIGS. 6A-6G can be achieved by applying different bias voltages ±V dc at the directional couplers 342 , 346 in the switch 300 illustrated in FIG. 3 A. FIG. 6A is a diagram that shows a crosstalk contour plot with the bias voltage at 0, FIG. 6B is a diagram that shows the crosstalk contour plot with the bias voltage at 0.5, and FIGS. 6C-6G are diagrams that show crosstalk contour plots when ±V dc is at 1.0, 1.4, 1.5, 1.6 and 1.7, note that V dc is the normalized applied voltage in the unit of Δβ dc L dc /π where L dc approximately equals the total length of the combined directional couplers (input and output), Δβ dc equals the difference in propagation constant induced between the two directional coupler waveguide pairs. FIG. 6F is a crosstalk contour plot similar to that shown in FIG. 4 for a bias voltage of approximately 1.6, where V dc is a normalized voltage in the unit of Δβ dc L dc /π.
The advantage of looking at different bias voltages V dc for the switch 300 illustrated in FIG. 3A , is that an empirical understanding of the advantages according to preferred embodiments can be seen through the series of crosstalk contour plots. FIG. 6A is a crosstalk contour plot of an equivalent related art type switch where there is no asymmetric Δβ dc coupling between the first and second directional couplers. As FIG. 6A illustrates, the cross-over state (×) occupies a very narrow region on the L dc /l c axis. This indicates that the ratio of L dc to l c must be tightly controlled in order for a low crosstalk switch to be achieved. FIG. 6B is a crosstalk contour plot showing the output when the normalized bias voltage in the unit of Δβ dc L dc /π, V dc at the directional couplers 342 , 346 is 0.5. The crosstalk contours shown in FIG. 6B are very similar to the contours shown in FIG. 6 A. The primary difference being that the −10 dB regions 620 in FIG. 6B have moved closer to each other along the axes L dc /l c . Turning to FIG. 6C where the bias voltage V dc at the directional couplers 342 , 346 is 1, the plot illustrates how the −30 dB contours 610 , 620 , 630 are closer yet along the axis represented by L dc /l c . FIG. 6D shows the crosstalk contour plot where the bias voltages V dc is 1.4. This contour plot shows yet again how the contours 610 , 620 , 630 have moved closer to each other due to the bias voltage V dc and that there is some overlap in the −10 dB region 610 of the crosstalk contour plot.
FIG. 6E shows the crosstalk contour plot for a bias voltage V dc of 1.5 where the contours 610 , 620 , 630 have moved even closer and there is almost overlap in the −20 dB region 620 . FIG. 6F shows the crosstalk contour plots for the bias voltage 1.6 where the 30 dB contours 630 have merged along the Y-axis representing the L dc /l c ratio. This elongated crosstalk contour along the Y-axis indicates that for a wide range of ratios of L dc /l c , a cross-over state at −30 dB can be achieved. This indicates that the switch can be manufactured with a wide range of ratios of L dc /l c and the switch will still function as a low crosstalk switch. FIG. 6G shows contours for a bias voltage V dc of 1.7 at the directional couplers 342 , 346 . FIG. 6G shows how as the bias voltage V dc is increased above 1.6, the −30 dB crosstalk contours 630 come even closer to one another so that there is less of a range for the ratio of L dc to l c where the switch 300 will operate with about −30 dB of crosstalk. FIG. 6G is an example whereby the bias voltage V dc has been increased beyond an optimal amount. FIGS. 6A-6G show that as the bias voltage V dc at the directional couplers 342 and 346 , is increased, the switch 300 becomes more and more tolerant of a range of ratios of L dc to l c with an optimal range being reached at about V dc being equal to approximately 1.6 yet still exhibit low crosstalk.
Looking at the difference in the cross-over contours between FIG. 6A which illustrates equivalent operations of a related art switch and FIG. 6F which illustrates operations of a preferred embodiment of the present invention, it is clear that the switch in FIG. 6F allows a much wider range of L dc over l c , which translates into at least a larger tolerance for error in the manufacturing process for the length L dc .
In the Z-propagation waveguide switches, even if the TE and TM modes have slightly different characteristics in their respective coupling behavior, or the waveguides using the +r 22 , −r 22 EO coefficients, that slight difference would merely be represented as a small vertical offset between close horizontal slices in the crosstalk contour plot of FIG. 6 F. Thus, the TE and TM modes can be designed to be completed completely within the large available −30 dB crosstalk contour 630 and thus, an effective polarization independent switch is achieved.
In addition, as coupling length is a function of wavelength (λ) of the input signal I in , a broad band light source can be used while the optical switch still performs at a −30 dB crosstalk level. Directional coupling length (l c ) is a function of the operating wavelength. Therefore, a change in wavelength λ simply means a change in the effect directional coupling length (L dc /l c ). Since the switch can be operated with very low crosstalk for an expanded range of (L dc /l c ) when V dc ˜1.6, a switch can be operated with very low crosstalk for an expanded range of wavelength as compared to conventional switch.
For example, a broad band light source having wavelengths between 1.4 and 1.7 microns can be permitted for operating an input signal to the optical switch 300 .
FIG. 7A is a diagram that illustrates a second preferred embodiment of the optical switch in accordance with the present invention. The second preferred embodiment is a polarization independent broad wavelength 2×2 switch relying on a balanced bridge Mach-Zender interferometer constructed on an X-axis cut Z-propagation lithium niobate waveguide (LiNbO 3 ) structure with asymmetrically biased directional couplers. In the second preferred embodiment, the asymmetric waveguide function is achieved by designing the waveguides to have different widths in the directional coupler section that result in a selected Δβ dc between the waveguides.
As shown in FIG. 7A , an optical switch 700 is formed in an X-axis cut Z-axis propagation electro-optic substrate 710 . The EO substrate is preferably lithium niobate LiNbO 3 , however, it may be made of other suitable electro-optic substrates. The switch 700 includes a lower waveguide input 712 and an upper waveguide input 714 , and the switch 700 also includes a first directional coupler 720 , an interferometer section 722 and a second directional coupler 724 . The output end of the switch 700 has a lower output waveguide 732 and an upper output waveguide 734 . The first and second directional couplers 720 and 724 are close enough so that the two waveguides experience evanescent coupling. The interferometer section 722 of the switch 700 does not experience evanescent coupling between the waveguides. In the interferometer section 722 of the switch 700 are three electrodes 746 , 744 and 742 . The electrodes 746 , 744 , 742 parallel the waveguides in the interferometer section 722 with the electrode 746 being along one side of the waveguides, the electrode 742 along the opposite side of the waveguides and the electrode 744 located between the waveguides. Electrodes 742 and 746 are preferably electrically connected to ground potential and the center electrode 744 is connected to the signal voltage V S . Referring to the first and second directional couplers 720 and 724 , the total length of the two directional couplers 720 , 724 is L dc , and L dc can be anywhere in the range of 1.5 to 2.2 times the characteristic coupling length l c . The directional coupler effective length L dc is preferably divided between each directional coupler 720 and 724 as L B and L B . The asymmetric (Δβ dc ) nature of the couplers is achieved by the un-equal width of the waveguides in the coupler regions.
The asymmetrically biased nature of the directional couplers 720 , 724 is achieved in the second embodiment by using asymmetric waveguide widths for the two waveguides in each directional coupler section 720 and 724 , which effectively results in a Δβ dc between the waveguides. The two waveguides with different widths are designed so that Δβ dc is equal but opposite in sign, where the propagation difference between them is Δβ dc L dc /π˜1.6 for the output directional coupler. For example, that portion of the waveguide 714 in the first directional coupler 720 , is wider, w 1 , than the corresponding narrower, w 2 , portion of the waveguide 712 in the first directional coupler 720 , and that portion of the waveguide 714 in the second directional coupler 724 , is narrower, w 2 , than the corresponding wider, w 1 , portion of the waveguide 712 in the second directional coupler 724 . Δβ dc L dc /π≈1.6 is achieved by fabricating the appropriate Δw, where Δw=(w 1 −w 2 ).
All the switch operations are similar to the first case where Δβ dc L dc /π˜1.6 using bias voltage. In operation, the switch 700 receives an optical signal into the input waveguide 714 , the first directional coupler 720 divides the optical signal between the two arms of the interferometer section 722 , the signal voltage V S then controls whether the divided optical signal couples into the upper output 734 or the lower output 732 at the second directional coupler 724 . The interferometer section 722 controls which waveguide the optical signal couples into using the signal voltage V S by relying on the EO effect of the lithium niobate substrate. The propagation constant of the lithium niobate substrate is altered based on the direction and the magnitude of the electric field applied by the signal voltage V S . The electrodes 746 , 744 and 742 are arranged to maximize the difference in Δβ i when the signal voltage is applied. For an X-cut lithium niobate substrate with waveguide propagation direction along the Z-axis, the electrodes 746 , 744 and 742 are placed alongside the waveguides in order to maximize the horizontal electric field, E y , inside the two arms of the interferometer section 722 .
When the switch 700 is in the bar state (=), the optical signal entering the input waveguide 714 exits the switch 700 at output waveguide 734 . When the switch 700 is in the crossover state (×), an input signal at input waveguide 714 exits the switch at output waveguide 732 . Because the waveguides are arranged on the lithium niobate substrate so that the propagation direction is along the Z-axis, both the TE and TM modes see the same ordinary index n 0 . Similar to the first case, when Δβ dc L dc /π˜1.6 using asymmetric waveguide widths, rather than an applied voltage, switch operation with low crosstalk can be achieved for a very wide range of directional coupler parameters (L dc /l c ˜1.5 to 2.2). Therefore a broad wavelength, polarization independent switch can be achieved.
As shown in FIG. 7B shows the same embodiment of the switch as shown in FIG. 7A , with like numbers referring to like elements. The graph of FIG. 7B shows the output of the straight-thru port 734 , as a function of applied switching voltage. The maximums of the output labeled “=” correspond to when substantially all the signal exits the interferometer switch 700 , through the straight-thru port 734 and the minimum labeled “×” corresponds to when substantially all the signal exits the interferometer switch through the cross-over port 732 .
A third preferred embodiment of an optical switch according to the present invention will now be described. As shown in FIG. 8 , a third preferred embodiment of a polarization independent broad wavelength band 2×2 switch 800 uses a Mach-Zender type balanced bridge interferometer waveguide structure with asymmetrically biased directional couplers. The asymmetrically biased nature of the directional couplers is achieved by manufacturing the waveguide with different propagation indices, n 1 and n 2 , between the waveguides in the directional couplers. Different propagation indices for the waveguides can be achieved, for example, by changing the thickness of the initial metal to be diffused or by using material loading effects on the waveguides in the coupler region. Either one of these methods achieves a selected difference in Δβ dc between the waveguides.
Turning to the switch 800 shown in FIG. 8 , the waveguide substrate material 810 is made preferably out of lithium niobate. The substrate material is X-cut with a preferred propagation direction along the Z-axis. There are two waveguide inputs 812 and 814 . There is a first directional coupler 820 followed by an interferometer section 822 , followed by a second directional coupler 824 , and on the output end of the switch 800 are two output waveguides 832 and 834 . In the interferometer section 822 of the switch 800 , are three electrodes 842 , 844 and 846 . For the optical switch 800 , the upper and lower waveguides 814 and 812 are single moded for both the TE and TM modes. For the X-cut lithium niobate substrate, the electrodes 842 , 846 are preferably arranged on the outside along opposite sides of the waveguides and the electrode 844 is positioned between the interferometer arms. The electrodes 846 and 842 are electrically connected to ground potential. A signal voltage V S can be applied to the electrode 844 to alter the propagation constant in the same amount but in different directions for each arm of the interferometer section 822 . The first and second directional couplers 820 and 824 are asymmetrically biased directional couplers.
In the third preferred embodiment shown in FIG. 8 , the difference in propagation constant (Δβ dc ) of the directional couplers is achieved by how the waveguides are constructed. In general, a waveguide is constructed on a lithium niobate substrate or other dielectric material by diffusing other materials into the substrate during the manufacturing process to change the optical index locally so that light will then propagate preferentially along the path created by the diffused material. By varying the amount of material diffused into the substrate, the propagation constant of a particular waveguide can be altered. In the third preferred embodiment, a Δβ dc between the first and second directional couplers 820 , 824 for each waveguide is achieved by starting with a different amount of metal to be diffused into the substrate. Otherwise known as differential optical loading, the differential propagation constant can also be achieved by asymmetric layering of a dielectric or metal over the waveguide.
By diffusing into, or layering upon, different amounts of metal or dielectric, different indexes of refractions and the corresponding waveguide indexes, n 1 and n 2 , are achieved for each waveguide section in the coupler region. ±Δn is the waveguide's difference in the index of refraction in the coupler region, where Δn=n 1 −n 2 , and the sign indicates the direction of the change. Δn is the same but opposite in sign between the input (first) 820 , and output (second) 824 , directional couplers. Δn is chosen so that Δβ dc L dc /π≈±1.6.
Alternatively, one can also change the optical waveguide index by using material such as a dielectric or metal loading effect to change the waveguide propagation index. By properly selecting a Δn designed to achieve Δβ dc L dc /π to be approximately ±1.6 (equal but opposite in sign between the input and output couplers), a switch with low crosstalk can be achieved for an extended range of directional coupler parameters L dc /l c ˜1.5 to 2.2.
In operation, the switch 800 as shown in FIG. 8 performs similar to the other preferred embodiments. Accordingly, a detailed description is omitted. Further, the switch 800 receives an input signal into input waveguide 814 . The input signal is divided between the two waveguides at the first directional coupler 820 . The divided signal travels through the upper and lower arms of the interferometer section 822 . The upper and lower arms of the interferometer section receive a signal voltage V S at the center electrode 844 while the outer electrodes 842 and 846 are held at ground. The signal voltage causes an electric field between the electrodes which changes Δβ i for the interferometer section. This causes a phase shift between the optical signals in the upper and lower arms so that when both signals arrive at the second directional coupler 824 , the optical signal is either coupled entirely into output waveguide 834 or output waveguide 832 . If the signal couples into waveguide 834 , the switch is in a bar state which is a straight-thru configuration. If the signal is coupled into waveguide 832 , the switch is in a cross-over state, when the Δβ dc L dc /π˜1.6, and the directional couplers 820 and 824 have a total coupling length of L dc equal to about 1.5 to 2.2 times the characteristic coupling length l c . Thus, the total directional coupler length L dc can be anywhere in the range of about 1.5 to 2.2 times the characteristic coupling length l c of the directional couplers 820 , 824 .
FIG. 9 shows the same embodiment of the switch as shown in FIG. 8 , with like numbers referring to like elements. The graph of FIG. 9 shows the output of the straight-thru port 834 , as a function of applied switching voltage. The maximums of the output labeled “=” correspond to when substantially all the signal exits the interferometer switch 800 , through the straight-thru port 834 and the minimum labeled “×” corresponds to when substantially all the signal exits the interferometer switch through the cross-over port 832 .
In the first, second and third embodiments of the optical switch, an X-cut, Z-propagation LiNbO 3 crystal was used as the substrate. In addition to not being limited to LiNbO 3 as the substrate material, the invention is not intended to be limited to an X-cut crystal orientation. It is contemplated that other orientations will work for the switch substrate. For example, FIG. 10 shows a Y-cut, Z-propagation optically active crystal as the substrate. In FIG. 10 , the interferometer switch 1000 has an upper and lower input port, 1002 and 1004 , respectively, and an input and an output directional coupler 1006 and 1010 , respectively. The input directional coupler 1006 , has an upper input electrode 1012 and a lower input electrode 1014 . The second directional coupler 1010 , has an upper output electrode 1016 and a lower output electrode 1018 . In the interferometer section 1008 , there is an upper switch electrode 1020 , and a lower switch electrode 1022 .
In FIG. 10 , because the crystal's X and Y axes are rotated about the Z axis by 90° from the X-cut examples, the electrodes 1012 , 1014 , 1016 , 1018 , 1020 , and 1022 must be placed in different positions relative to the waveguides in order to induce the change in propagation constant, Δβ, in the Y-direction. As FIG. 10 illustrates, the electrodes must be placed above the waveguides to induce a Δβ in the Y direction. Also contemplated for the Y-cut crystal is placing some or all of the electrodes under the waveguides.
After a switch made according to the preferred embodiments has been installed, the aforementioned tuning feature of the switch (e.g., the switch 300 shown in FIG. 3A ) can be used to optimize the switching function if the switch is degraded by local conditions such as for example, temperature, pressure, mechanical stresses such as bending or twisting, and chemical environment. The switch's tuning characteristics can also be used to optimize the switching function if it degrades over time. For example, switching degradation can be caused by substances diffusing into the switch substrate and waveguides, or by the frequency of the optical signal changing, etc. Virtually any change in the switching characteristics based on altered directional coupler functionality can be compensated by tuning the directional couplers using their associated electrodes.
FIG. 11A shows related art balanced-bridge interferometer 1100 , with a graph of the signal output of the straight-thru port. 1110 and 1120 , are the top and bottom input ports, respectively. 1130 and 1140 , are the first and second directional couplers. 1150 is the interferometer section, and includes an upper and lower electrode 1160 and 1180 , respectively, which are held at ground potential, and a middle electrode 1190 , which receives a controlling signal. 1195 and 1197 are the straight-thru and cross-over outputs, respectively. All the waveguides are single-moded.
For the related art balanced-bridge interferometer switch 1100 , to function with low cross-talk, each directional coupler 1130 and 1140 , should have an effective length of one-half the characteristic coupling length. In operation, a differential phase shift is induced within the interferometer section 1150 , by application of a switching signal to the middle electrode 1190 .
The output of the straight-thru port as a function of applied switching voltage for coupler lengths of one-half the characteristic coupling length is shown in FIG. 11 B. The maximums of the output labeled “=” correspond to when substantially all the signal exits the interferometer 1100 , through the straight-thru port 1195 , and the minimum labeled “×” corresponds to when substantially all the signal exits the interferometer through the cross-over port 1197 . When the lengths of the first and second directional coupler 1130 and 1140 , respectively, are one-half the characteristic coupling length, the interferometer exhibits low cross-talk as indicated by the minima of FIG. 11B being substantially equal to 0.
FIGS. 12A through 12E show the output of the straight-thru port 1195 , as a ratio between input signal and output through the straight-thru port, of the interferometer switch 1100 , for a range of directional coupler 1130 and 1140 , lengths from 0.6l c to 1.4l c . When the ratio is close to one, substantially all the signal exits through the straight-thru port, and when the ratio is close to 0, substantially all the signal exits through the cross-over port. In FIG. 12C , where the minimum represented by the reference letter “A” is close to 0, the interferometer switch 1100 is exhibiting low cross-talk, and has a minimum of cross-talk when L dc =1.0l c . The interferometer switch 1100 exhibits increasing cross-talk as indicated by the minimum at A increasing in value as L dc deviates from 1.0l c . FIGS. 12A , 12 B, 12 D, and 12 E are for L dc =0.6l c , L dc =0.8l c , L dc =1.2l c , L dc =1.4l c
FIG. 13A is an example of a balanced bridge interferometer switch 1300 , with an input directional coupler 1302 , an interferometer section 1304 , and an output directional coupler 1306 . The input directional coupler 1302 , has a pair of electrodes 1308 and 1310 . The output directional coupler 1306 , has a pair of electrodes 1312 and 1314 . The interferometer section has a pair of electrodes 1316 and 1318 . The interaction lengths L B , of the input and output directional couplers, 1302 and 1306 , respectively are each equal to one-half the characteristic coupling length l c .
Via the electrodes 1308 , 1310 , 1312 , and 1314 , associated with the directional couplers 1302 and 1306 , a difference in the propagation constant Δβ dc , of the waveguides in the couplers can be induced. A normalized applied voltage of Δβ dc L B /π=±0.8 is the preferred voltage to be applied between the electrodes 1308 and 1310 , as well as between 1312 and 1314 . It is further preferred that the each directional coupler be biased the same amount but with an opposite sign, and this would be achieved by suitably controlling the polarity of the bias voltages. By applying a normalized voltage of Δβ dc L B /π=±0.8, the widest range of coupler interaction length L B is allowed for a coupler to function as a 3 dB coupler.
FIG. 13B is a contour plot for a single directional coupler which could be used as either the input directional coupler 1302 or the output directional coupler 1306 of the balanced bridge interferometer switch 1300 . The horizontal axis is the induced change in propagation constants between the waveguides of a directional coupler as expressed in units of Δβ dc L B /π, where Δβ dc is the difference in the propagation constant between the waveguides and L B is the interaction length of the coupler. The vertical axis is the normalized interaction length between the couplers as expressed in units of L B /l c , where L B is the same as for the horizontal axis and l c is the characteristic coupling length. Characteristic coupling length is the interaction length between the two waveguides sufficient to transfer all the power in one waveguide into the other. Reference letter “A” indicates the locus of the 3 dB half power points. Reference letter “D” is where the locus of the 3 dB half power point crosses the zero vertical axis. Reference letter “C” is that section of the 3 dB locus corresponding to where Δβ dc L B /π is approximately equal to 0.8. Reference letter “D” indicates the contour for when all of the output power exits from the straight through output with less than 30 dB power exiting through the crossover output. Reference letter “E” indicates the power contour region when all the output power exits through the cross-over output with less than 30 dB power exiting through the straight-thru output.
The line where the normalized applied voltage bias equals zero on the horizontal axis corresponds to the 0 bias state of related art directional couplers. Hence FIG. 13B indicates that, with a normalized applied voltage bias equal to zero, the line associated with the interaction length of a coupler bisects the locus of the 3 dB half power point near 0, and consequently intersects the locus in a region corresponding to a point.
The physical implication of FIG. 13B is that the interaction length of the coupler must be precisely controlled in order to achieve the 3 dB coupler. When the normalized applied voltage bias (Δβ dc L B /π) equals either negative 0.8 or positive 0.8, the edge of the locus of the 3 dB point is intersected. Consequently, the coupler interaction length can have a much greater variation, and 3 dB coupling would still being achieved. Corresponding to ±0.8 normalized voltage bias, the 3 dB coupling length of the coupler ranges from 0.75 to 1.1 in units of l c . In other words, at the bias point of Δβ dc L B /π˜±0.8, 3 dB splitting can be achieved for an extended range of L B /l c ˜0.75 to 1.1 (i.e. L dc /l c ˜1.5 to 2.2), not a singular point as in the conventional design.
The 3 dB locus in the regions of Δβ dc L B /π=+0.8 and −0.8 normalized voltage bias has an opposite curvature. The bias of the input and output directional couplers for the balanced bridge interferometer switch are chosen to have the same magnitude, but opposite polarity to balance out this slight asymmetry.
The contour plot of FIG. 13B is derived using standard coupled wave formula. The derivation and starting equations can be found, for example, in the “Handbook of Microwave and Optical Components,” Vol. 4, Chapter 4, “Optical Modulation, Electro-Optic devices,” by Suwat Thaniyavarn, which is incorporated herein by reference.
FIGS. 14A through 14H show the output of the switch 300 shown in FIG. 3A for various coupling lengths ranging from 1.2l c to 2.6l c . When the ratio shown in FIGS. 14A through 14H is close to one, substantially all the signal exits through the straight-thru port, and when the ratio is close to 0, substantially all the signal exits through the cross-over port. In FIGS. 14B through 14G , which corresponds to L dc =1.4l c to 2.4l c , reference letter “A” indicates that there is substantially 0 cross talk. This is a much wider operational range than the related art interferometer switch represented by FIGS. 12A through 12E .
FIG. 15 shows contour plots of straight-thru and cross-over switch states for a related art balanced bridge interferometer. The “×” corresponds to the cross-over switch state with three levels of cross-talk of <−30 dB, <−20 dB, and <−10 dB. The “=” corresponds to straight-thru switch states with three levels of cross-talk of <−30 dB, <−20 dB, and <−10 dB.
As described above, the present invention provides various advantages. According to the preferred embodiments, polarization independent switching over a broad wavelength can be realized because of relaxed coupler length tolerances. Further, the polarization independent switching has a very low polarization mode dispersion (PMD) and polarization dependent loss (PDL) through the use of Z-axis (i.e., optic-axis) propagation waveguide orientation on an electro-optic substrate where TE and TM see an identical ordinary index.
A low crosstalk switch (less than −25 dB) can be achieved for a very large range of L dc values (first preferred embodiment 1.5l c to 2.2l c ). In accordance with the large range of the directional coupler effective coupling length L dc , a fabrication tolerance of L dc equal to 1.5l c to 2.2l c can be achieved, which creates an increased production yield. Further, since the characteristic coupling length l c of the directional coupler is a function of an optical wavelength and polarization (and to a small degree a function of environmental parameters such as waveguide loading effects from a dielectric layer, electrode layer, stress, temperature, etc.), the switch can be designed to operate in a very broad range of wavelengths for both TE and TM polarizations.
The foregoing embodiments and advantages are merely exemplary and are not to be construed as limiting the present invention. The present teaching can be readily applied to other types of apparatuses. The description of the present invention is intended to be illustrative, and not to limit the scope of the claims. Many alternatives, modifications, and variations will be apparent to those skilled in the art. In the claims, means-plus-function clauses are intended to cover the structures described herein as performing the recited function and not only structural equivalents but also equivalent structures.
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Optical switches based on the balanced bridge interferometer design require precisely made (or half a coupling length) directional couplers to achieve minimum crosstalk for the two switch outputs. Precision 3 dB-directional couplers require the waveguide dimensions and fabrication parameters of the evanescent region to be tightly controlled making a low crosstalk switch difficult to manufacture and expensive. A new type of balanced bridge interferometer type switch is disclosed where the input and output directional couplers are asymmetrically biased to induce a certain difference in the propagation constants between the two waveguide in the directional couplers. By using the asymmetrically biased directional couplers with a certain tuning a bias voltage for the directional couplers. Low crosstalk switches can be achieved for a very wide range of directional coupler strengths, relaxing the precise half-coupling length directional couplers required in conventional design. This relaxation of the precise directional coupler waveguide regions allows a relaxation in the manufacturing tolerance of the devices and therefore make the switch much easier to make. Because low crosstalk switches can be a device with an extended operating range and broader directional coupler parameters, switches can be used for a much broader wavelength bandwidth. In one of the embodiments, this new design allows a device to switch both TE and TM mode optical signals simultaneously at low crosstalk levels to result in a polarization-independent optical switch.
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CROSS REFERENCE TO RELATED APPLICATIONS
Reference is made to the following copending applications filed concurrently herewith: application Ser. No. 131,163 entitled "Process Unit Incorporating A Charging Device" in the name of Alan C. R. Howard et al.; application Ser. No. 131,162 entitled "Process Unit For An Imaging Apparatus" in the name of Robert A. Carter; application Ser. No. 131,074 entitled "Process Unit For An Imaging Apparatus" in the name of Alan C. R. Howard et al, application Ser. No. 131,073 entitled "Fiber Traps In Copiers" in the name of Philip R. Thompson. Reference is also made to copending application Ser. No. 038,093 entitled "Process Unit For An Imaging Apparatus" field Apr. 14, 1987 in the name of Robert A. Carter.
BACKGROUND OF THE INVENTION
This invention relates to an electrostatographic reproducing machine, particularly a xerographic copier, comprising a transfer corotron for transferring a developed electrostatic latent image from an imaging member to a copy sheet, wherein the copy sheets are guided into contact with the imaging member by a guide member adjacent the transfer corotron. The invention further relates to a process unit adapted to be removably mounted in a main assembly of an electrostatographic reproducing machine, wherein the imaging member, the transfer corotron, and the guide member are included in the process unit.
There is a trend nowadays to incorporate the imaging member together with other process means such as a charge corotron, a development device, and a cleaning device in a removable process unit or cassette as described, for example, in U.S. Pat. No. 3,985,436 to Tanaka et al. The use of such a cassette enables the easy replacement of those parts of the xerographic machine which are most likely to deteriorate with use, especially the photoreceptor, but also the development and cleaning systems as well as the charge corotron wire. A further advantage of containing the major xerographic process elements within a cassette is that interchangeable cassettes may be used in a given copying machine to provide different development characteristics or different colored development.
In the art of electrostatographic copying it is known that the electrical conductivity of a paper copy sheet influences the quality of image transfer thereto from the imaging member. If the conductivity of the paper is too high, charges on the paper are able to leak away immediately via those parts of the reproducing machine which are in contact with the sheet, such as the paper guides. Many papers suitable for xerographic copy paper have a conductivity which is satisfactory when the paper is dry, but which becomes too high for effective image transfer when the paper is damp. Under conditions of high ambient relative humidity, copy paper which would otherwise be satisfactory, can absorb moisture to an extent where it becomes so conductive that image transfer is badly impaired.
PRIOR ART
To overcome this problem GB No. 2 165 491A to Milton proposes the use of electrically biasing the paper guide to minimize charge leakage from the paper. Thus, the paper guide which guides the paper to the imaging member adjacent the transfer corotron is electrically conductive and is maintained at a predetermined potential approximating the surface potential of a copy sheet during image transfer. To this end the guide is in electrical communication with the shield of the transfer corotron. The shield itself is electrically connected so as to be self-biasing to a potential such as to maintain the predetermined potential on the guide member.
Another problem with moist paper is that there is a tendency for the trail edge to flop away from the imaging member resulting in impaired image transfer and in some cases the image may not be transferred at all at the trail edge.
In U.S. Pat. No. 4,609,276 to Mitzutani there is disclosed a copying machine employing a process cassette, wherein a guide member is present in the main assembly of the machine for guiding copy sheets into contact with the imaging member in the vicinity of the transfer corotron when the cassette is inserted in its operative position in the main assembly. The guide is necessarily disposed in close proximity, e.g. 1 to 2 mm, from the imaging member in order to prevent the developed toner image on the imaging member from being unduly disturbed, e.g. by scattering, when it is transferred to a copy sheet. Because of its very close proximity to the imaging member at least part of the guide member is hingedly mounted on the main assembly of the machine so that it can be pivoted out of the way whenever the process unit is inserted into or removed from the main assembly to avoid causing physical damage to the highly sensitive imaging member. In addition FIGS. 10A through 10G illustrate several alternative arrangements for a process unit to contain various process means. FIG. 10G illustrates a unit which in addition to including an imaging drum, charging device and developer also includes a transfer discharger and a protective cover. In this regard attention is also directed to the discussion in U.S. Pat. No. 4,462,677 to Onoda of FIGS. 13A to 13F at column 8, lines 35 to 64 and U.S. Pat. No. 4,470,689 to Nomura et al of FIGS. 15A to 15F at column 8 lines 15 to 45 concerning the inclusion of a transfer discharger in the process unit. Incorporating the transfer charging device in the cassette housing has the advantage that the charging device itself shields and protects the imaging member from light exposure, damage, and contamination even when the unit is removed from the main assembly of the copying machine, thus dispensing with the need for a separate protecting cover. An additional advantage of having the transfer charging device integral with the unit housing is that it will be replaced automatically whenever the process units is exchanged for a fresh one without having to change the transfer charging device separately.
SUMMARY OF THE INVENTION
According to a first aspect of the present invention there is provided an electrostatographic reproducing apparatus comprising a transfer corotron for transferring a developed electrostatic latent image from an imaging member on to a copy sheet, and an electrically conductive guide member for guiding copy sheets in the vicinity of the transfer corotron characterized in that the guide member is integral with the shield of the transfer corotron.
A reproducing machine in accordance with the invention has the advantage that the transfer guide member may be provided simply as an extension of the transfer corotron shield. An additional advantage resulting from the conductivity of the guide member is that an electrical potential applied to the transfer corotron shield will automatically be applied to the paper guide without the need for a separate electrical connection. Hence effective image transfer is possible for more highly conductive paper, e.g. paper with a relatively high moisture content, because current leakage through the paper is reduced. The guide member may be either (a) the entrance guide for guiding copy sheets into contact with the imaging member, or (b) the exit guide for guiding copy sheets away from the imaging member. In a preferred embodiment both the entrance guide and the exit guide are integral with the corotron shield.
According to a further aspect of the present invention there is provided a process unit adapted to be removably mounted in a main assembly of an electrostatographic copying machine, the unit comprising a housing, an imaging member inside the housing, and a transfer corotron for transferring a developed electrostatic latent image from the imaging member to a copy sheet characterized in that the process unit further comprises an electrically conductive guide member integral with the transfer corotron for guiding copy sheets in the vicinity of the imaging member when the process unit is inserted in the main assembly.
In addition to the advantage of enabling effective image transfer with more highly conductive paper as mentioned above, a process unit in accordance with the invention has the distinction over the prior art that the transfer corotron and integral guide member are actually incorporated in the process unit itself and as such may be mounted in close proximity and in fixed relation to the operative position of the imaging member thereby avoiding the risk of physically damaging the imaging member when the process unit is inserted into or removed from the main assembly of the copying machine.
Again, the guide member may be either (a) the entrance guide for guiding copy sheets into contact with the imaging member, or (b) the exit guide for guiding copy sheets away from the imaging member. In a preferred embodiment both the entrance guide and the exit guide are integral with the corotron shield. The integral guide member(s) are automatically biased to the same potential as the corotron shield.
Preferably, the biased exit guide is inclined and contoured in such manner that the trail edge of the copy sheet is tipped to wipe against the imaging member for improved image transfer at the trail edge particularly for moist copy sheets.
BRIEF DESCRIPTION OF THE DRAWINGS
An embodiment of the invention will now be described, by way of example, with reference to the accompanying drawings in which:
FIG. 1 is a schematic cross section of a process unit having a transfer corotron with integral copy sheet guide members in accordance with the invention;
FIG. 2 is a schematic cross section of the process unit taken on the line II--II in FIG. 1;
FIG. 3 is a cross section showing detail of a latch mechanism for retaining the corotron in the process unit taken on the line III--III in FIG. 2;
FIG. 4 is a sectional view of the process unit of FIG. 2 partially inserted in the main assembly of a xerographic copier;
FIG. 5 is a perspective view of a ramp flexure member which supports the transfer corotron in the main assembly;
FIG. 6 is a perspective view of the latch in the closed position when the process unit is partially inserted into the main assembly;
FIG. 7 is a cross section showing detail of the latch mechanism of FIG. 2, but with the latch in the open position;
FIG. 8 is a sectional view of the process unit of FIG. 2 fully inserted in the main assembly;
FIG. 9 is a perspective view of the transfer corotron and integral copy sheet guide members;
FIG. 10 is a sectional view of the process unit of FIG. 8 when it is fully inserted in the main assembly with the transfer corotron in its hinged-open position; and
FIG. 11 is a schematic view in cross section of a reproducing machine having a process cassette according to the present invention.
It is noted that, for the sake of clarity, the Figures are not drawn to scale. In particular in the sectional views the dimensions in the vertical direction have been exaggerated. The same features are denoted by the same reference numerals in each of the Figures.
DETAILED DESCRIPTION OF THE INVENTION
The process unit or cassette 1 shown in FIG. 1 is designed to be removably mounted in the main assembly 100 of a xerographic copier as described, for example, in the aforementioned US patents and also in our copending U.S. patent application No. 38,093 filed Apr. 14, 1987, entitled Process Unit For An Imaging Apparatus in the name of Robert A. Carter commonly assigned to the assignee of the present invention to which reference is invited for further details, The cassette 1 comprises a housing 2 made for example, primarily of polystyrene, which encloses an imaging member in the form of a belt photoreceptor 3 in addition to various process means, in particular a development device 4, a cleaner 5, and a charge corotron 6. The belt photoreceptor is an endless flexible belt having a photosensitive surface. In the arrangement shown, when the cassette 1 is removed from the main assembly of the copier, the belt is only loosely retained in the cassette but when the cassette is inserted into the main assembly of the copying machine, the photoreceptor belt is supported in an operative position by a member 40 forming part of the main assembly (see especially FIG. 8). A cassette having this kind of loosely retained photoreceptor arrangement forms the subject of our aforementioned copending U.S. patent applicatin No. 38,093.
Returning to FIG. 1, a transfer charging device 7 is included in the cassette housing in the vicinity of the photoreceptor belt at the area where a toner image is to be transferred from the belt to a copy sheet. The technique of actually transferring a toner image is well known to those skilled in the art and no further details need be given here. The transfer charging device is in the form of a corotron having an outer shield 8 which, as is conventional, is substantially U-shaped and made, for example, of stainless steel. A corona wire 9 extends the full length of the shield 8 and is spaced apart from the walls thereof in the usual manner.
At its upper end the shield has extended portions 10 and 11 on its left-and right-hand sides respectively, as viewed in the drawing. These portions 10 and 11 act as guide members and define the path which a copy sheet follows as it passes through the cassette for the purposes of having a toner image transferred thereto, as described in more detail below. As shown in FIG. 2, the corotron 7 has end caps 21, 22 fastened to opposite ends of shield 8. The end caps 21, 22 are made of a plastics material. End cap 21 has a laterally-projecting pin extending from its side faces both into and out of the plane of FIG. 2. The pin 23 is accommodated in sockets 24 formed integrally in the cassette housing, two such sockets being provided, one on each side of the end cap 21. The pin and socket arrangement is such as to allow the corotron a small amount of vertical movement, typically 2 mm, at its pivoted end. At the opposite end of the corotron 7, the other end cap 22 has a longitudinally projecting tab 25 which engages in a latch mechanism 26 shown more clearly in FIG. 3. The tab 25 is held by two jaws 27a, 27b of the latch which are biased together by an inverted keyhole-shaped spring 28. The spring 28 is held in place by pairs of tabs 29a, 29b; 30a, 30b formed integrally on the inward face of the jaws 27a, 27b. The upper portion of each jaw 27a, 27b is provided with a protruding post 31a, 31b with an enlarged head 33a, 33b extending from the outward face. The posts 31a, 31b are accommodated in slots 32a, 32b respectively in the cassette housing 2, thus providing a pivotal mounting for the jaws. The enlarged heads 33a, 33b which act to retain the latch in its own plane are present on the outside of the cassette housing as can be seen more clearly in FIGS. 2 and 6. The latch is also held in place by two bail bars 34a, 34b formed on a recessed portion of the internal wall of the cassette housing 2. The bail bars 34a, 34b are both joined to the cassette housing at each of their two ends, thereby providing a slot between the bars and the cassette housing through which the jaws 27a, 27b are threaded, thereby limiting their pivotal movement as well as holding them in their own plane (see FIG. 6). When the cassette is outside the main assembly of the copying machine, the jaws 27a, 27b of the latch 26 are closed to grip tab 25 and so support the corotron as shown in FIG. 3. However, the latch is adapted to be opened automatically to release the corotron when the cassette is inserted into the main assembly of a copying machine, which enables the corotron to be located accurately relative to the photoreceptor and also enables the corotron to be hinged open about pivot pin 23 to allow for clearance of jammed copy sheets, as described in more detail below.
As can be seen from FIGS. 1 and 2, the outside of the corotron shield 8 forms part of the external wall of the cassette housing 2.
FIG. 4 shows the situation as the cassette 1 is almost, but not quite, fully inserted into its operative position in the main assembly 100 of a reproducing machine. For the sake of clarity the whole of the machine main assembly is not shown in this Figure. As the cassette is first inserted into the main assembly, the support member 40, which is integral with the main assembly, enters the cassette 1 through aperture 2a in the housing 2 and threads through the belt photoreceptor 3. To facilitate this threading operation the support 40 is provided with a chamfered leading end face 40a. Extending from the end face 40a is a spigot 41, the purpose of which is to actuate the latch mechanism 26 when the cassette is fully inserted in the main assembly as explained in more detail below.
With the cassette in the position shown in FIG. 4, electrical connection is about to be made with the corotron 7 by means of compression spring 45 which is fastened to block 44 of the main machine assembly. The spring 45 is electrically connected to a high voltage source. As the cassette approaches the position shown in FIG. 4, the spring 45 enters the tapered bore of socket member 19 projecting from the leading face of the corotron end cap 21. In FIG. 4, the socket member is cutaway for enhanced clarity of the features being discussed here. As the cassette continues to be inserted the spring 45 engages around electrical contact 47 protruding within the socket 19. Contact 47 is tapered in such a manner as to permit the spring 45 to thread over it easily and to ensure intimate electrical contact therewith. The contact 47 is electrically connected to corona wire 9.
With the cassette at the position shown in FIG. 4, the underside of leading end cap 21 has just engaged leaf spring 46 which extends cantilever-fashion from the block 44 of the main assembly 100. Spring 46 acts to urge the corotron 7 up towards the support 40 until a projection 48 provided on the upper surface of end cap 21 abuts the underside of support member 40. Projection 48 thus acts as a spacer.
Electrical connection is made to the shield 8 of corotron 7 via leaf spring 46. Being integral therewith the guide members 10 and 11 will be at the same potential as the shield 8. Suitably, the shield is maintained as a potential of approximately 1 KV preferably in a self-biasing manner, e.g. by grounding the shield via a zener diode circuit as disclosed in GB No. 2 165 491A.
At the same time the end cap 22 at the trailing end of the corotron approaches ramp flexure 49 fastened on a surface 50 which may be withdrawn from the main assembly of the reproducing machine as discussed in more detail below.
The ramp flexure 49 which is shown in more detail in FIG. 5 is made of plastics material, for example polypropylene and comprises a double ramp 51, 52 in back-to-back configuration defining an apex 53 therebetween. The inwardly extending ramp 51 comprises a lower sloping portion 51a and an integral upper portion 51b which is more steeply inclined. The ramp 51 is slightly wider than the corotron end cap 22 and is provided with upstanding wall portions 54 at its edges, thus presenting a guide channel for the corotron. Extending from the underside of lower ramp portion 51a is a T-shaped lug 55 which extends through a slot 56 in the surface 50 to lock the ramp member 59 thereto. The ramp member is further fastened to the surface 50 by a bifurcated barbed member 57 extending through a slot 58 in the surface 50. The outwardly extending ramp portion 52 is shorter than the inwardly extending portion 51 and at its lower end curves inwardly and terminates in a block 58 which is bolted to an upstanding flange 50a at the outside edge of surface 50. The ramp portion 52 provides a guide surface for the leading end cap 21 of corotron 7 when the cassette is first inserted into the main assembly 100.
As the cassette is inserted further, the spigot 41 of the support member 40 approaches the latch mechanism 26. Referring to FIG. 6, it can be seen that the spigot 41 is aligned with two substantially semicircular boss members 60, 61 at the facing edges of the two jaws 27a, 27b. The boss members 60, 61 are each chamfered at their inwardly directed faces 60a, 61a respectively. As the cassette approaches its fully inserted position within the main assembly 100 the spigot 41 engages the bosses 60, 61 at their chamfered surfaces 60a, 61a and prizes them apart against the bias of spring 28, thus forcing the jaws 27a, 27b to move apart thereby releasing tab 25 of corotron end cap 22 as shown in FIG. 7. At this stage the trailing end of the corotron will drop slightly under its own weight until it abuts ramp portion 52 of ramp flexure 49.
The cassette is then pushed all the way to its fully inserted position in which the underside of end cap 22 is supported by the apex 53 of ramp flexure 49, as shown in FIG. 8. The ramp flexure 49 acts to urge the trailing end of the corotron up towards the support 40 until two flange-like projections 62 provided on the top side of end cap 22 abut the underside of support member 40 and thus act as spacers. Thus the projection 48 on end cap 21 and the two projections 62 on end cap 22 which can be seen most clearly in FIG. 9 act as spacers which accurately locate the corotron 7 relative to the support member 40.
As described in our aforementioned copending U.S. application No. 038,093 the photoreceptor belt 3 may be tensioned after the cassette has been fully inserted in the main assembly, e.g. by using a pair of rollers (not shown here) which can be moved apart, whereupon the belt 3 will adopt an operative position in which it conforms closely with the support member 40. It follows, therefore, that by accurately locating the corotron 7 relative to the support member 40 it is also located accurately relative to the photoreceptor, as required.
Although the ramp flexure 49 may itself be sufficiently resilient to urge the corotron 7 against the support member 40 additional bias may be provided by threading a compression spring (not shown) over bifurcated member 57 so that it buts against the apex 53 of the flexure 49 at its upper end and against the surface 50 at its lower end.
As shown in FIG. 1, an aperture 14 is present between the right-hand extension 11 of corotron shield 8 and the main part of the cassette housing to enable a copy sheet to enter the process unit for the purpose of transferring an image thereto from the photoreceptor belt 3 in the vicinity of the transfer corotron when the cassette is inserted into the main assembly of the copying machine. The aperture 14 is in the form of a slot extending substantially the full width of the cassette and is relatively narrow, for example, 2 mm wide. Thus the slot is sufficiently wide to permit a copy sheet to enter the cassette, but narrow enough to provide appreciable protection for the photoreceptor from damage, contamination, and light exposure, thus prolonging the useful life of the photoreceptor.
The path which a copy sheet follows as it passes through the cassette for image transfer purposes is denoted by an arrow in FIG. 1. The external wall portion 15 of the main part of the cassette housing is shaped so as to deflect and guide the approaching copy sheets towards the aperture 14. Furthermore, the extreme right-hand side of the extended portion 11 of corotron shield 8 has a downturned lip 16 inclined obtusely relative to the adjacent plateau portion 17. The downturned lip 16 thus also acts to guide approaching copy sheets towards the aperture 14.
As the copy sheet enters the cassette it follows the path defined between the photoreceptor belt 3 and the plateau portion 17 of the corotron shield extension 11 which thus acts as a paper guide. By virtue of the electric connection to the shield 8 described previously, shield extension 11 being integral therewith is held at the same potential as the shield, as mentioned previously, typically 1 KV. By biasing the paper guide 11 in this way current leakage through the copy sheet is reduced during image transfer enabling the use of more highly conductive paper, e.g. paper with a relatively high moisture content, while still achieving high quality image transfer. The copy sheet then passes over the main part (i.e. the shield 8 and the wire 9) of the transfer corotron 7 where it comes into contact with the photoreceptor belt 3 when the toner image is transferred from the photoreceptor belt to the copy sheet itself in known manner. From there the copy sheet traverses the slightly upwardly inclined ramp 18 forming part of the shield extension 10 on the left-hand side of the corotron 7, and thence to aperture 20 in the cassette housing where the copy sheet exists the cassette for further processing, in particular for the toner image to be fixed permanently to the copy sheet using techniques well known to persons skilled in the art. The shield extension 10 acts as an exit paper guide and being integral with the corotron shield 8 is also held at the same potential. Hence current leakage through the copy sheet is also reduced as the copy sheet exits the cassette enabling effective image transfer even to the trailing edge of the copy sheet by which time the leading edge may have come into contact with other parts of the main assembly through which the copy sheet might otherwise discharge.
The ramp 18 also has a slightly convex configuration (as seen by the copy sheet) which tends to cause the trail edge of the copy sheet to tip up after it leaves the entrance guide 11 and wipe against the imaging member 3 thereby ensuring positive contact and consequently effective image transfer even at the trail edge of moist copy sheets.
In case a copy sheet becomes jammed while it passes through the cassette 2, surface 50 with the ramp flexure 49 mounted thereon may be withdrawn manually from the main assembly 100 of the reproducing machine when the cassette is fully inserted therein, as shown in FIG. 10. As the surface 50 and ramp 49 are withdrawn the end cap 22 of corotron 7 will begin to descend the ramp 51 of ramp flexure 49, because it is no longer retained by latch 26. The end cap 22 is guided down the ramp 51 by edge wall portions 54. As the free end of the corotron descends, it pivots about hinge pin 23 at the other end cap 21. Leaf spring 46 is displaced against subjacent platform 68 extending from the block 44 in the main assembly 100. As the surface 50 continues to be withdrawn, the corotron end cap 22 continues to descend ramp portion 51 unti it engages the surface 50 which limits the corotron's pivotal movement. FIG. 10 shows the corotron 7 hinged in its fully open position away from the photoreceptor to permit access to the transfer region of the cassette, especially for clearing copy sheets which may have jammed there without damaging the photoreceptor. Once the jam has been cleared, the corotron 7 is returned to its former operative position simply by reinserting surface 50. Initially the end cap 22 will slide along the surface 50 until the ramp flexure 49 approaches when it will begin to ascend ramp portion 51 again guided by edge wall portions 54. For this purpose, end cap 22 is flanked by a pair of wings 66 with outwardly extending sloping faces 67 complementary to ramp 51 to facilitate sliding thereover. When the surface 50 is returned to its fully inserted position, the corotron end cap 22 reverts to its former position at the apex 53 of ramp flexure 49 with the projecting flanges 62 abutting the supporting member 40 of the main assembly 100, as shown in FIG. 8. When it comes to removing the cassette 1 from the main assembly 2 the spigot 41 of support 40 disengages from the latch 26 whereby the jaws 27a, 27b of the latch close together under the bias of spring 28 to regrip the tab 25 of corotron end cap 22. Thus, when the cassette is removed from the main assembly the transfer corotron is automatically latched back into, and as such again becomes an integral part of, the cassette housing 2.
Referring now to FIG. 11, there is shown schematically a xerographic printing machine 110 having the removable process unit 1 of the present invention in its operational position in the main assembly 100. The machine includes an endless flexible photoreceptor belt 3 mounted for rotation in the clockwise direction as shown about support rollers 111a and 111b to carry the photosensitive imaging surface 112 of the belt 3 sequentially through a series of xerographic processing stations, namely a charging station 114, an imaging station 116, a development station 118, a transfer station 110, and a cleaning station 122.
The charging station 114 comprises a corotron 6 which deposits a uniform electrostatic charge on the photoreceptor belt 3. The photoreceptor belt 3, the charge corotron 6, the developer device 4, the transfer corotron 7, and the blade cleaner 5 may all be incorporated in a process cassette 1 adapted to be removably mounted in the main assembly 100 of the xerographic copier as described in aforementioned copending application Ser. No. 038,093.
An original document D to be reproduced is positioned on a platen 124 and is illuminated in known manner a narrow strip at a time by a light source comprising a tungsten halogen lamp 126. Light from the lamp is concentrated by an elliptical reflector 125 to cast a narrow strip of light on to the side of the original document D facing the platen 124. Document D thus exposed is imaged on to the photoreceptor 1 via a system of mirrors M1 to M6 and a focusing lens 127. The optical image selectively discharges the photoreceptor in image configuration, whereby an electrostatic latent image of the original document is laid down on the belt surface at imaging station 116. In order to copy the whole original document the lamp 126, the reflector 125, and mirror M1 are mounted on a full rate carriage (not shown) which travels laterally at a given speed directly below the platen and thereby scans the whole document. Because of the folded optical path the mirrors M2 and M3 are mounted on another carriage (not shown) which travels laterally at half the speed of the full rate carriage in order to maintain the optical path constant. The photoreceptor 1 is also in motion whereby the image is laid down strip by strip to reproduce the whole of the original document as an image on the photoreceptor.
By varying the speed of the scan carriages relative to the photoreceptor belt 1 it is possible to alter the size of the image along the length of the belt, i.e. in the scanning direction. In full size copying, that is to say with unity magnification, the speed of the full rate carriage and the speed of the photoreceptor belt are equal. Increasing the speed of the scan carriage makes the image shorter, i.e. reduction, and decreasing the speed of the scan carriage makes the image longer, i.e. magnification.
The image size can also be varied in the direction orthogonal to the scan direction by moving the lens 127 along its optical axis closer to the original document i.e. closer to mirrors M2 and M3, for magnification greater than unity, and away from the mirrors M2 and M3 for reduction, i.e. magnification less than unity. When the lens 127 is moved, the length of the optical path between the lens and the photoreceptor, i.e. the image distance, is also varied by moving mirrors M4 and M5 in unison to ensure that the image is properly focused on the photoreceptor 1. For this purpose mirrors M4 and M5 are suitably mounted on a further carriage (not shown).
At the development station 118, a magnetic brush developer device with a developer roll 128 develops the electrostatic latent image into visible form. Here, toner is dispensed from hopper (not shown) into developer housing 129 which contains a two-component developer mixture comprising a magnetically attractable carrier and the toner, which is deposited on the charged area of belt 1 by a developer roll 128.
The developed image is transferred at transfer station 120 from the belt to a sheet of copy paper according to the practice of the present invention. The copy paper is delivered into contact with the belt in synchronous relation to the image from a paper supply system 131 in which a stack of paper copy sheets 132 is stored on a tray 133. The top sheet of the stack in the tray is brought, as required, into feeding engagement with a top sheet separator/feeder 134. Sheet feeder 134 feeds the top copy sheet of the stack towards the photoreceptor around a 180° path via two sets of nip roll pairs 135 and 136. The path followed by the copy sheets through the aperture in the cassette is denoted by a broken line. At the transfer station 120 transfer corotron 7 provides the electric field to assist in the transfer of the toner particles thereto.
The copy sheet bearing the developed image is then stripped from the belt 1 and subsequently conveyed to a fusing station 138 which comprises a heated roll fuser 139 to which release oil may be applied in known manner. The image is fixed to the copy sheet by the heat and pressure in the nip between the two rolls 139 and 140 of the fuser. The final copy is fed by the fuser rolls into catch tray 141 via two further nip roll pairs 142 and 143.
After transfer of the developed image from the belt some toner particles usually remain on the surface of the belt, and these are removed at the cleaning station 122 by a cleaner blade 5 which scrapes residual toner from the belt. The toner particles thus removed fall into a receptacle 145 below. Also, any electrostatic charges remaining on the belt are discharged by exposure to an erase lamp 146 which provides an even distribution of light across the photoreceptor surface. The photoreceptor is then ready to be charged again by the charging corotron 6 as the first step in the next copy cycle.
The patents and applications referred to herein are hereby specifically and totally incorporated herein by reference.
From the foregoing it will be evident that various modifications may be made within the scope of the present invention. For example, instead of a flexible belt the imaging member may comprise a photoreceptor drum as commonly used in xerographic machines. Moreover, apart from the transfer corotron, the cassette may enclose additional or alternative processing means to those described above. Alternatively, it is not necessary for the copying machine to employ a cassette or process unit as described above. Instead, the xerographic components, including the transfer corotron may all be fixed within the main assembly of the copier in conventional manner, the transfer guide member nevertheless being formed integrally with the shield of the transfer corotron. In addition, while the invention has been illustrated with repect to copying apparatus it will be understood that it may be used in printer apparatus wherein a light beam such as a laser beam may be used to selectively dicharge portions of the photoconductor. All such modifications and embodiments as may readily occur to the artisan are intended to be within the scope of the appended claim.
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A process unit which can be removably mounted in a main assembly of an electrostatographic copying machine. The unit comprises a housing enclosing an imaging member and, optionally, other processing means such as a development device, a cleaner, and a charge corotron. The transfer corotron for transferring a toner image from the imaging member to a copy sheet is incorporated in the cassette housing, thus avoiding the need to provide a separate movable cover to protect the imaging member from contamination, physical damage, and light exposure when the cassette is removed from the main assembly of the copier. An electrically conductive guide member for guiding a copy sheet into contact with the imaging member and an electrically conductive guide member for guiding the copy sheet away from the imaging member are both formed integrally with the shield of the transfer corotron as extensions thereof. In consequence of electrically biasing the shield when the process unit is inserted into its operative position in the main assembly, the guides are maintained at the same potential as the shield thereby reducing charge leakage through the copy sheet in the transfer zone, enabling effective image transfer even for moist and relatively highly conductive copy sheets. The exit guide is suitably contoured to ensure that the trailing edge of the copy sheet positively contacts the imaging member.
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RELATED APPLICATIONS
This application claim priority to “System, Method, and Apparatus for Displaying Pictures on an Interlaced Display”, Provisional Application for Patent, Application Ser. No. 60/727,983 filed Oct. 18, 2005 by MacInnis, which is incorporated herein by reference.
FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[Not Applicable]
MICROFICHE/COPYRIGHT REFERENCE
[Not Applicable]
BACKGROUND OF THE INVENTION
Video data can have a variety of formats. For example, motion pictures are typically filmed at 24 progressive frames per second. Other material can be filmed at 30 progressive frames per second, or 30 interlaced frames per second.
The display devices are also associated with a specific display rate and format. For example, display devices according to the National Television Standards Committee display 30 interlaced frames per second.
The source video content for display on a display device can include video that has a variety of different display rates. For example, the video can include a motion picture with commercials.
While the motion picture is filmed at 24 progressive frames per second, the display device displays 30 interlaced frames per second. Accordingly, the display device uses what is known as 3:2 pull down. In 3:2 pulldown, 24 progressive frames are separated into 48 fields. Since every four fields represent the display time of five fields, one of the four fields is repeated. For example, where the progressive frames include frames F 0 , F 1 , F 2 , F 3 . . . , the display order is T 0 , B 0 , T 1 , B 1 , T 1 , B 2 , T 2 , B 3 , T 3 , B 3 , . . . , where T# is the top field from frame F#, and B# is the bottom field from frame F#.
The motion picture can then be followed by a commercial that is filmed at 30 interlaced frames per second. The commercials are displayed without using 3:2 pull down. For interlaced frames, the top field and bottom field are captured at and represent different video times. Therefore, either top fields or bottom fields are to be displayed first.
When the last field for display from the motion picture movie has the same polarity as the first field from the commercial, the first field from the commercial is not aligned with the display device.
Further limitations and disadvantages of conventional and traditional approaches will become apparent to one of skill in the art, through comparison of such systems with some aspects of the present invention as set forth in the remainder of the present application with reference to the drawings.
BRIEF SUMMARY OF THE INVENTION
Aspects of the present invention may be found in system(s), method(s), and apparatus for displaying pictures on an interlaced display, substantially as shown in and/or described in connection with at least one of the figures, as set forth more completely in the claims.
These and other advantages and novel features of the present invention, as well as illustrated embodiments thereof will be more fully understood from the following description and drawings.
BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 is an illustration of a plurality of fields that can be displayed in accordance with an embodiment of the present invention;
FIG. 2 is a block diagram of an exemplary circuit in accordance with an embodiment of the present invention;
FIG. 3 is a flow chart for providing fields in accordance with an embodiment of the present invention; and
FIG. 4 is an illustration of a plurality of frames and fields that can displayed in accordance with an embodiment of the present invention; and
FIG. 5 is a block diagram of an exemplary circuit for displaying pictures in accordance with an embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to FIG. 1 , there is illustrated a block diagram describing an exemplary video source in accordance with an embodiment of the present invention. The video source comprises a first plurality of fields 100 a ( 0 . . . m) for display, a second plurality of fields for display 100 b ( 0 . . . n), a third plurality of fields for display 100 c ( 0 . . . x), a fourth plurality of fields for display 100 d ( 0 . . . y), and a fifth plurality of fields 100 e ( 0 . . . z).
The plurality of fields for display 100 a , 100 b , 100 c , 100 d , and 100 e comprise top fields, e.g., fields 100 a ( 0 , 2 , 4 , . . . ), 100 b ( 0 , 2 , 4 , . . . ), 100 c ( 1 , 3 , 5 . . . ), 100 d ( 1 , 3 , 5 . . . ) 100 e ( 0 , 2 , 4 , . . . ) and bottom fields, e.g., fields 100 a ( 1 , 3 , 5 , . . . ), fields 100 b ( 1 , 3 , 5 , . . . ), fields 100 c ( 0 , 2 , 4 , . . . ), fields 100 d ( 0 , 2 , 4 ), and fields 100 e ( 1 , 3 , 5 ).
Top fields 100 a ( 0 , 2 , 4 , . . . ) represent one set of alternating lines of pixels in a frame during a period of time 0−>T a , 2T a −>3T a , 4T a −>5T a , . . . , while the bottom fields 100 a ( 1 , 3 , 5 , . . . ) represent the other set of alternating lines during alternating periods of time T a −>2T a, 3T a −>4T a , 5T a −>6T a . . . . For example, a top field can include even numbered lines while a bottom field can include odd numbered lines.
An interlaced display displays interlaced video data by displaying one of the top or bottom fields followed by the other during alternating periods of time. The display simulates motion video when displaying the top fields 100 a ( 0 , 2 , 4 , . . . ) at times D−>D+T a , D+2T a −>D+3T a , D+4T a −>D+5T a . . . , and the bottom fields 100 a ( 1 , 3 , 5 , . . . ) at times D+T a −>D+2T a , D+3T a −>D+4T a , D+5T a −>D+6T a . . . .
After displaying field 100 a (m), display field 100 b ( 0 ) is the next field for display in the video source. However, if field 100 a (m) and field 100 b ( 0 ) are both top fields (this is known as having the same polarity), the field 100 b ( 0 ) will provide a top field at D+mT a when a bottom field is expected. At time T m , the interlaced display may display the received top field as a bottom field and subsequent fields may also be displayed with inverted polarity. This tends to cause objectionable artifacts.
Similarly, if both field 100 b (n) and field 100 c ( 0 ) are bottom fields, or if both field 100 c (x) and field 100 d ( 0 ) are bottom fields, or if both 100 d (y) and 100 e ( 0 ) are top fields, fields 100 c ( 0 ), 100 d ( 0 ), or 100 e ( 0 ) will provide fields that are opposite in polarity to what is expected.
In the foregoing circumstance, interlaced display can lag or lead the fields 100 . Lagging the fields refers to delaying the display of fields 100 b by at least one field period. The delay of the display of fields 100 b is relative to an order of display that would occur, except for the opposing polarity of the field and the interlaced display. In cases, such as where 3:2 pulldown is used, the delay is relative to the 3:2 pulldown order. For example, the fields 100 b ( 0 , . . . n) can be displayed starting at D+(m+1)T a . If at time D+mT a , the interlaced display expects bottom fields, at time D+(m+1)T a , the interlaced display expects top fields.
During time D+mT a , the field 100 a (m) can be repeated with the opposite polarity. When a top field is displayed with opposite polarity, a vertical phase shift filter can be applied to the field to convert it from e.g. a top field to a bottom field, or vice versa. In another example, a field may be displayed as if it had the opposite polarity to its actual polarity, e.g. display a top field as a bottom field, or vice versa. Alternatively, the field 100 a (m−1) can be repeated. In another case, the field 100 b ( 0 ) can displayed with opposite polarity, as a bottom field, and repeated at D+(m+1)T a as a top field.
Leading the fields refers to displaying at least one field from fields 100 b ahead of time. The display of fields 100 b ahead of time is relative to an order of display that would occur, except for the opposing polarity of the field and the interlaced display. The order of display that would occur, except for the opposing polarity of the field and the interlaced display is often explicitly indicated in a data structure that provides the fields 100 from the video source, or can be the order that the fields 100 are received. In cases, such as where 3:2 pulldown is used, the delay is relative to the 3:2 pulldown order. For example, field 100 b ( 0 ) can be skipped. Field 100 b ( 1 ), that is a bottom field, can be displayed starting at time D+(m+1)T a . Each of the remaining fields 100 b ( 2 . . . n) can then be displayed in order.
In the case of lagging the fields, the fields 100 b can be shown one time period later, while in the case of leading the fields, the fields 100 b can be shown one time period earlier.
If fields 100 b (n) and 100 c ( 0 ) are both bottom fields, when the interlaced display finishes displaying fields 100 b (n), the interlaced display is ready to display a top field. Similarly, if the fields 100 c (x) and 100 d ( 0 ) are both bottom fields, the display is ready to display a top field after field 100 c (x). If fields 100 d (y) and 100 e ( 0 ) are both top fields, the interlaced display is ready to display a bottom field after field 100 d (y).
If in every case, the decision is to lag the pictures, the lag will accumulate over time. Many decoding systems and display systems include a buffer for storing pictures before decoding or before display. If the lag accumulates beyond a certain threshold, the buffers may overflow.
Alternatively, if in every case, the decision is to lead the pictures, the lead will accumulate over time. If the lead accumulates over a certain threshold, fields may not be available for display.
According to certain aspects of the present invention, the decision to lag or lead, such as after displaying 100 d (y) can be based on at least one previous decision, the decisions made after displaying fields 100 a (m), 100 b (n), or 100 c (x). The decision to lag or lead, based on at least one previous decision, can be made in a manner to offset accumulated lags, with leads, and vice versa. In one embodiment, the decisions can alternate between leading and lagging. For example, where after displaying field 100 a (m), the decision is to lag, the decision after displaying field 100 b (n) can be to lead, after displaying fields 100 c (x), lag.
Referring now to FIG. 2 , there is illustrated a block diagram of an exemplary circuit 200 for providing fields 100 for display on an interlaced display 220 . The circuit receives fields 100 from a video source and provides the fields 100 for display. The interlaced display 220 displays fields at time periods. The circuit 200 provides the fields 100 for display at approximately the time period that the interlaced display 220 displays the fields 100 . The circuit 200 may include a buffer 205 for buffering some of the fields 100 , a memory 210 for storing one or more indicators, and output port(s) 215 for providing fields to the interlaced display 220 , as will be set forth below. The circuit 200 can be hardwired, comprise logic or a state machine, or comprise a programmed processor.
The operation of the circuit 200 will now be described with reference to FIG. 3 , which illustrates a flow diagram for displaying pictures in accordance with an embodiment of the present invention. At 305 , the circuit 200 makes a determination whether the next field for display in the buffer 205 has the same polarity as expected for the next output. If the polarity is the same as expected for the next output, the circuit 200 provides ( 310 ) the next picture to the display 220 via output port(s) 215 .
If at 305 , the polarity is different, the circuit 200 decides whether to lag or lead at 315 , based on previous decisions to lag or lead. In certain embodiments of the present invention, the decision to lead or lag at 315 can be set to be the opposite of the decision at the last iteration of 315 . The decision is then recorded at 320 , and carried out at 325 .
It is noted that the rate the fields 100 are captured can be different from the rate that the fields 100 are displayed. It is also noted that the video source can include progressive frames. For example, a motion picture that includes commercials often includes progressive frames that are captured at one rate, and fields that are captured at another rate.
Referring now to FIG. 4 , there is illustrated a plurality of progressive frames 400 a and interlaced frames 400 b that are part of the transmission from a single stream. The progressive frames 400 a can carry, for example, a motion picture, while the fields 400 b can carry, for example commercials. The progressive frames 400 a and fields 400 b are commingled together.
The frames 400 a ( 0 . . . n), and 400 b ( 0 . . . x) correspond to time intervals 0−>T a , T a −>2T a , . . . , nT a −>(n+1)T a and 0−>T b , T b −>2T b , . . . , xT b −>(x+1)T b . When displayed at corresponding times D+T a , . . . , D+nT a , D+nT a +T b , D+nT b +xT b , motion video is simulated. The amount of time that the first plurality of frames 400 a and the second plurality 400 b are displayed can be different.
The frames 400 can be displayed as interlaced video. When displayed as interlaced video, the display device displays top fields at particular time intervals, e.g., D−>D+T c , D+2T c −>D+3T c , . . . , while displaying bottom fields at particular time intervals, e.g., D+T c −>D+2T c , D+3T c −>D+4T c , . . . .
The format, and time periods T a , T b , and T c can be different from each other, but are usually defined by standards. For example, for motion pictures, usually the frames are progressive at a rate of approximately 24 (23.976) per second. According to the National Television Standards Committee (NTSC) standard, the frames are interlaced having a rate of approximately 60 fields per second (59.94 fields/second), or 30 frames/second (29.97 frames/second).
It is common when a motion picture is broadcast with commercials, wherein-the motion picture frames 400 are captured at 24 frames per second while the commercials are captured at 60 fields per second.
In the case where 24 progressive frames/second are displayed on an interlaced display at 30 interlaced frames/sec., i.e. 60 fields/sec., a technique known as 3:2 pulldown is used. In 3:2 pulldown, the frames, e.g., top fields 400 a T( 0 . . . n) can be created from one set of alternating lines, while bottom fields 400 a B( 0 . . . n) can be created from the other.
The fields 400 a T and 400 a B are then displayed in the order, 400 a T( 0 ), 400 a B( 0 ), 400 a T( 1 ), 400 a B( 1 ), 400 a T( 1 ), 400 a B( 2 ), 400 a T( 2 ), 400 a B( 3 ), 400 a T( 3 ), 400 a B( 3 ), . . . , at each period T c . It is noted that one field from every second progressive frame is repeated.
The foregoing fields can then be renumbered 100 ( 0 ) . . . 100 ( 9 ). Due to the repetition of a field, the frames can either be displayed top field first or bottom field first. At the transition from displaying frames 400 a to frames 400 b , the display may be ready to display a field with a different polarity than field 400 b ( 0 ). In the foregoing cases, a lag or a lead occurs. At the next transition, the opposite action is taken.
Referring now to FIG. 5 , there is illustrated a block diagram of an exemplary circuit 500 in accordance with an embodiment of the present invention. Data is received and stored in a buffer 532 . The data can be received from either a communication channel or local memory, such as a hard disk or DVD.
The data output from the compressed data buffer 532 is then passed to a data transport processor 335 . The data transport processor 535 demultiplexes different data packets. At least some of the data packets carry compressed versions of the frames 400 a , and fields 400 b.
It is noted that in many implementations, the frames 400 a and fields 400 b may be compressed in accordance with a particular video compression standard, such as MPEG-2, or Advanced Video Coding (AVC, also known as H.264 or MPEG-4 Part 10). Additionally, it is noted that the foregoing video compression standards may reorder the fields/frames 400 a / 400 b for encoding and decoding purposes.
A video decoder 545 receives and decompresses the compressed video data. While decompressing the video data, the decoded frames 400 a /fields 400 b are stored in frame buffers 570 to await display by the display engine 550 . The display engine 550 scales the video, renders the graphics, and provides fields to the display device 580 .
Additionally, for motion picture progressive frames, frames 400 a , the decoder 545 effectuates 3:2 pulldown by indicating the fields 400 a T/ 400 a B that can be generated from the progressive frames 400 a . The foregoing results in a plurality of fields 100 a ( 0 . . . x).
After displaying field 100 a (x) , field 400 b ( 0 ) is displayed. After outputting a top field, the next field to output should be a bottom field. Where field 400 b ( 0 ) is a top field, a decision is made by the display manager 585 whether to lag or lead.
The display manager 585 also includes a control bit 592 that indicates the most recent decision to lead or lag at the previous transition point. The display manager 585 makes the opposite decision and toggles the control bit 592 .
The embodiments described herein may be implemented as a board level product, as a single chip, application specific integrated circuit (ASIC), or with varying levels of the system integrated with other portions of the system as separate components. Alternatively, if the processor is available as an ASIC core or logic block, then the commercially available processor can be implemented as part of an ASIC device wherein certain aspects of the present invention are implemented as firmware.
The degree of integration may primarily be determined by speed and cost considerations. Because of the sophisticated nature of modern processors, it is possible to utilize a commercially available processor, which may be implemented external to an ASIC implementation.
While the present invention has been described with reference to certain embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted without departing from the scope of the present invention.
Additionally, many modifications may be made to adapt a particular situation or material to the teachings of the present invention without departing from its scope. Therefore, it is intended that the present invention not be limited to the particular embodiment disclosed, but that the present invention will include all embodiments falling within the scope of the appended claims.
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Presented herein are system(s), method(s), and apparatus for displaying pictures on a display. In one embodiment, there is presented a method for outputting pictures. The method comprises receiving the plurality of fields for display in a particular order, where the plurality of fields are associated with the stream; detecting that a first field and a field adjacent to the first field have the same polarities; selecting between leading or lagging the fields after the first field; detecting that a second field and a field adjacent to the second field have the same polarities; selecting between leading and lagging the fields after the second field, based at least in part on the selection after the first field; detecting that a third field and a field adjacent to the third field have the same polarities; and selecting between leading and lagging the fields based at least in part on the selection after the second field.
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FIELD OF THE INVENTION
This is the National Phase of International Application PCT/US95/09471, filed on Jul. 26, 1995 by Laser Products Corporation, the Assignee of the entire interest hereof, as International applicant, and by the subject inventor.
The subject invention relates to holstering systems for handguns and other hand weapons, including security holsters that prevent accidental and unauthorized removal of weapons from holsters and that permit weapons with attachments to be holstered.
BACKGROUND
The use of holsters for hand weapons goes back to prehistoric times, when hunters started to use quivers for their arrows. Even the use of holsters for handguns is almost as old as handguns themselves.
More recent effort have concentrated on the development of security holsters.
By way of example, the following patents present descriptions of related background developments.
In particular, U.S. Pat. No. 5,127,566, by Robert J. Beletsky, issued Jul. 7, 1992 for Security Holster Thumb-Break, discloses an assembly for releasably securing a holster safety strap. A dual position thumb break prevents removal of the pistol unless the open position is selected.
U.S. Pat. No. 5,150,825, by Richard E. D. Nichols, issued Sep. 29, 1992 for Holster with Retention Device, discloses a holster having a retention device for applying pressure to a handgun in the holster to resist inadvertent removal of the handgun. An elongate band prevents removal of the pistol when force is applied.
U.S. Pat. No. 5,199,620, by Robert J. Beletsky, issued Apr. 6, 1993 for Security Holster Thumb-Break, discloses another assembly for releasably securing a holster safety strap, including a thumb break with directional release to open the holster.
U.S. Pat. No. 5,215,238, by Alan Baruch, issued Jun. 1, 1993 for a Holster for a Weapon with Laser Light capable of accommodating a pistol with attached laser light and including a safety retention.
U.S. Pat. No. 5,269,448, by Randy R. Shoemaker, issued Dec. 14, 1993 for a Front Draw Handgun Holster whose side wall portions are adjustable toward one another to prevent a handgun from falling from the holster and from being grabbed by an attacker, and adjustable away from one another to release the gun for fast front draw as well as upward removal from the holster. The holster is angularly adjustable relative to the wearer's body. U.S. Pat. No. 5,275,317, by William H. Rogers and Norman E. Clifton, Jr., issued Jan. 4, 1994 for a Handgun Holster with a Lockable Trigger Guard Restraint. Such holster has a rigid body portion and two upwardly extending oppositely facing wall members forming a channel therebetween to receive a handgun trigger guard, a pivotable cam member in at least one wall member and locking means engageable with the cam to prevent it from being pivoted and a finger operable member to unlock the locking means. According to that patent, the holster disclosed therein preferably is made of a moldable leather/plastic laminate which is processed to have the unique contours to receive a selected handgun and is not suitable as a holster for any other gun shape.
U.S. Pat. No. 5,282,559, by Glen Wisser et al., issued Feb. 1, 1994 for a Holster with Frame, and discloses anti-twist plates for resisting unauthorized removal of a handgun from the holster, and a security strap and thumb-break attached to the frame of the holster.
U.S. Pat. No. 5,284,281, by Richard E. D. Nichols, issued Feb. 8, 1994 for a Holster with Trigger Guard Gripping Device having at least one projection for extending into the trigger guard of a handgun, and being moveable with the gun between a first position in which the projection is rigidly held in the trigger guard and a second position in which the projection is only loosely biased into the trigger guard so that it can be released by simply pulling the handgun away from the gripping device.
U.S. Pat. No. 5,395,021, by Alvah B. Brown, issued Mar. 7, 1995 for a Handgun Holster and Retention Block Therefor discloses a spring biased trigger guard latch that reduces the possibility of unauthorized release and that is located under the sheath material of the holster to conceal it from view.
Drawbacks of such prior-art proposals include impediment of fast draws of handguns through the presence of thumb breaks or other safety devices that need to be actuated by the legitimate user of the weapon, need of extensive training for intended users in the case of complex holstering systems, and lack of accommodation of accessories without provision of special holster pockets therefor.
SUMMARY OF THE INVENTION
From a first aspect thereof, the invention resides in a method of holstering an elongate hand weapon and, more specifically, resides in the improvement comprising, in combination, making a track structure, forming that track structure as a holstering device for the elongate hand weapon, and equipping the elongate hand weapon with an adapter equipping complementary with the track structure for holstering that adaptor in that track structure while holstering the elongate hand weapon in the holstering device and making that adapter integral with that elongate hand weapon as distinguished from the holstering device, so that that adapter is removed with that elongate hand weapon from the holstering device when that hand weapon is drawn from that holstering device, and equipping the holstering device and the adapter with a detent releasably retaining that adapter at the track structure.
From another aspect thereof, the invention resides in a method of holstering an elongate hand weapon in a holstering device having a track structure and, more specifically, resides in the improvement comprising, equipping the elongate hand weapon with an adapter complementary with the track structure for holstering the an adapter in that track structure while holstering the elongate hand weapon in the holstering device and making that adapter integral with that elongate hand weapon as distinguished from the holstering device, so that that adapter is removed with that elongate hand weapon from the holstering device when that hand weapon is drawn from that holstering device, and equipping the holstering device and the adapter with a detent releasably retaining that adapter at the track structure.
From another aspect thereof, the invention resides in a method of holstering an elongate hand weapon having an adapter for holstering that elongate hand weapon in a holstering device and having an accessory exteriorily attached to and part of the hand weapon, and, more specifically, resides in the improvement comprising, in combination, equipping the holstering device with a track structure complementary with the adapter for holstering that slide structure in that track structure while holstering the elongate hand weapon in the holstering device; the adapter being integral with that elongate hand weapon as distinguished from the holstering device, so that that adapter is removed with that elongate hand weapon from the holstering device when that hand weapon is drawn from that holstering device, and equipping the holstering device with an accommodation for the accessory.
From another aspect thereof, the invention resides in a method of holstering any one of a number of different types of elongate hand weapons and, more specifically, resides in the improvement comprising, in combination, making a standard holstering device for the different types of elongate hand weapons, and equipping each of the different types of elongate hand weapons with an adapter interfacing with the standard holstering device for the different types of elongate hand weapons, making each adapter integral with that elongate hand weapon as distinguished from the holstering device, so that that adapter is removed with that elongate hand weapon from the holstering device when that hand weapon is drawn from that holstering device, and equipping the standard holstering device and each adapter with a detent releasably retaining each adapter.
From another aspect thereof, the invention resides in a method of holstering an elongate hand weapon and, more specifically, resides in the improvement comprising, in combination, making a holstering device, holstering the hand weapon in the holstering device, equipping the elongate hand weapon and the holstering device with a normally deactivated detent for selectively retaining said hand weapon in that holstering device, drawing the hand weapon from the holstering device with a hand having an outstretched finger, and blocking removal of the hand weapon from the holstering device upon attempts to remove the hand weapon from the holstering device without the hand having the outstretched finger substantially parallel to the elongate hand weapon by activating the detent only upon attempts to remove the hand weapon from the holstering device without the hand having the outstretched finger substantially parallel to the elongate hand weapon.
From another aspect thereof, the invention resides in apparatus for holstering an elongate hand weapon and, more specifically, resides in the improvement comprising, in combination, a track structure, a holstering device for the elongate hand weapon including that track structure, and a adapter for the elongate hand weapon complementary with that track structure and removable with the elongate hand weapon from the holstering device, such adapter being integral with the elongate hand weapon as distinguished from the holstering device, so that such adapter is removed with the elongate hand weapon from the holstering device when that hand weapon is drawn from that holstering device. This apparatus includes a detent adapted to releasably retain the adapter at the track structure until a wearer of the holstered hand weapon pulls such hand weapon from the holstering device.
From another aspect thereof, the invention resides in apparatus for holstering an elongate hand weapon in a holstering device including a track structure and, more specifically, resides in the improvement comprising an adapter for the elongate hand weapon complementary with the track structure and removable with the elongate hand weapon from the holstering device, such adapter being integral with the elongate hand weapon as distinguished from the holstering device, so that such adapter is removed with the elongate hand weapon from the holstering device when that hand weapon is drawn from the holstering device. This apparatus includes a detent adapted to releasably retain the adapter at the track structure until a wearer of the holstered hand weapon pulls the hand weapon from the holstering device.
From another aspect thereof, the invention resides in apparatus for holstering an elongate hand weapon having structure for the elongate hand weapon and, more specifically, resides in the improvement comprising, in combination, a track structure complementary with the adapter, and a holstering device for the elongate hand weapon including that track structure; the slide structure being removable with the elongate weapon from the holstering device, that slide structure being integral with that elongate hand weapon as distinguished from the holstering device, so that that slide structure is removed with that elongate hand weapon from the holstering device when that hand weapon is drawn from that holstering device. The adapter is removable with the elongate hand weapon from the holstering device, and is integral with the elongate hand weapon as distinguished from the holstering device, so that such adapter is removed with the elongate hand weapon from the holstering device when the hand weapon is drawn from the holstering device. This apparatus includes a detent adapted to releasably retain the adapter at the track structure until a wearer of the holstered hand weapon pulls such hand weapon from the holstering device.
From another aspect thereof, the invention resides in apparatus of holstering any one of a number of different types of elongate hand weapons and, more specifically, resides in the improvement comprising, in combination, a standard holstering device for the different types of elongate hand weapons, and for each of the different types of elongate hand weapons an adapter interfacing with the standard holstering device for the different types of elongate hand weapons and removable with the elongate hand weapon from the holstering device, each adapter being integral with a corresponding elongate hand weapon as distinguished from the holstering device, so that that adapter is removed with that elongate hand weapon from that holstering device when that hand weapon is drawn from that holstering device. This apparatus includes a track structure in the standard holstering device with each adapter being complementary with that track structure in that standard holstering device. This apparatus further includes a detent adapted to releasably retain the adapter at the track structure until a wearer of the holstered hand weapon pulls the hand weapon from the holstering device.
From another aspect thereof, the invention resides in apparatus for holstering an elongate hand weapon and, more specifically, resides in the improvement comprising, in combination, a holstering device for the hand weapon, and a normally deactivated detent adapted to block removal of the hand weapon from the holstering device by selectively retaining said hand weapon in the holstering device, and a detent activator adapted to activate the detent only upon attempts to remove the hand weapon from the holstering device without a hand having a finger outstretched substantially parallel to the elongate hand weapon.
From yet another aspect thereof, the invention resides in a method of holstering an elongate hand weapon in a holstering device having a track structure, and, more specifically, resides in the improvement comprising, in combination, equipping that elongate hand weapon with a slide structure complementary with the track structure for holstering such slide structure in that track structure while holstering the elongate hand weapon in the holstering device, making the slide structure integral with the elongate hand weapon as distinguished from the holstering device, so that the slide structure is removed with the elongate hand weapon from the holstering device when that hand weapon is drawn from the holstering device, equipping the holstering device and the slide structure with a detent for releasably retaining that slide structure at the track structure against removal of the holstered hand weapon from the holstering device; that detent being deactivated as long as the hand weapon is in the holstering device, that detent remaining deactivated by presence of part of a hand of a wearer drawing the hand weapon from the holstering device, and the detent becoming activated for retaining the hand weapon in the holstering device upon attempts to remove that hand weapon from the holstering device in the absence of the mentioned part of a hand of a wearer drawing that hand weapon.
From a related aspect thereof, the invention resides in apparatus for holstering an elongate hand weapon in a holstering device including a track structure, and, more specifically, resides in the improvement comprising, in combination, a slide structure for that elongate hand weapon complementary with the track structure and removable with that elongate hand weapon from the holstering device; that slide structure being integral with the elongate hand weapon as distinguished from the holstering device, so that such slide structure is removed with the elongate hand weapon from the holstering device when that hand weapon is drawn from that holstering device, a detent adapted to releasably retain the slide structure at the track structure against removal of the holstered hand weapon from the holstering device, a first detent deactivator adapted to deactivate the detent as long as the hand weapon is in the holstering device, a second detent deactivator adapted to deactivate the detent in response to a presence of part of a hand of a wearer drawing the hand weapon from the holstering device, and a detent activator adapted to activate the detent for retaining the hand weapon in the holstering device upon attempts to remove that hand weapon from that holstering device in the absence of the mentioned part of a hand of a wearer drawing that hand weapon.
From a related aspect thereof, the invention resides in apparatus for holstering an elongate hand weapon in a holstering device including a track structure, and, more specifically, resides in the improvement comprising, in combination, a slide structure for that elongate hand weapon complementary with the track structure and removable with that elongate hand weapon from the holstering device; that slide structure being integral with the elongate hand weapon as distinguished from the holstering device, so that such slide structure is removed with the elongate hand weapon from the holstering device when that hand weapon is drawn from that holstering device; that holstering device including an angularly moveable portion and a relatively stationary portion; the track structure being on that angularly moveable portion, and a detent on the relatively stationary portion being positioned to engage the slide structure when the hand weapon is in the holstering device prior to angular movement of the angularly moveable portion relative to the stationary portion.
No recitation in any description herein or claim hereof is intended to be limited to any recited sequence of steps, features or other elements.
Recitation of any combination of steps, features or elements in any preamble of any claim hereof is not intended as a representation or concession that such combination is prior art.
BRIEF DESCRIPTION OF THE DRAWINGS
The subject invention and its various aspects and objects will become more readily apparent from the following detailed description of preferred embodiments thereof, illustrated by way of example in the accompanying drawings which also constitute a written description of the invention, wherein like reference numerals designate like or equivalent parts, and in which:
FIG. 1 is a perspective view of a hand weapon holstering system according to an embodiment of the invention;
FIG. 1A is a detail view, on an enlarged scale, of a detent that may be implemented in the holstering systems herein disclosed according to an embodiment of the invention;
FIG. 2 is a section taken approximately on the line 2--2 in FIG. 1, and together with FIGS. 2A to 2C shows a standard holstering device for different types of weapons;
FIG. 3 is a perspective view similar to FIG. 1 but showing the holstering structure without the hand weapon, with an edge broken away for better visibility of the track structure;
FIG. 4 is a perspective view of a hand weapon with holstering adapter according to an embodiment of the invention;
FIG. 5 is a perspective view of a holstering system according to a further embodiment of the invention, showing the hand weapon half drawn from the holster, such as by an assailant;
FIG. 6 is a side view of the holster region of FIG. 5, with parts broken away to show a safety mechanism of the holstering structure of FIG. 5 in action;
FIG. 7 is a detail view similar to FIG. 6, showing the normally unlatched holstered condition of the hand weapon of FIG. 5, and indicating a normal draw of the hand weapon by the hand of the wearer of the holstered hand weapon;
FIG. 8 is a perspective view of a holstering system according to yet another embodiment of the invention;
FIG. 9 is a detail view of the holstering system of FIG. 8; and in a different stage of operation.
FIG. 10 is a perspective view similar to FIG. 8, but turned around showing in dotted outline a rest position of the holstering system and holstered weapon, and showing in solid outline a tilted position of weapon and holster, ready for a draw of the weapon.
DESCRIPTION OF PREFERRED EMBODIMENTS
The drawings illustrate and show methods and apparatus 10 for holstering handguns or other elongate hand weapons 12 according to embodiments of the invention. Such methods and apparatus provide or comprise a track structure 13 which is provided as a holstering device 14 for the elongate hand weapon 12. In apparatus terms, holstering devices 14 for elongate hand weapons 12 include the track structure 13.
Also according to an embodiment of the invention, such elongate hand weapon is provided with or comprises a slide structure or adapter 15 which is or is made complementary with the track structure or adapter 13 for holstering the slide structure 15 in that track structure, while holstering the elongate hand weapon 12 in its holstering device 14. This may also be expressed by saying that the track structure 13 is or is made complementary with the slide structure or adapter 15 for holstering such slide structure or adapter 15 in that track structure, while holstering the elongate hand weapon 12 in its holstering device 14. In this respect the drawings, such as FIGS. 2, 2A, 2B, 2C, 4 and 8, show that the slide structure or adapter 15 is integral with the elongate hand weapon 12 as distinguished from the holstering device 14, so that such slide structure is removed with that elongate hand weapon from that holstering device 14 when that hand weapon is drawn from such holstering device such as seen in FIG. 4 and again in FIG. 7.
Embodiments of the invention extend not only to such combinations, but also to methods and apparatus for holstering an elongate hand weapon 12 in a holstering device 14 having a track structure 13, which reside in the improvement of providing such elongate hand weapon with a slide structure or adapter 15 complementary with the track structure or adapter 13 for holstering such slide structure in that track structure while holstering the elongate hand weapon in the holstering device 14.
Conversely, embodiments of the invention reside in methods and apparatus for holstering an elongate hand weapon 12 having a slide structure or adapter 15 for holstering such elongate hand weapon in a holstering device 14, which reside in the improvement of providing such holstering device with a track structure 13 complementary with the slide structure or adapter 15 for holstering that slide structure or adapter in the track structure while holstering the elongate hand weapon in the holstering device 14.
Pursuant to a preferred embodiment of the invention, the track structure 13 is provided with or includes two tracks 16 and 17 in the holstering device 14, and the slide structure or adapter 15 is provided with or includes two slides 18 and 19 complementary with those two tracks in the holstering device.
According to a related embodiment of the invention, the track structure or adapter 13 and slide structure 15 are provided as or comprise a tongue and groove combination, including a tongue structure, such as shown at 16 and 17, and a groove structure, such as shown at 18 and 19. Within the scope of the invention, such tongue structure, while shown as part of the track structure 13, could be on the slide structure or adapter 15, while the groove structure or adapter, while shown in such slide structure, could be in the track structure instead. In this respect, the drawings show the slide structure or adapter 15 with lateral tongues 21 and 22, and the track structure with corresponding grooves 23 and 24. Accordingly, the tongue and groove combination may include a tongue structure, such as shown at 16, 17, 21 or 22, as one of the track structure and slide structure or adapter, and a groove structure, such as shown at 18, 19, 23 or 24, as the other of the track structure and slide structure.
For hand weapons having an accessory 25 exteriorly attached or otherwise exterior to, but part of such hand weapon, the holstering device 14, according to an embodiment of the invention, is provided with an accommodation for such accessory. Such accommodation may include an elongate opening 26 in the holstering device 14, extending along the track structure 13 or the tracks 16 and 17 or the tongues 16 and 17. By way of example, FIGS. 4 and 5 show a target illumination light or lamp as the accessory 25. Other examples include a laser light, such as in the above mentioned U.S. Pat. No. 5,215,238 or otherwise, and various auxiliary gun sights, pepper spray and mace containers, knives or bayonets, high-voltage or stunning devices, etc. etc., all symbolized in FIG. 2 by an attachable accessory part 25. In this respect, FIG. 2 shows such accessory 25 attached to the slide structure or adapter 15 by a dovetail structure 27. Within the scope of the invention, a bayonet socket or any other mount for an accessory 25 for the hand weapon 12 may be provided at 27 as part of the hand weapon.
According to an embodiment of the invention, the holstering device 14 is open along one side thereof, typically the rear side, such as seen at 26 in FIGS. 2, 2A to C, and 3.
The overall goal of prior-art effort has been to provide each holster for a specific hand weapon. The above mentioned U.S. Pat. No. 5,275,317 typifies such prior-art goal by stating that its holster preferably is made "to have the unique contours to receive a selected handgun 20 and is not suitable as a holster for any other gun shape."
While holstering devices of the subject invention, indeed, may be made to receive only a specific hand weapon or handgun, preferred embodiments of the invention provide methods and apparatus for holstering any one of a number of different types of elongate hand weapons. Such methods provide a standard holstering device for such number of different types of elongate hand weapons, and provide each of such elongate hand weapon with an adapter interfacing with such standard holstering device 14 for elongate hand weapons. By way of example, the slide structure 15 may serve as such adapter.
Where the standard holstering device 14 is provided with or has a track structure 13, each adapter is a slide structure 15 complementary with that track structure in that standard holstering device. By way of example, where the track structure 13 is provided with two tracks 16 and 17 in the standard holstering device 14, each slide structure or adapter 15 is provided with two slides 18 and 19 complementary with these two tracks in the standard holstering device.
FIGS. 2 and 2A to C illustrate an embodiment of this principle. By way of example, FIGS. 2A, 2B and 2C show different types of hand weapons 112, 212 and 312. According to the embodiment of the invention illustrated in FIGS. 2 and 2A to 2C, all these different types of weapons 12, 112, 212, 312 are capable of being holstered in the same standard holstering device 14; typically one at a time. Each of the weapons 12, 112, 212 and 312 has an adapter 15 interfacing with the standard holstering device for such weapons 12, 112, 212 and 312. While such adapter may be the above mentioned slide structure 15, the adapters for the different types of weapons 12, 112, 212, 312 need not be identical within the scope of the invention. By way of example, the adapter for the weapon 112 may be different from the adapter for the weapon 12, and so forth, as long as all adapters interface with the standard holstering device 14.
Within the scope of the invention, any slide structure or adapter 15 may be manufactured separately from the hand weapon and may be attached or retrofitted to such weapon, or may be provided as part of any of the weapons during manufacture of such weapon or weapons.
However, the slide or adapter structures 15 of the different types of weapons 12, 112, 212, 312 all have to have some configuration that is complementary with essentials of the holstering device 14.
The holstering device 14 is the same for all of the different types of weapons 12, 112, 212, 312. Where such holstering device has a track structure 13 comprising one or more rails or tracks 16 or 17, adapters 15 will have a corresponding structure, such as shown at 18 and 19. Similarly, where such holstering device has a track structure 13 comprising one or more grooves 23 or 24, adapters 15 will have a corresponding structure, such as shown at 21 and 22.
In this respect, if the track structure 13 of the holstering device 14 has one or more rails or tracks 16 or 17, as well as one or more grooves 23 or 24, then the adapters for the different types of weapons may for instance all be configured with one or more groove structures 18 and 19 and with one or more tongue structures 21 and 22, or adapters for some of the weapons 12, 112, 212, 312 may be provided with one or more groove structures 18 and 19, while other adapters for these different types of weapons may be provided one or more tongue structures 21 and 22 instead of groove structures, with all such different adapters fitting into the same standard holster 14 for a holstering of all such different types of weapons.
So far, handguns have been mentioned as hand weapons. However, there are other hand weapons within the scope of the invention, including pepper spray and mace containers, knives or bayonets, intense light sources, high-voltage or stunning devices, etc. etc., that can be holstered by a holstering device 14 standard for different ones of such weapons.
According to embodiments of the invention, the track structure or adapter and the slide structure are provided with or include a detent 28, 33 or 54 for releasably retaining or adapted to releasably retain such slide structure or adapter 15 at the track structure 13. In this manner, the hand weapon 12 is secure against falling out of the holstering device 14, such as when the wearer rolls over or carries out some jumping motion or engages in similar action.
By way of example, FIG. 1a shows a latching device or latch 29 which is provided in the holstering structure 14, such as indicated by the arrow 30 in FIGS. 1 and 1a. The detent 28 also has a notch 31 in the slide structure or adapter 15 that corresponds with the latch 29. That latch may, for instance, be a leaf spring that is attached to the holstering device 14, such as by rivets 32, and that engages or is engaged by the slide structure or adapter 15 at its notch 31 when the hand weapon 12 is holstered in its holster 14.
Some applications and situations require greater safety against loss or removal of the weapon from its holster. Law enforcement and military personnel, for instance, are often exposed to situations in which law breakers or attackers attempt to take away, or even have succeeded in taking away, the hand weapon from its holster, frequently with the intent of injuring its wearer or of committing another crime or assault with the wrested away hand weapon.
Accordingly, a preferred embodiment of the invention provides the holstering device and slide structure or adapter with a detent 33 or 54 which releasably retains or which is adapted to releasably retain the slide structure or adapter 15 at the track structure 13 until a wearer of the holstered hand weapon 12 pulls that hand weapon from the holstering device or, in other words, until the holstered hand weapon is pulled from its holstering device 14 by the wearer of that holstering device.
A preferred embodiment of the invention, such as shown in FIGS. 5 to 7, provides the track structure 13 or other part of the holstering device 14, and the slide structure or adapter 15 with a detent 33 for releasably retaining such slide structure or adapter at that track structure against removal of the holstered hand weapon 12 from its holstering device 14, and, more specifically, provides such detent with a device 34 for sensing a presence of a part of a hand 51 of a wearer of the holstered hand weapon at a predetermined location at that holstering device 14 and deactivates that detent in response to such presence of that part of the hand 51 at that predetermined location 36.
By way of example, the wearer-hand-sensing device 34 includes a lever 37 that is pivoted, such as at 38. The lever 37 carries or is coupled to a latching device or latch 39 that is biased against the slide or adapter structure 15 on the hand weapon 12, such as by a spring 41. In addition to such latch 39, the detent 33 includes a notch 42 in the slide structure 15 that corresponds to the latch 39.
Within the scope of the invention, the biased latch 39 may engage the slide structure or adapter 15 at its notch 42 when the hand weapon is holstered in its holster 14. An assailant thus would be prevented from pulling the hand weapon 12 from its holster 14, as such assailant would have to move the lever 37 effectively while pulling the hand weapon 12 out of its holster 14, all against the will and the resistance of the wearer of the hand weapon.
On the other hand, if the wearer of the holstered hand weapon intends to draw such hand weapon 12 from its holster 14, then such wearer grips the handle or stock 43 of the hand weapon with one hand 51, such as the "gun hand" in the case of a handgun. Simultaneously, the wearer places the side of that one hand 51 along the index finger or trigger finger 52 against the hand sensor 34, thereby pushing or angularly moving the lever 37 about its pivot 38 until the latch 39 is disengaged from the notch 42 in the slide or adapter structure 15. This enables the wearer to draw the weapon 12 without fumbling with leather straps or other prior-art security device which impede a fast draw and thereby impair the value of the weapon and the safety of its user.
A preferred embodiment of the invention even relieves the wearer from any conscious action as far as the safety against unauthorized or violent removal of the weapon from its holster is concerned.
In this respect, FIG. 7 shows a preferred embodiment according to which the latch 39 rest on an unnotched portion 40 of the slide or adapter structure 15 when the weapon 12 is fully inserted in its holster 14.
In this preferred embodiment of the invention, gripping the weapon 12 at its handle or grip 43 automatically prevents the security system 33 from locking the weapon in its holster. The marksman or authorized user can draw the weapon 12 as fast as if no safety 33 were present, with the latch 39 clearing the slide or adapter 15 including its notch 42 all the way, as the side of the user's hand 51 along the index finger or trigger finger 52 slides along the lever 37 at its hand sensor portion 34.
This preferred embodiment of the invention requires no action by the weapon user or shooter other than what shooters always have done in drawing a handgun; namely having the trigger finger 52 outstretched downward outside the holster during the draw for insertion of that trigger finger into the trigger guard area 45 as that trigger finger is bent for actuation of the trigger 46 and possible firing of the weapon.
In this respect and in general, an aspect of the invention resides in a method of holstering an elongate hand weapon 12 and, more specifically, resides in the improvement of providing a holstering device 14, holstering the hand weapon in that holstering device, drawing the hand weapon from that holstering device with a hand 51 having an outstretched finger 52, and blocking removal of the hand weapon from the holstering device upon attempts to remove the hand weapon from the holstering device without the hand having the outstretched finger 52.
An embodiment of the invention provides a method which includes providing the elongate hand weapon 12 and the holstering device 14 with a normally deactivated detent 33 or 39 and 42 at 15 for selectively retaining the hand weapon in the holstering device, and activating such detent only upon attempts to remove the hand weapon from the holstering device without the hand 51 having the outstretched finger 52.
Apparatus within the scope of the currently disclosed aspect of the invention for holstering an elongate hand weapon 12, comprise a holstering device 14 for such hand weapon, and a detent 33 or 39 and 42 at 15 adapted to block removal of the hand weapon from the holstering device upon attempts to remove such hand weapon from that holstering device without a hand 51 having a finger 52 outstretched substantially parallel to the elongate hand weapon 12.
According to the preferred embodiment illustrated in FIGS. 5 to 7, the detent is a normally deactivated detent, such as the detent 39 resting on the unnotched portion 40 of the slide structure or adapter 15 when the weapon 12 is seated in its holster 14. However, such normally deactivated detent is capable of selectively retaining, or is adapted to selectively retain, the hand weapon in its holstering device. In this respect, a detent activator, such as shown at 41, is adapted to activate the detent only upon attempts to remove the hand weapon from the holstering device without the hand 51 having the outstretched finger 52, such as by prompting the detent 39 into the notch 42 when the trigger finger portion of the wearer is missing at the lever or sensor 34 in the area 36.
In this respect, FIG. 5 shows the hand 151 of an assailant whose effort to remove the weapon from the holster is frustrated by the safety mechanism 33.
Within the scope of that aspect of the invention, the holstering device 14 again may be provided with a track structure 13, and the elongate hand weapon 12 is then provided with a slide structure or adapter 15 complementary with that track structure for holstering such slide structure or adapter in the track structure while holstering the elongate hand weapon in the holstering device 14. Moreover, use of safety mechanisms according to aspects of the subject invention is not limited to specific track and slide or adapter structures.
By way of further example, such as shown in FIGS. 8 and 9, detent 54 may releasably retain or may be adapted to releasably retain the slide structure or adapter 15 at the track structure 13 until a wearer of the holstered hand weapon 12 angularly moves that hand weapon and the track structure 13.
According to an embodiment of the invention, the detent 54 is deactivated such as shown in FIGS. 8 to 10 by angular movement of the elongate hand weapon 12 and track structure 13.
For instance, according to the embodiment illustrated in FIGS. 8 to 10, a holstering device 114 includes an angularly moveable portion 56 and a relatively stationary portion 57. By way of example, the holster portion 56 may be pivoted at 58 on the portion 57. A slot and pin arrangement, including a pin 59 and an arcuate slot 60, may be used to limit angular movement or tilt of the hand weapon 12 and holster portion 56, from and between a rest position, such as shown in FIG. 8, in which the holster protion 56 may be held by a spring 61, to a position, such as seen in FIG. 10 in solid outline, which is fully tilted against the bias of the spring 61.
The track structure 13 is on the angularly moveable portion 57. A detent 54 is on the relatively stationary portion 57, and is positioned to engage the slide structure 15 when the hand weapon 12 is in that holstering device 114 prior to angular movement of the angularly moveable portion 56 with the hand weapon 12 relative to the stationary portion 57. The detent or latch 54 may engage the slide portion 15 of the hand weapon 12 at its notch 42, or at its upper end 115 (see FIG. 4) or in any other manner that will retain or block the weapon 12 in its holster 114 against forcible removal.
Within the scope of the invention, the slide structure 15 could simply be removed from the detent 54 as the hand weapon 12 and the track structure 13 and angularly moveable holster portion 56 which it engages are angularly moved prepratory to a draw of the hand weapon 12 from its holster 114.
However, for greater safety, the illustrated embodiment provides a detent deactivator 62 on the angularly moveable portion 56 of the holstering device 114. The detent 54 is located in a path of angular movement of such detent deactivator 59 which is on the angularly moveable portion 56. By way of example, the detent 54 may be resiliently mounted, such as by a leaf spring 63 attached to the stationary portion 57. Such resiliently mounted detent 54 may, for instance, project through an aperture 64 in the angularly moveable portion 56 to engage the slide structure 15 when the weapon 12 and its track structure 13 and angularly moveable holster portion 56 are in their rest position seen in FIG. 8 relative to FIG. 9.
The above mentioned detent deactivator 59 may, for instance, be an edge region 65 of the angularly moveable portion 56 at its aperture 64.
When the wearer of the holstered weapon 12 angularly moves the same, such as with his or her gun hand, so that the moveable holster portion 56 is angularly moved about its pivot 58, the detent deactivator edge 65 of the aperture 64 slides past the detent 54, thereby moving such detent out of the path of the angularly moving weapon 12 and slide portion 15, such as against the bias of the spring 63.
The weapon 12 may thus easily be pulled out of the holstering device with the gun hand. On the other hand, it would be difficult for an assailant to pull the weapon from the modified holster, especially since the wearer of the holstered weapon would not just stand by idly, while an assailant is working on his or her gun.
The adapter or slide structure 15 of or on the hand weapon may be universal for different types of holstering devices, such as for the holstering devices 14 and 114 shown in FIGS. 1, 2, 2A to C, 3, and 5 to 10.
An overall method according to this aspect of the invention may provide the track structure 13 and slide structure 15 with a detent 33 for releasably retaining that slide structure at that track structure against removal of the holstered hand weapon 12 from the holstering device 14. Such detent may be provided with a device 34 for sensing a presence of a part of a hand 51 of a wearer of the holstered hand weapon at a predetermined location 36 at the holstering device 14. The detent 33 may be or may remain deactivated in response to that presence of that part of said hand 51, such as of an outstretched index finger, at predetermined location 36, such as described above in conjunction with FIGS. 5 to 7.
This overall method according to the currently disclosed aspect of the invention also provides the holstering device 114 of FIGS. 8 to 10 as an alternative holstering device, and provides such alternative holstering device 114 with an alternative track structure which is complementary with the slide structure 15, and which may be similar or identical to the track structure 13, variations of which have been disclosed above. This method also provides the alternatvie holstering device 114 with an alternative detent 54 releasably retaining the slide structure 15 at the alternative track structure until a wearer of the holstered hand weapon angularly moves the hand weapon 12 and the alternative track structure 13, such as described above in conjunction with FIGS. 8 to 10 with respect to the angularly moveable holster portion 56.
An overall system as embodied in FIGS. 1, 2, 2A to C, 3, and 5 to 10 may include a detent 33 adapted to releasably retain a universal slide structure 15 at track structure 13 against removal of the holstered hand weapon 12 from holstering device 14. Such detent may include a device 34 adapted to sense a presence of a part of a hand 57 of a wearer of the holstered hand weapon at a predetermined location 36 at holstering device 44, and a device 37 with or without 40, adapted to deactivate detent 33 in response to presence of part of hand 51 at predetermined location 36. An alternative holstering device 114 for hand weapons with like slide structure 15 has an alternative track structure 13 in that alternative holstering device 114 complementary with such slide structure 14 and an alternative detent 54 adapted to releasably retain such slide structure 15 at its alternative track structure until a wearer of the holstered hand weapon angularly moves such hand weapon and the track structure 13 which at this point is designated as alternative, even though the track structure 13 of the embodiments shown in FIGS. 1, 2, 2A to C, 3, and 5 to 10 may be identical within the scope of the invention.
Hand weapon users thus are able to chose between different holstering systems.
Different people have different preferences, and the same people have different preferences for different tasks. For instance, where levers of the type shown at 37 in FIGS. 5 to 7 are disfavored, people likely would opt for the embodiment of FIGS. 8 to 10 that affords safety against violent hand weapon removal while requiring less of a conscious effort of the wearer to remove the weapon from its holster than do prior-art safety systems.
True professionals, however, likely will opt for the system exemplified in FIGS. 5 to 7, since that permits drawing of the hand weapon 12 without conscious effort as far as the detent 33 against violent removal is concerned. Especially where the detent 33 is uncocked by the upper slide portion 40 and remains uncocked during the entire draw by nothing more than the wearer's gun hand 51, the wearer does not have to do anything that he or she does not do already during the draw; namely, stretch down his or her trigger finger 52 ready for insertion into the trigger area 45 as soon as the weapon 12 is out of the holster.
The same person, police department or agency may, however, own or possess two or more of the embodiments herein disclosed, for different tasks or situations.
By way of example, the holstering device 14 may be worn on a belt 47 and, for that purpose, may be provided with or may include a belt loop structure 48 that may be attached to or integral with the holster proper. However, the part 47 also may be symbolic of waist band and shoulder straps, and the like, within the scope of the invention.
Moreover, the subject extensive disclosure will render apparent or suggest to those skilled in the art various modifications and variations within the spirit and scope of the invention.
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Holstering systems for hand weapons comprise a track structure provided as a holster for such hand weapons. Each hand weapon may be provided with an adapter complementary with the track structure. The holster may be a standard holster for different types of elongate hand weapons that may have adapters interfacing with such standard holster. Such holsters may have an accommodation for accessories. Security holsters prevent accidental and unauthorized removal of weapons from holsters, such as with the aid of detents, sensors of a hand of a wearer, or other detent deactivators.
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FIELD
The present disclosure relates to a cylindrical heat applying device and more particularly to a cylindrical heat applying device for applying pressure and heating protective coverings on suspension bridge cables and the like.
BACKGROUND
The statements in this section merely provide background information related to the present disclosure and may or may not constitute prior art.
The cables of suspension bridges and cable stayed bridges as well as similar lengthy tubular metal articles utilized outdoors are frequently subjected to severe environmental and climatic conditions. Even if conditions are relatively mild, the initial investment and the expected, extended service life demand that all practical efforts be undertaken to maintain the structure. Typically, therefore, such cables and articles are painted or otherwise coated to minimize rusting or other deterioration from such exposure. Although protected with suitable weather resistant paint or other coatings, periodic repainting or recoating of such cables and articles is invariably necessary. Such activity is costly and time consuming because of the relative inaccessibility of such cables. The cost and time involved are further increased because proper maintenance practice generally dictates removal of the previous paint or coating. Such removal typically raises environmental issues.
An alternative to such repeated repainting or recoating involves permanent application of a spiral or helical wrap of a Neoprene or similar polychloroprene band or strip about the cable or article. This approach to cable protection was not without drawbacks, however. First of all, the Neoprene could not be colored and thus, after application, if it was desired that the cable covering match the rest of the structure, it would still require painting. Second of all, it was necessary to seal adjacent layers of the wrap to one another with a solvent. This again was a labor intensive undertaking.
An improvement to this approach comprehends the application of a spiral wrap of Hypalon® to the cable or article. Hypalon is a registered trademark of the E.I. DuPont de Nemours Company for its brand of chlorosulfonated polyethylene. This material can be sealed to itself with the application of sufficient heat and thus eliminates the above-noted solvent sealing step. The use of a heat sealed spiral wrap of a band or strip of Hypalon® is described in detail in co-owned U.S. Pat. No. 5,390,386. Study of the subject patent reveals that proper sealing of the adjacent wraps or layers of Hypalon® is dependent upon sufficient and uniform application of heat to the exterior of the wrapped cable.
Because the various strands and cables that constitute the suspension cable do not assemble and nest uniformly, the outer surface of the suspension cable is irregular. Such an irregular surface, of course, is generally duplicated by the spiral wrapped band or strip, rendering uniform heat application difficult: protruding regions are in intimate contact with a heating device and may receive excessive heat while recessed regions may not contact the heating device and thus receive little heat. The present invention is directed to ensuring the sufficient and uniform application of heat to the exterior of the wrapped cable to provide the optimum protection to the cable and therefore its longest life with reduced maintenance expense.
SUMMARY
The present invention provides a heat application apparatus in the form of a split cylinder or clamshell that may be disposed about a section of a suspension bridge cable or similar tubular article. The cylinder is split lengthwise into two essentially identical semi-cylindrical halves which are pivotally connected by an elongate hinge. A plurality of toggle clamps are arranged transversely across the opens ends of the halves and may be engaged to positively connect and lock the edges together. On each of the inner faces of the halves is secured a semi-cylindrical air bladder. The bladders are covered by a flexible heat blanket having an electrical resistance heating element uniformly distributed over its area. Independent air pressure regulators which provide compressed air at low pressure to the bladders and a suitable electrical connector all reside on the exterior of the apparatus. Optionally, an air compressor may be mounted on each half to supply each air bladder independently, thereby configuring the apparatus so that it requires only electrical power to operate.
In operation, the apparatus is connected to suitable sources of electricity and compressed air, or only electrical power if the optional air compressors are utilized. The toggles are unlatched and released and the halves are opened, placed about a cable or other article, closed and the toggles relatched. The air bladders are then filled with compressed air to a pressure of between about 1 p.s.i. and 10 p.s.i. and the heater is activated for a prescribed time to heat and seal the wrapped layers of the cable or other article.
Thus it is an aspect of the present invention to provide a heat application apparatus for suspension bridge cables and similar tubular articles.
It is a further aspect of the present invention to provide a heat application apparatus having a cylindrical body that is split into two semi-cylindrical halves.
It is a still further aspect of the present invention to provide a heat application apparatus having a cylindrical body that is split into two semi-cylindrical halves which are pivotally joined by an elongate hinge.
It is a still further aspect of the present invention to provide a heat application apparatus having a cylindrical body that is split into two semi-cylindrical halves which may be releasably closed by toggle clamps.
It is a still further aspect of the present invention to provide a heat application apparatus having two semi-cylindrical halves each including an air bladder.
It is a still further aspect of the present invention to provide a heat application apparatus having two semi-cylindrical halves each including a electrical heating blanket.
It is a still further aspect of the present invention to provide a heat application apparatus having two-semi-cylindrical halves each having an independent air supply.
Further aspects, advantages and areas of applicability will become apparent from the description provided herein. It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure, invention or claims.
DRAWINGS
The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure, invention or claims in any way.
FIG. 1 is perspective view of a cylindrical heat application apparatus according to the present invention in place on a suspension bridge cable shown in phantom lines;
FIG. 2 is an end elevational view of a cylindrical heat application apparatus according to the present invention in an open position;
FIG. 3 is an enlarged, fragmentary end view of a cylindrical heat application apparatus according to the present invention showing the mounting of the air bladder and heat blanket with the toggles in the locked position;
FIG. 4 is an enlarged, fragmentary end view of the hinge of a cylindrical heat application apparatus according to the present invention showing the mounting of the air bladder and heating blanket;
FIG. 4A is a greatly enlarged, fragmentary, sectional view of a first embodiment of a heating blanket utilized in the present invention;
FIG. 5 is an enlarged, fragmentary end view of an alternate embodiment of the heating blanket of the apparatus according to the present invention showing the mounting of the air bladder and heating blanket;
FIG. 5A is a greatly enlarged, fragmentary, sectional view of a second embodiment of a heating blanket utilized in the present invention;
FIG. 6 is a fragmentary perspective view of a cylindrical heat application apparatus according to the present invention showing the air supply components; and
FIG. 7 is a fragmentary perspective view of a cylindrical heat application apparatus according to the present invention showing the electrical input connector.
DETAILED DESCRIPTION
The following description is merely exemplary in nature and is not intended to limit the present disclosure, invention, claims, or use.
With reference to FIGS. 1 and 2 , a cylindrical heat application apparatus for use with cables on conventional suspension bridges, cable stayed bridges and other tubular or cylindrical articles or components of indefinite length is illustrated and designated by the reference number 10 . The heat application apparatus 10 is shown in place in a suspension bridge cable 12 having a core 14 of a plurality of wound strands, ropes and cables that is spirally or helically wrapped by a strip or band 16 of a heat sealable, thermoplastic material such as Hypalon®, as described in U.S. Pat. No. 5,390,386.
The heat application apparatus 10 is essentially a longitudinally split hollow cylinder or tube of a convenient length, typically between two and four feet (0.617 to 1.23 meters). The diameter, in turn, is dependent upon the outside diameter of the cable 12 or other article upon which the heat application apparatus 10 will be utilized. Typically, the nominal inside diameter of the apparatus 10 will be approximately one to three inches (25 to 76 millimeters) larger than the cable 12 or other article with which it will be utilized. Thus, it should be appreciated that the nominal diameter of the apparatus 10 may be as small as one foot (0.308 meters) or less to as large as four feet (1.23 meters) or more.
The heat application apparatus 10 comprises a first or left semi-cylindrical half or portion 20 A and a second or right semi-cylindrical half or portion 20 B pivotally secured together along adjacent longitudinal edges by a preferably full length, piano style hinge 30 having a first flange 32 A attached to the first or left semi-cylindrical half or portion 20 A and a second flange 32 B attached to the second or right semi-cylindrical half or portion 20 B as will be more fully described below. Alternatively, a plurality of separate, longitudinally spaced-apart hinges may be employed to pivotally connect the first and second halves or portions 20 A and 20 B. In most respects, the first cylindrical portion 20 A and the second cylindrical portion 20 B are symmetrical, mirror images of one another. Thus, only the first or left semi-cylindrical half or portion 20 A will be fully described, it being understood that such full description applies equally to the second or right semi-cylindrical half or portion 20 B and that any differences between them are also described.
The first semi-cylindrical half 20 A includes a first rigid semi-cylindrical body panel 22 A which is attached to the first flange 32 A of the hinge 30 by suitable fasteners 24 such as rivets, machine bolts and nuts, self-threading screws and the like. Depending upon the materials from which the first body panel 22 A and the first hinge flange 32 A are constructed and other design and construction considerations, more permanent attachment means such as welding may also be utilized.
The first rigid semi-cylindrical body panel 22 A includes a curved outside surface 26 A and a curved inside surface 28 A. Disposed on the outside surface 26 A of the first body panel 22 A are a pair of spaced apart semi-circular braces or reinforcements 34 A. The braces 34 A each include a flat, lower portion 36 A adjacent the hinge 30 which serve as feet to maintain the apparatus 10 in an upright and non-rolling disposition for transport and when not in use. The braces 34 A are preferably secured by welding to the outside surface 26 A of the first body panel 22 A. The braces or reinforcements 34 A are intended to maintain the integrity and the circularity of the apparatus 10 against the hoop stress generated when it is in use. Accordingly, although the apparatus 10 illustrated in FIG. 1 utilizes two of the braces 34 A, as the diameter of the apparatus 10 increases, additional braces 34 A may be both desirable and utilized. In addition to preventing longitudinal warpage of the apparatus 10 , the braces or reinforcements 34 A also function as handles which an operator can grip to maneuver the apparatus 10 . Extending longitudinally between the braces or reinforcements 34 A are a plurality of stabilizing beams or rods 38 A. Once again, while three of the stabilizing beams or rods 38 A are illustrated, more may be utilized as the size of the apparatus 10 increases.
Referring now to FIGS. 1 , 2 and 3 , at the top of the apparatus 10 , opposite the hinge 30 are a plurality of toggle clamp assemblies 40 . On one side, for example, on the first or left semi-cylindrical half or portion 20 A are a plurality of hooks 42 arranged in a line parallel to the adjacent edge of the first semi-cylindrical body panel 22 A. On the other side, for example, the second or right semi-cylindrical half or portion 20 B are a like plurality of complementary toggle clamps 44 also arranged in a line along the adjacent edge of the second semi-cylindrical body panel 22 B. Each of the toggle clamps 44 includes a U-shaped strap 46 secured to an over-center pivoted handle 48 . To close and secure the two halves or portions 20 A and 20 B together, they are moved into the position illustrated in FIG. 3 , the straps 46 are placed over the hooks 42 and the handles 48 are moved from the position illustrated in FIG. 2 to the position illustrated in FIG. 3 .
Referring now to FIGS. 3 , 4 and 4 A, on the inside surface 28 A of the first body panel 22 A is a flexible air bladder panel 50 A. The air bladder panel 50 A is sealingly secured along the edges of the inside surface 28 A of the first body panel 22 A by a silicone adhesive 52 or similar material that provides an air-tight seal and defines a first air chamber 54 A with the first body panel 22 A. Alternatively, aluminum strips over the edges of the air bladder panel 50 A with fasteners may be utilized as a holddown. Extending over the surface of the air bladder panel 50 A is a first flexible heating blanket 60 A. The first heating blanket 60 A is preferably fabricated of a heat resistant flexible material such as silicone rubber and includes an embedded electrical resistance heating element 62 A. The heating element 62 A is preferably arranged in a zig-zag pattern in parallel strips or bands having a width of from two to three inches (51 to 76 millimeters). The first heating element 62 A is preferably designed to generate and dissipate between about 2 and 7 watts per square inch.
The first heating blanket 60 A also includes a peripheral region 64 A which lacks the heating element 62 A and which is wrapped around three edges of the first body panel 22 A and secured there by elongate retaining plates or strips 66 A and a plurality of suitable fasteners 68 A or other attachment means which extend through suitable openings in the strips 66 A, the first body panel 22 A and two layers of the first heating blanket 60 A. The inner retaining plate or strip 66 A may either include threaded openings complementary to the fasteners 68 A or may be unthreaded and thus require nuts (not illustrated).
It will be appreciated that the hinge 30 including the first flange 32 A and the second flange 32 B pivotally connects the first body panel 22 A to the second body panel 22 B. The edges of the air bladder panels 50 A and 50 B are secured to the inside surfaces 28 A and 28 B of the body panels 22 A and 22 B by the silicone adhesive 52 or similar material adjacent the hinge 30 . The longitudinal edges of the heating blankets 60 A and 60 B, including the regions 64 A and 64 B without the heating elements 62 A and 62 B are secured to the respective edges of the first body panel 22 A and the second body panel 22 B with additional elongate plates or strips 66 A and 66 B and the plurality of suitable fasteners 24 .
Referring now to FIGS. 5 and 5A , an alternate embodiment of the heating blanket which improves uniformity of heat application is illustrated. The embodiment is the same with regard to the body panels 22 A and 22 B, the hinge 30 , the toggle assemblies 40 , the bladder panels 50 A and 50 B and the elongate plates or strips 66 A and 66 B along the hinge 30 . Each of the heating blankets 72 A and 72 B includes a pair of flexible, spaced-apart panels or electrodes 74 which are co-extensive with and are in intimate electrical contact with an inner resistive layer or element 76 . A thin, preferably electrically insulating outer protective layer or skin 78 may be formed on or disposed over the outside surfaces of the panels or electrodes 74 . The heating blankets 72 A and 72 B provide exceedingly uniform heat and heat application. More importantly, the heating blankets 72 A and 72 B provide heat along their edges or extremities and holes or perforations may be cut or formed in the blankets 72 A and 72 B at any location so long as the panels or electrodes 74 remain separated, i.e., not in electrical contact.
To ensure this, the fasteners 24 ′ are fabricated of nylon or other rugged, electrically insulating material. It will thus be appreciated that, as illustrated in FIG. 5 , the edges of the heating blankets 72 A and 72 B may be overlapped slightly to ensure more uniform and improved heat application. It should be understood, however, that the heating blankets 72 A and 72 B are not wrapped around the edges of the first and second semi-cylindrical halves or portions 20 A and 20 B. Rather, they are attached along the edges of the hinge 30 and the rest of the heating blankets 72 A and 72 B float and the remaining edges hang free as this type of heating element cannot be wrapped around an edge as the panels or electrodes 74 are thin but relatively rigid structures.
Referring now to FIG. 6 , each of the first and second semi-cylindrical halves or portions 20 A and 20 B of the apparatus 10 also includes an independent air supply assembly 80 A and 80 B. The first air supply assembly 80 A includes a first manifold 82 A having a quick release connector 84 A at one end. The quick release connector 84 A may be coupled to a hose having a complementary connector which is in communication with a source of compressed air (all not illustrated). Additionally and optionally, if it is desired that the apparatus 10 require only electrical power in order to operate, a first small electrically powered air compressor 86 A may be mounted to the exterior surface 26 A of the first body panel 22 A with its output provided to the first manifold 82 A. The first manifold 82 A communicates with the first air chamber 54 A through a suitable fitting 88 A. Also in fluid communication with the first manifold 82 A is a first pressure gauge 90 A. The first pressure gauge 90 A preferably has a range of approximately zero to fifteen or twenty p.s.i. Also in fluid communication with the manifold 82 A is a manually activated pressure release valve 92 A. The pressure release valve 92 A is activated to reduce air pressure or release air within the first air chamber 54 A at the end of a heating cycle or at other times.
Referring to FIGS. 1 , 2 , 3 and 4 , the second or right semi-cylindrical half or portion 20 B is, as noted above, essentially a mirror image of the first or left semi-cylindrical half or portion 20 A. Thus, it includes an outside surface 26 B having a plurality of braces 34 B including the flat lower portions 36 B, a plurality of stabilizing rods 38 B, an inside surface 28 B, a portion of the toggle clamp assemblies 40 , an air bladder panel 50 B defining a second air chamber 54 B, a heating blanket 60 B having an electrical resistance heating element 62 B as well as retaining plates 66 B and suitable fasteners 68 B. It also includes the second air supply assembly 80 B having a second manifold 82 B, a second quick release connector 84 B, an optional second air compressor 86 B, a second fitting 88 B, a second pressure gauge 90 B and a second pressure relief valve 92 B.
Referring now to FIG. 7 , the apparatus 10 includes a single electrical connector assembly 100 which may be secured to the outside surface 26 B of the second body panel 22 B at any convenient location. The electrical connector assembly 100 includes a housing 102 having a pivoting and locking cover 104 which protects a plurality of electrical terminals 106 which are connected to various conductors in a cable 110 . The cable 110 terminates at one or more junctions or feed-throughs 112 where the conductors are connected to the wires of the heating elements 62 A and 62 B or to the electrodes 74 . The conductors in the cable 110 provide electrical energy to the heating blankets 60 A and 60 B (or 72 A and 72 B) and the compressors 86 A and 86 B, if the heat application apparatus 10 is so equipped.
In operation, the heat application apparatus 10 is opened wider than the position illustrated in FIG. 2 and placed about a portion of a suspension bridge cable 12 or other cylindrical article. The halves 20 A and 20 B are then closed about the cable 12 or other article and the toggle clamp assemblies 40 engaged and locked. Next, the individual air bladders 54 A and 54 B are filled to an appropriate pressure, preferably between approximately one and five p.s.i. Finally, electrical energy is applied to the heating elements 62 A and 62 B (or 72 A and 72 B) and sufficient heat is applied to the strip or band 16 of cable wrap to cure and/or seal the layers together. The air is then released from the air bladders 54 A and 54 B through the pressure relief valves 92 A and 92 B, the toggle clamp assemblies 40 are released, the apparatus 10 opened and repositioned on the cable 12 or other article. These steps are repeated until the heating and curing or sealing is completed along the length of the cable 12 or other article.
The description of the invention is merely exemplary in nature and variations that do not depart from the gist of the invention are intended to be within the scope of the invention. Such variations are not to be regarded as a departure from the spirit and scope of the invention.
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A heat application apparatus includes a longitudinally split cylinder that may be disposed about a section of a suspension bridge cable or similar tubular article. The cylinder is split into two essentially identical semi-cylindrical halves which are pivotally connected by an elongate hinge. A plurality of toggle clamps are arranged transversely across the opens ends of the halves and may be engaged to positively connect and lock the edges together. On each of the inner faces of the halves is secured a semi-cylindrical air bladder. The bladders are covered by a flexible heat blanket having a uniformly distributed electrical resistance heating element. Independent air pressure regulators which are supplied with compressed air provide air at low pressure to the bladders and a suitable electrical connector all reside on the exterior of the apparatus. Optionally, an air compressor may be mounted on each half to supply each regulator and bladder independently, thereby configuring the apparatus so that it requires only electrical power to operate.
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[0001] This application claims priority to U.S. provisional application Ser. No. 10/581,047 filed Jun. 18, 2004 to the extent permitted by law.
BACKGROUND
[0002] The present disclosure relates to a heat dissipating device and a method of dissipating heat away from a heat emitting component. In particular, the present disclosure relates to a heat dissipater which dissipates heat from an appliance positioned within a vehicle.
[0003] In the recreational vehicle and the boating industry, manufacturers or retailers install appliances such as refrigerators into the vehicle or a boat to provide the user more comfort in using the vehicle/boat. In locating a refrigerator within an enclosure of the vehicle, however, access to the back of the refrigerator must be considered since the back of the refrigerator houses components such as compressors and heat fins. As such, the position of the refrigerator must present accessibility from the outside through the side wall of the vehicle for maintenance purposes. Additionally, the location of the refrigerator must be considered for heat transfer purposes since components such as the compressor and heat fins emit heat during use. This emitted heat must be dissipated out of the vehicle enclosure in order for the appliance unit to work properly.
SUMMARY
[0004] The present disclosure relates to a heat dissipater and a method of dissipating heat away from a heat generating device. In particular, the present disclosure relates to a heat dissipater which removes heat from an appliance positioned within a vehicle. In an embodiment, the heat dissipating device comprises a housing positioned within the enclosure. The housing has an intake, an exhaust and a body positioned between the intake and the exhaust, wherein the body is positioned to surround at least one component which is positioned within the enclosure and which is adapted to emit heat within the enclosure. The intake is adapted to direct an amount of air medium, which is positioned within the enclosure, into the body. The body is adapted to direct the amount of air medium from the intake and over the at least one component which emits heat within the body, wherein the emitted heat from the at least one component causes a temperature differential within the body such that the amount of air medium flows through the body. The exhaust is adapted to direct the amount of air medium, which is flowing through the body as a result of the temperature differential, to a position beyond the enclosure.
[0005] In an embodiment, the present disclosure relates to a method of dissipating heat emitted by a component. The method comprises removably positioning a housing within the vehicle enclosure such that the housing surrounds the at least one component. Next, a temperature differential is created within the body by emitting heat from the at least one component in order to heat an amount of air medium which is positioned within the housing wherein the heated air medium flows through the housing as a result of the temperature differential. Then, the vehicle enclosure is cooled by directing the amount of air medium out of the vehicle enclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] The detailed description particularly refers to the accompanying figures in which:
[0007] FIG. 1 illustrates in a perspective view a heat emitting appliance such as a refrigerator positioned within a vehicle enclosure;
[0008] FIG. 2 illustrates in a perspective view a heat dissipating device which covers portions of the heat emitting appliance of FIG. 1 ;
[0009] FIG. 3 illustrates in a perspective view at least one air handler coupled to the heat dissipating device;
[0010] FIG. 4 illustrates in a perspective view at least one channel coupled to the heat dissipating device;
[0011] FIG. 5 illustrates in a perspective view another embodiment of the at least one channel coupled to the heat dissipating device;
[0012] FIGS. 6A-6C illustrate in perspective views other embodiments of the at least one channel coupled to an exhaust of the heat dissipating device and coupled to the enclosure;
[0013] FIGS. 7A-7C illustrate in perspective views other embodiments of the at least one channel coupled to an intake of the heat dissipating device and coupled to the enclosure; and
[0014] FIG. 8 illustrates in a side elevational view the heat dissipating device and heat emitting appliance positioned within the vehicle enclosure.
DESCRIPTION
[0015] FIG. 1 illustrates in a perspective view a heat emitting appliance 10 such as a refrigerator positioned within an enclosure 12 such as a vehicle enclosure, wherein the enclosure 12 contains an amount of air medium 14 . The appliance 10 may include at least one component 16 such as a cooling unit 18 , an evaporator 20 , coils 22 , and heat fins 24 which may emit heat during use. Typically, the appliance 10 is positioned within the enclosure 12 defined by a roof 26 , a floor 28 and side walls 30 wherein the roof 26 may include a vent 32 . Since the appliance 10 is positioned within the enclosure 12 and away from the vent 32 , the heat 34 emitted by the components 16 cannot easily escape away from the appliance 10 . As such, the enclosure 12 experiences an increase in temperature leading to failure of the heat emitting appliance 10 among other undesirable consequences.
[0016] Turning to FIG. 2 , a heat dissipating device 36 is shown removably connected to the appliance 10 . In an embodiment, the heat dissipating device 36 may include a housing 38 having a body 40 which includes a front 42 , sides 44 , a top 46 and a bottom 48 . The sides 44 and bottom 48 form an intake 50 while the sides 44 and top 46 form an exhaust 52 . As such, the body 40 is positioned between the intake 50 and the exhaust 52 . The top 46 may taper outward from the sides 44 to form the exhaust 52 wider than the intake 50 . In an embodiment, the intake 50 and exhaust 52 may remain free from contacting the floor 28 and the roof 26 respectively. In this embodiment, the intake 50 may be positioned above the floor 28 such that the intake 50 is exposed to the enclosure 12 to direct movement of the air medium 14 as will be discussed. Additionally, the exhaust 52 may be exposed to the enclosure 12 to direct the air medium 14 toward the vent 32 as will be discussed. As illustrated, the body 40 partially surrounds the at least one component 16 ( FIG. 1 ) of the appliance 10 .
[0017] The heat dissipating device 36 may also comprise a divider 54 such as a panel, wherein the divider 54 is positioned between the housing 38 and the side wall 30 of the enclosure 12 . As such, the divider 54 extends outward from the front 42 of the housing 38 to the side walls 30 of the enclosure 12 . The divider 54 may extend perpendicularly from the housing 38 to the side walls 30 . The divider 54 may also extend at an angle from the housing 38 to the side walls 30 . In an embodiment, the divider 54 may be positioned between the intake 50 and the exhaust 52 to separate the enclosure 12 ( FIG. 8 ) as will be discussed.
[0018] The heat dissipating device 36 further comprises at least one air handler 56 , wherein the at least one air handler 56 may be positioned adjacent to the intake 50 as illustrated in FIG. 2 . In other embodiments, however, the at least one air handler 56 may be positioned on the sides 44 of the body 40 . In an embodiment, the at least one air handler 56 may comprise a fan. The at least one handler 56 is adapted to force the amount of air medium 14 through the intake 50 , the body 40 and out of the exhaust 52 .
[0019] Turning to FIG. 3 , the at least one air handler 56 may be coupled to the housing 38 , wherein the at least one air handler 56 draws the amount of air medium 14 through the body 40 and out of the exhaust 52 in this embodiment. In an embodiment, the at least one air handler 56 may be positioned between the intake 50 and the exhaust 52 . In an embodiment, the at least one air handler 56 may be horizontally coupled near the top 46 and in alignment with the exhaust 52 . In an embodiment, the at least one air handler 56 may be vertically coupled near the top 46 on either the front 42 or walls 44 (not shown).
[0020] Turning to FIG. 4 , the heat dissipating device 36 may further comprise at least one channel 57 coupled to the exhaust 52 such that the at least one channel 57 is in communication with the body 40 of the heat dissipating device 36 . In this embodiment, a cover 58 may be positioned over the exhaust 52 in order to direct the air medium 14 from the body 40 , through the exhaust 52 and into the at least one channel 57 . The at least one channel 57 may extend beyond the enclosure 12 , wherein the at least one channel may extend into the vent 32 . In an embodiment, the at least one channel 57 may include an opening 60 . The opening 60 is adapted to direct the air medium 14 , which may be at ambient temperature, into the channel 57 to assist in cooling the channel 57 and the housing 38 .
[0021] Turning to FIG. 5 , the heat dissipating device 36 may further comprise the at least one channel 57 coupled to the at least one air handler 56 . In this embodiment, the cover 58 may be positioned over the exhaust 52 in order to direct the air medium 14 from the body 40 , through the at least one air handler 56 and into the at least one channel 57 . The at least one channel 57 may extend beyond the enclosure 12 , wherein the at least one channel may extend into the vent 32 . In an embodiment, the at least one air handler 56 may be positioned within the at least one channel 57 .
[0022] Turning to FIGS. 6A-6C , the heat dissipating device 36 of the present disclosure may comprise coupling the exhaust 52 to the enclosure 12 by the at least one channel 57 such that the exhaust 52 is in communication with an environment beyond the enclosure 12 . In an embodiment, the exhaust 52 may be coupled to the top 46 of the enclosure as shown in FIG. 6A . In an embodiment, the exhaust 52 may be coupled to the side walls 30 of the enclosure 12 as shown in FIG. 6B . In an embodiment, the exhaust 52 may be coupled to the floor 28 of the enclosure 12 as shown in FIG. 6C .
[0023] Turning to FIGS. 7A-7C , the heat dissipating device 36 of the present disclosure may comprise coupling the intake 50 to the enclosure 12 by the at least one channel 57 such that the intake 50 is in communication with an environment beyond the enclosure 12 . In an embodiment, the intake 50 may be coupled to the top 46 of the enclosure as shown in FIG. 7A . In an embodiment, the intake 50 may be coupled to the side walls 30 of the enclosure 12 as shown in FIG. 7B . In an embodiment, the intake 50 may be coupled to the floor 28 of the enclosure 12 as shown in FIG. 7C .
[0024] Turning to FIG. 8 and referring to FIGS. 1-7 , during use, the heat emitting appliance 10 is positioned within the vehicle 62 . When positioned, the front, such as a door, of the heat emitting appliance 10 faces the vehicle interior 64 while the at least one component 16 faces the vehicle enclosure 12 . The heat dissipating device 36 is removably positioned within the vehicle enclosure 12 such that the housing 38 is attached to the heat emitting appliance 10 to surround the at least one component 16 . The heat dissipating device 36 may be removably attached to the appliance 10 to provide convenient access to the components 16 .
[0025] When activated, the components 16 ( FIG. 1 ) of the appliance 10 emit heat. The emitted heat creates a temperature differential within the body 40 to heat the amount of air medium 14 positioned within the housing 38 , wherein the heated air 14 flows through the housing 38 as a result of the temperature differential. The heat dissipating device 36 is adapted to channel the heat upward and away from the appliance 10 via convection since heat will travel from a hotter medium to a cooler medium. As the heated air 14 expands and rises upward through the housing 38 , convection of the heated air 14 draws in cooler fresh air 14 from the intake 50 while emitting the heated air 14 out of the exhaust 52 . Since the intake 50 is positioned above the floor 28 , the air 14 within the enclosure 12 easily transfers into the housing 38 . As such, the heat dissipating device directs the air 14 within the enclosure 12 across the components 16 . The heat dissipating device 36 then channels the heated air 14 away from the components 16 toward the vent 32 while drawing in cool air across the components 16 , thereby cooling the vehicle enclosure 12 by directing the heated air 14 out of the vehicle enclosure 12 . The divider 54 of the heat dissipating device 36 prevents the heated air 14 which has exited the exhaust 52 of the housing 38 from re-entering the intake 50 of the housing 38 .
[0026] In an embodiment, the at least one air handler 56 , which may be positioned adjacent to the intake 50 , may activate in order to provide forced flow to assist in dissipating heat away from the components 16 while drawing in cooler air 14 through the intake 50 . The at least one air handler 56 , which may be coupled to the housing 38 , may activate to draw the heated air 14 through the housing 38 . The at least one air handler 56 may be coupled to the housing 38 near the exhaust 52 to draw the air 14 across the components 16 . As such, the at least one air handler 56 transfers the air 14 through the housing 38 and across the components 16 to transfer the heat emitted by the components 16 toward the vent 32 . Additionally, during use, the divider 54 separates the enclosure 12 to prohibit heated air 14 emitted from the exhaust 52 to be re-circulated into the intake 50 via either convection or forced flow from the at least one air handler 56 .
[0027] In other embodiments, the at least one channel 57 may connect to the exhaust 52 to connect the exhaust 52 to the enclosure 12 such that the exhaust 52 communicates with an environment beyond the enclosure 12 . The at least one channel 57 may connect to the intake 50 to connect the intake 50 to the enclosure 12 such that the intake 50 communicates with an environment beyond the enclosure 12 . In an embodiment, the at least one air handler 56 may be positioned within the at least one channel 57 to assist in the forced flow to dissipate the heated air 14 out of the dissipater 32 . In another embodiment, the at least one air handler 56 may also be positioned within the vent 32 and in communication with the at least one channel 57 in order to dissipate the heated air 14 out of the enclosure 12 .
[0028] While the present disclosure describes refrigerators, it is understood that the present disclosure is not limited to the appliance described in the disclosure. Additionally, while the concepts of the present disclosure have been illustrated and described in detail in the drawings and foregoing description, such an illustration and description is to be considered as exemplary and not restrictive in character, it being understood that only the illustrative embodiments have been shown and described and that all changes and modifications that come within the spirit of the disclosure are desired to be protected by the following claims.
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A heat dissipater and a method of dissipating heat. The present disclosure relates to a heat dissipating device which dissipates heat out of an enclosure. The device comprises a housing positioned within the enclosure, wherein the housing has an intake and an exhaust. The device further comprises an air medium disposed within the enclosure. At least one air handler in communication with the housing transfers the air medium through the housing and out of the enclosure. The present disclosure relates to a method of dissipating heat generated by a component comprising disposing a housing within an enclosure, the enclosure having the component which generates heat. Next, a convection is maintained through the housing and across the component. Cooling is then performed by channeling the air out of the enclosure.
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BACKGROUND
Customers use databases from external providers to store data. There are many reasons to move from one database (DB) to another DB—better performance, change in data received from external providers, corporate policy to move to a new DB, etc.
Customers need to make a lot of changes to make an application compatible with a new DB. They have to migrate all their Business Objects content namely: universes, reports and other dependent components. It is a huge task to make all of these compatible with a new DB. A lot of time is expected to be needed for creating and tuning Universes.
Potential problems with a new DB may be that each DB has its own way of supporting Structured Query Language (SQL); tables and views are case sensitive; a qualifier added to identify the table and view varies in each DB; DB specific parameters need to be re-mapped to a new DB, etc. Another problem may be if not all tables are present in a DB. Some objects in a universe may have reference in queries and may not be part of the schema.
BRIEF DESCRIPTION OF THE DRAWINGS
The claims set forth the embodiments with particularity. The embodiments are illustrated by way of examples and not by way of limitation in the figures of the accompanying drawings in which like references indicate similar elements. The embodiments, together with its advantages, may be best understood from the following detailed description taken in conjunction with the accompanying drawings.
FIG. 1 is a block diagram illustrating a semantic layer (universe) and its connections to a database and reporting servers.
FIG. 2 is a flow diagram illustrating an embodiment of a method for universe migration from a source database (DB) to a target DB.
FIG. 3 is a flow diagram illustrating an embodiment of a method for examining a source universe.
FIG. 4 is a flow diagram illustrating an embodiment of a method for creating a new data foundation in a target DB.
FIG. 5 is a block diagram illustrating an embodiment of a system for universe migration from a source database (DB) to a target DB.
FIG. 6 is a block diagram illustrating an embodiment of a computing environment in which the techniques described for universe migration from a source database (DB) to a target DB can be implemented.
DETAILED DESCRIPTION
Embodiments of techniques for universe migration from a source database (DB) to a target DB are described herein. In the following description, numerous specific details are set forth to provide a thorough understanding of the embodiments. One skilled in the relevant art will recognize, however, that the embodiments can be practiced without one or more of the specific details, or with other methods, components, materials, etc. In other instances, well-known structures, materials, or operations are not shown or described in detail.
Reference throughout this specification to “one embodiment”, “this embodiment” and similar phrases, means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one of the one or more embodiments. Thus, the appearances of these phrases in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments.
There are many Business Intelligence (BI) products that provide insight into customer data. There are also many report based solutions that allow customers to analyze and create ad-hoc reporting on the data. Universe is a semantic layer that hides database details and gives business perspective. It allows end users easy way to understand customer data. It hides all the database internals and also it contains various parameters that would help users to tune queries and improve the performance. FIG. 1 represents a semantic layer (universe) 110 and its connections to a database 120 and reporting servers 130 , 140 . Customers create universes on a database in a generic way that can cater the needs of hundreds of reports. Many reporting solutions use universes as input for creating ad-hoc report for analysis. Universe designers spend a lot of time in designing universes as being input for ad-hoc reporting and analysis. A universe contains components that can be divided in to two categories: visual components and data foundation. Visual components are used for reporting and are also called objects. They are dimensions, details, measures and filters. The end-users choose combination of objects to create reports. Data foundation includes database schema and various parameters. A database schema is a graphical representation of DB structures. The database schema contains physical tables, views and virtual tables (based on, for example, Structure Query Language (SQL) queries that provide a result). The database schema also contains relations between the tables (primary key, foreign key etc.) and joins (left outer, left inner, right outer, right inner). The joins link tables so that correct data is returned for queries. All the information is used to generate queries during the report creation. The various parameters are used for report creation, customization and performance tuning.
FIG. 2 is a flow diagram illustrating an embodiment of a method 200 for universe migration from a source database (DB) to a target DB. At block 210 , a source universe using a source connection to a source DB is selected for migration. The source universe is a currently used semantic layer that uses the source DB for data persistency. The source universe may be, for example, semantic layer 110 , and the source DB may be such as DB 120 . A target connection to a target DB is also selected. The target DB is a new DB that is going to be used instead of the source DB. Switching from the source DB to the target DB requires data transfer, configuration, and tuning.
At block 220 , configuration data is loaded by flapping DB functions front the source DB to the target DB. The mapping is performed using the source connection and the target connection. DB functions may be used in SQL queries, part of the universe objects. When these objects are used in reports, the SQL queries will be generated based on objects syntax. DB functions may vary from one database to another. Configuration data provides mapping of DB functions from a source DB to a target DB.
At block 230 , the source universe is examined. In one embodiment, examining the source universe includes the steps as described further in connection to FIG. 3 .
At block 240 , a script is generated to create corresponding tables in the target DB that are unavailable in the target DB, compared to the source DB. A list of tables not present in the target DB is created after the source universe examination and comparison to the target DB.
At block 250 , the integrity of all tables in the target DB is checked. These tables include available tables in the target DB and tables created at block 240 . The integrity means the data contained is accurate and reliable.
At block 260 , a new data foundation is created in the target DB. In one embodiment, creating the new data foundation includes the steps as described further in connection to FIG. 4 .
At block 270 , a new universe is created based on the new data foundation.
At block 280 , the new universe is persisted and the integrity of the new universe is checked.
At block 290 , reports created on the source universe are determined and the reports are adapted to point to the new universe. In one embodiment determining the reports includes determining of consumers of the source universe, preparing a list of reports created on the source universe, and changing references of the reports created on the source universe to point to the new universe.
FIG. 3 is a flow diagram illustrating an embodiment of a method 300 for examining a source universe. At Block 310 , a list of used tables in the source DB is determined. In one embodiment, the list of used tables includes tables, views, alias tables, and derived tables. The tables are physical tables present in the source DB. Views can be views created in the source DB. Alias tables are copies of the tables present in the database schema. Derived tables may be results in form of tables based on queries.
Further, at block 320 , joins and contexts are determined for the list of used tables in the source DB. Context is a set of joins in a universe, which provides a valid join path between tables for generating queries. First, a list of joins is prepared (type, syntax, etc.), and then for each context—the used joins.
At block 330 , a list of objects is determined. In one embodiment, determining the list of objects includes identifying used DB functions. In one embodiment, the list of objects includes dimensions, details, measures, and filters.
At block 340 , security applied on the source universe is determined. The security may be applied on tables and objects. In one embodiment, determining the security applied on the source universe includes examining security rules and determining queries containing DB functions.
FIG. 4 is a flow diagram illustrating an embodiment of a method 400 for creating a new data foundation in a target DB. At block 410 , tables and views are added to the target DB from the list of used tables in the source DB.
At block 420 , alias tables and derived tables are added to the target DB from the list of used tables in the source DB based on dependency logic. For a derived table, the source table functions have to be replaced with matched functions according to step 220 in FIG. 2 . A new query is then used to create the derived table in the target DB.
At block 430 , joins are created and contexts from the source universe are replicated.
At block 440 , objects are replicated by replacing queries to the source DB with queries to the target DB.
FIG. 5 is a block diagram illustrating an embodiment of a system 500 for universe migration from a source database (DB) to a target DB. The system 500 includes a source universe using a source DB 530 through a source connection 560 . The system 500 also includes a new universe using a target DB 535 through a target connection 565 . The source universe and the new universe are accessible to users through the user interface 510 . A loading engine 575 is operable, based on the source connection 560 and the target connection 565 to load configuration data comprising mapping of one or more DB functions of the source DB 530 and the target DB 535 . In one embodiment, a connection server 555 mediates the connections to the source database 530 and the target database 535 .
A script generator engine 540 is operable to generate a script to create one or more corresponding tables in the target DB, wherein the created one or more corresponding tables are from a list of used tables in the source DB 530 unavailable in the target DB 535 .
A data foundation generator 520 is operable to create a new data foundation in the target DB 535 .
A universe generator 525 is used to create the new a universe based on the new data foundation.
A migration engine 515 performs the migration from the source universe to the new universe. The migration engine 515 is operable to examine the source universe. In one embodiment, the migration engine 515 is also operable to determine the list of used tables in the source DB 530 , determine joins and contexts for the determined list of used tables, determine a list of objects, and determine security applied on the source universe 530 . In one embodiment the of used tables includes tables, views, alias tables and derived tables. In one embodiment, the migration engine 515 is operable to identify used DB functions 505 . In one embodiment, the objects may be dimensions, details, measures, and filters. In one embodiment, the migration engine 515 is operable to examine security rules 570 and determine queries containing DB functions. The migration engine 515 is also operable to check integrity of available and created tables in the target DB 535 . The migration engine 515 is further operable to persist the new universe and check the integrity of the new universe. In one embodiment, the new universe is persisted in repository 580 . The migration engine 515 is also operable to determine reports 550 created on the source universe and adapt the reports 550 to point to the new universe, in one embodiment, the reports 550 are accessed through a reporting server 545 .
Some embodiments may include the above-described methods being written as one or more software components. These components, and the functionality associated with each, may be used by client, server, distributed, or peer computer systems. These components may be written in a computer language corresponding to one or more programming languages such as, functional, declarative, procedural, object-oriented, lower level languages and the like. They may be linked to other components via various application programming interfaces and then compiled into one complete application for a server or a client. Alternatively, the components maybe implemented in server and client applications. Further, these components may be linked together via various distributed programming protocols. Some example embodiments may include remote procedure calls being used to implement one or more of these components across a distributed programming environment. For example, a logic level may reside on a first computer system that is located remotely from a second computer system containing an interface level (e.g., a graphical user interface). These first and second computer systems can be configured in a server-client, peer-to-peer, or some other configuration. The clients can vary in complexity from mobile and handheld devices, to thin clients and on to thick clients or even other servers.
The above-illustrated software components are tangibly stored on a computer readable storage medium as instructions. The term “computer readable storage medium” should be taken to include a single medium or multiple media that stores one or more sets of instructions. The term “computer readable storage medium” should be taken to include any physical article that is capable of undergoing a set of physical changes to physically store, encode, or otherwise catty a set of instructions for execution by a computer system which causes the computer system to perform any of the methods or process steps described, represented, or illustrated herein. A computer readable storage medium may be a non-transitory computer readable storage medium. Examples of non-transitory computer readable storage media include, but are not limited to: magnetic media, such as hard disks, floppy disks, and magnetic tape; optical media such as CD-ROMs, DVDs and holographic devices; magneto-optical media; and hardware devices that are specially configured to store and execute, such as application-specific integrated circuits (“ASICs”), programmable logic devices (“PLDs”) and ROM and RAM devices. Examples of computer readable instructions include machine code, such as produced by a compiler, and files containing higher-level code that are executed by a computer using an interpreter. For example, an embodiment may be implemented using Java C++, or other object-oriented programming language and development tools. Another embodiment may be implemented in hard-wired circuitry in place of, or in combination with machine readable software instructions.
FIG. 6 is a block diagram of an exemplary computer system 600 . The computer system 600 includes a processor 605 that executes software instructions or code stored on a computer readable storage medium 655 to perform the above-illustrated methods of the invention. The computer system 600 includes a media reader 640 to read the instructions from the computer readable storage medium 655 and store the instructions in storage 610 or in random access memory (RAM) 615 . The storage 610 provides a large space for keeping static data where at least some instructions could be stored for later execution. The stored instructions may be further compiled to generate other representations of the instructions and dynamically stored in the RAM 615 . The processor 605 reads instructions from the RAM 615 and performs actions as instructed. According to one embodiment of the invention, the computer system 600 further includes an output device 625 (e.g., a display) to provide at least some of the results of the execution as output including, but not limited to, visual information to users and an input device 630 to provide a user or another device with means for entering data and/or otherwise interact with the computer system 600 . Each of these output devices 625 and input devices 630 could be joined by one or more additional peripherals to further expand the capabilities of the computer system 600 . A network communicator 635 may be provided to connect the computer system 600 to a network 650 and in turn to other devices connected to the network 650 including other clients, servers, data stores, and interfaces, for instance. The modules of the computer system 600 are interconnected via a bus 645 . Computer system 600 includes a data source interface 620 to access data source 660 . The data source 660 can be accessed via one or more abstraction layers implemented in hardware or software. For example, the data source 660 may be accessed by network 650 . In some embodiments the data source 660 may be accessed via an abstraction layer, such as, a semantic layer.
A data source is an information resource. Data sources include sources of data that enable data storage and retrieval. Data sources may include databases, such as, relational, transactional, hierarchical, multi-dimensional (e.g., OLAP), object oriented databases, and the like. Further data sources include tabular data (e.g., spreadsheets, delimited text files), data tagged with a markup language (e.g., XML data), transactional data, unstructured data (e.g., text files, screen scrapings), hierarchical data (e.g., data in a file system, XML data), files, a plurality of reports, and any other data source accessible through an established protocol, such as, Open DataBase Connectivity (ODBC), produced by an underlying software system (e.g., ERP system), and the like. Data sources may also include a data source where the data is not tangibly stored or otherwise ephemeral such as data streams, broadcast data, and the like. These data sources can include associated data foundations, semantic layers, management systems, security systems and so on.
In the above description, numerous specific details are set forth to provide a thorough understanding of embodiments. One skilled in the relevant art will recognize, however that the embodiments can be practiced without one or more of the specific details or with other methods, components, techniques, etc. In other instances, well-known operations or structures are not shown or described in details.
Although the processes illustrated and described herein include series of steps, it will be appreciated that the different embodiments are not limited by the illustrated ordering of steps, as some steps may occur in different orders, some concurrently with other steps apart from that shown and described herein. In addition, not all illustrated steps may be required to implement a methodology in accordance with the one or more embodiments. Moreover, it will be appreciated that the processes may be implemented in association with the apparatus and systems illustrated and described herein as well as in association with other systems not illustrated.
The above descriptions and illustrations of embodiments, including what is described in the Abstract, is not intended to be exhaustive or to limit the one or more embodiments to the precise forms disclosed. While specific embodiments of, and examples for, the invention are described herein for illustrative purposes, various equivalent modifications are possible within the scope of the invention, as those skilled in the relevant art will recognize. These modifications can be made in light of the above detailed description. Rather, the scope is to be determined by the following claims, which are to be interpreted in accordance with established doctrines of claim construction.
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A semantic layer (universe), which is created on a source database (DB), is migrated to a target DB. The migration includes pre-migration steps, actual migration and post-migration steps. The pre-migration steps prepare the target DB for the actual migration by configuring the target DB and determining the differences between the source DB and the target DB. During the actual migration, data, tables and views are migrated to the target DB conforming to the target database structure, functions and configuration. A new universe is created on the target database and all consumers of the source universe such as created reports are changed to refer to the new universe.
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FIELD AND BACKGROUND OF THE INVENTION
The present invention builds on a method for the production of a disk-form or disk-shaped workpiece based on a dielectric substrate, which production method comprises the treatment in a plasma process volume, formed between two opposing electrode faces in a vacuum receptacle.
DEFINITION
We are defining “electrode face” as a surface freely exposed to the plasma process volume.
In said method, on which the present invention builds, an electric high-frequency field is generated between the electrode faces and therewith in the process volume charged with a reactive gas, a high-frequency plasma discharge is generated. The one electrode face is herein comprised of a dielectric material and a high-frequency potential is applied to it with a specified distribution varying along the face. The distribution of the electric field in the plasma process volume is set through the potential distribution on the dielectric electrode face. In the method forming the basis, the substrate either forms the dielectric electrode face or the substrate is disposed at the second electrode face developed metallically. Furthermore, at the electrode face opposing the substrate the reactive gas is introduced into the process volume through an aperture pattern.
In recent years increased effort has been exerted to produce larger disk-form workpieces incorporating reactive high-frequency plasma-enhanced methods. One of the reasons was the wish to reduce the production costs. High-frequency plasma enhanced methods (P Hf ECVD) are employed for substrate coating or as reactive high-frequency plasma-enhanced etching methods. Said efforts can be seen in particular in the production of liquid crystal displays (LCD), of TFT or plasma displays, as well as in the field of photovoltaics, and therein especially in the field of solar cell production.
When carrying out such production methods by means of said high-frequency plasmas-enhanced reactive methods with the known use of areal metal electrodes opposing one another in parallel, each with a planar electrode face facing the process volume in a vacuum receptacle and applying the electric high-frequency field for the plasma excitation, it was observed that with substrates increasing in size and/or increasingly higher excitations frequency f Hf the dimension of the vacuum receptacle, in top view onto the substrate, is no longer of secondary importance. This is especially true in view of the wavelength of the applied high-frequency electromagnetic field in a vacuum. The distribution of the electric high-frequency field in the vacuum chamber, viewed parallel to the electrode faces, becomes inhomogeneous and to some extent differs decisively from a mean value, which leads to the inhomogeneous treatment of the workpiece positioned on one of the electrode faces: during etching an inhomogeneous distribution of the etching action results, with coating, for example of the layer thickness, the layer material stoichiometry, etc. Such significant inhomogeneities in the treatment are not acceptable for some applications, such as in particular in the production of said liquid crystals, TFT or plasma displays, as well as in photovoltaics, and here especially in the production of solar cells. Said inhomogeneities are more pronounced the more said dimension or extent of the receptacle approaches the wavelength of the electric field in the receptacle.
To solve this problem, in principle different approaches are known:
U.S. Pat. No. 6,631,692 as well as US A 2003/0089314 discloses forming the plasma process volume between two metallic electrode faces, which are opposite one another, and to shape one or both of the opposing metallic electrode faces.
The metallic electrode face, which is opposite the substrate disposed on the other electrode face or the metallic electrode face on which the substrate is supported, or both opposing metallic electrode faces are developed such that they are concave. This known approach is shown schematically in FIG. 1 , in which denote:
1 a and 2 b : the metallic electrode faces opposing one another above the process volume, between which faces the high-frequency field E is generated, E r , E c : the electric field, respectively generated peripherally and centrally.
A physically fundamentally different approach, on which also the present invention builds in order to solve the above problem, is known from U.S. Pat. No. 6,228,438 by the applicant of the present application. The principle of this approach according to U.S. Pat. No. 6,228,438 will be explained in conjunction with FIG. 2 , which, however, represents a realization not disclosed in said document. But this realization is intended to serve as the foundation for an understanding. One of the opposing electrode faces 2 a , for example, as depicted is metallic. The second electrode face 2 b , in contrast, is comprised of the dielectric material, for example a dielectric areal thin plate 4 . Along the dielectric electrode face 2 b a potential distribution φ 2b is generated, which, in spite of a constant distance between the two electrode faces 2 a and 2 b , in the process volume PR yields a desired local field distribution, as shown for example in the margin region a stronger field E r than in the center region E c . This can be realized, for example as shown in FIG. 2 , thereby that a high-frequency generator 6 is coupled to the dielectric plate 4 across capacitive elements C R , C c differently, according to the desired distribution. In the implementation depicted in
FIG. 2 , however not disclosed in said U.S. Pat. No. 6,228,438, of the principle realized in said patent, the coupling capacitors C R must be selected to have higher capacitance values than the center capacitors C c . The development of the capacitors C R or C c is solved according to U.S. Pat. No. 6,228,438 in the manner depicted in FIG. 3 . A dielectric 8 is provided which, on the one hand, forms the electrode face 2 b according to FIG. 2 , which simultaneously, due to its locally varying thickness d, with respect to a metallic coupling face 10 forms the locally varying capacitances C R, C provided according to FIG. 2 ,. The dielectric 8 can therein, as shown in FIG. 4 , be formed by a solid dielectric or by an evacuated or gas-filled hollow volume 8 a between metallic coupling face 10 and a dielectric plate 4 forming the electrode face 2 b . It is essential that in this hollow volume 8 a no plasma discharge is developed.
The present invention builds on the known method according to U.S. Pat. No. 6,228,438, which was explained in principle in conjunction with FIGS. 2 to 4 . In this approach the question arises of where to place a substrate to be treated in the process volume P R , wether at the dielectric electrode face 2 b or at the metallic electrode face 2 a . Said U.S. Pat. No. 6,228,438 teaches placing dielectric substrates on the electrode face 2 b or electrode face 2 a , but (column 5 , line 35 ff) substrates with electrically conducting surface on the metallic electrode face 2 a.
It is furthermore known from said document to introduce reactive gas into the process volume and specifically distributed from an aperture pattern at the electrode face opposite the substrate to be treated. Therefore, if a dielectric substrate according to FIG. 3 or 4 is disposed on the electrode face 2 b , the aperture pattern with the gas supply is to be provided on the side of the metallic electrode face 2 a . If the substrate is disposed on the metallic electrode faces 2 a , the aperture pattern for the reactive gas is to be provided on the side of the dielectric electrode face 2 b . In this case, as is clearly evident in FIG. 4 , the hollow volume 8 a can be employed as equalization chamber and the reactive gas is only introduced through the metallic coupling configuration with coupling face 10 into the equalization chamber 8 a and through the aperture pattern provided in dielectric plate 4 into the process volume Pr. However, it is entirely possible to fill the hollow volume 8 a with a dielectric solid, be that with the material forming the dielectric electrode surface 2 b or one or more to some extent different therefrom and to supply the aperture pattern through this solid via distributed lines with the reactive gas.
It can fundamentally be assumed that the combination of the aperture pattern for the inflow of the reactive gas into the process volume and the dielectric 8 or 8 a according to FIG. 3 or 4 on a single electrode configuration requires significantly more effort than providing the aperture pattern on the electrode face 2 a according to FIG. 3 and placing the substrate to be treated on the dielectric electrode face 2 b or even developing the dielectric electrode face 2 b by a dielectric substrate itself.
For it appears advantageous to separate functionally the gas inlet measures with the aperture pattern and the measures for affecting the electric field, i.e. if possible to deposit the substrate to be treated on the dielectric electrode face 2 b or to structure the dielectric electrode face 2 b at least partially by the substrate and to shape the gas inlet conditions through the aperture pattern on the metallic electrode face 2 a.
SUMMARY OF THE INVENTION
It is the task of the present invention to propose a method for the production of a disk-form workpiece based on a dielectric substrate, by means of which workpieces provided with a special layer can be produced utilizing the method fundamentally known from U.S. Pat. No. 6,228,438. The disk-form workpieces produced in this way are to be suitable in particular for use as solar cells. This is attained thereby that the dielectric substrate, first, thus before the treatment in said high-frequency plasma process volume, is coated at least regionally with a coating material to whose specific resistance applies:
10 −5 Ωcm≦ ≦10 −1 Ωcm
and on which for the surface resistance R S of the layer applies:
0 <R S ≦10 4 Ω □ ,
subsequently the coated substrate is positioned on the metallic electrode face is reactively and under plasma enhancement etched or coated in the plasma process volume.
Although, as has been stated, the aim in the known method was the separation of the function of gas inlet measures and field affecting measures and their assignment on particular electrode faces for reasons of structuring, it has now been found that the combination of precoating the dielectric substrate with said layer and the basically known P Hf ECVD method is only successful if, after the coating, the substrate is deposited in the plasma process volume on the metallic electrode face and the field affecting measures as well as the reactive gas inlet through said aperture pattern are combined and realized on or in the proximity of the dielectric electrode face.
It has been found that after the completed coating of the dielectric substrate with the specific layer only said substrate position leads to success and therewith the function combination, which initially was considered to be rather disadvantageous, must be realized on the dielectric electrode face.
With the proposed approach, in addition, high flexibility with respect to the type of Hf plasma treatment is advantageously attained. Independently of whether or not the dielectric substrate previously coated with the specified layer is being etched or coated, further also independently of whether or not it is being coated by a P Hf ECVD process to be dielectric up to electrically highly conducting: the particular treatment process is not affected by it as far as the effect of the field distribution measures in the plasma process volume or the gas inlet measures are concerned.
As previously stated, within the scope of the present invention the dielectric substrate is first coated with a material whose specific electric resistance is significantly higher than on materials conventionally referred to as “metallic” or “electrically conducting”. The specific resistances of conventional conductor materials, such as of gold, silver, copper or aluminum are in the range from 1.7×10 −6 Ωcm to 2.7×10 −6 Ωcm.
Definition
The surface resistance R S is obtained from the quotient of the specific resistance and the layer thickness. It has the dimension Ω indicated by the symbol □ .
The surface resistance R S of a considered layer is consequently a function of the material as well as also the layer thickness.
It was found according to the present invention that the choice of the method depends not only on whether or not the surface of a dielectric substrate is precoated with a more electroconducting or less electroconducting material but critically also on the surface resistance R S of the layer in the case of said materials.
In an embodiment of the method according to the invention the distribution of the high-frequency potential at the dielectric electrode face and the inlet of reactive gas into the process volume is realized thereby that the dielectric electrode face is formed by a surface of a dielectric plate configuration facing the process volume, whose backside forms with a metallic coupling face a chamber, and the distance of the backside from the coupling face varies along these faces and that, further, the reactive gas is introduced into the chamber, then through the aperture pattern provided in the plate configuration into the process volume. On the coupling face and the other electrode face, which is electrically conducting, a high-frequency signal is applied for the plasma excitation.
Due to the varying distance between metallic coupling face and backside of the dielectric plate configuration, the capacitance distribution according to FIG. 2 is realized and the chamber volume between this backside and the metallic coupling electrode face, is simultaneously utilized as a distribution chamber for the reactive gas, which flows through the aperture pattern in the dielectric plate configuration into the process volume.
When within the scope of the present application the term “reactive gas” is used, it should be understood that under this term is also included a gas mixture of one or several reactive gases.
In view of FIG. 2 , the stated dielectric plate configuration forms with its capacitance value also determined by its thickness, a portion of the coupling capacitors C R or C C depicted in FIG. 2 . Therewith, in one embodiment, the dielectric plate configuration with a specified varying thickness distribution can be utilized. However, in another embodiment the dielectric plate configuration with an at least approximately constant thickness is employed. In a further embodiment, the potential distribution on the dielectric electrode face approximates from the center toward its periphery increasingly the potential on the coupling face. In the realization of the above described chamber between metallic coupling face and backside of the dielectric plate configuration this is attained, for example, thereby that the respective distance is chosen to be smaller in the peripheral region than in the central region and/or thereby that the thickness of the dielectric plate configuration is laid out such that it is less in the peripheral region than in the center region.
The capacitance value is selected to be lower in the center region than in the peripheral region. When developing this capacitance across a chamber ( 8 a of FIG. 4 ), this is realized for example in that
a) the metallic coupling face is developed substantially planar, the dielectric plate configuration substantially of constant thickness, and convex, when viewed from the direction of the process volume, b) the dielectric plate configuration is developed such that it is planar with substantially constant thickness, the coupling face, when viewed from the direction of the process volume, concave, c) the coupling face is developed such that it is concave, the backside of the dielectric plate configuration also, and, when viewed from the direction of the process volume, the dielectric electrode face concave, d) the coupling face is developed such that it is substantially planar, the dielectric plate configuration with planar backside parallel to the coupling face and with convex electrode face when viewed from the direction of the process volume, e) the coupling face is developed such that it is planar, likewise the electrode face, the plate backside, in contract, convex when viewed from the direction of the process volume.
If no chamber is provided, the coupling face and the electrode face can, for example, be parallel, the dielectric constant of the solid dielectric disposed between them can increase toward the periphery.
It is evident that for the optimization, on the one hand, of the field distribution in the process volume, on the other hand, of the gas inlet direction distribution into the process volume, high flexibility is given. Although the field distribution measures and the gas distribution measures are realized on the same electrode configuration, each of the two values can be optimized. It is possible to mix or combine said approaches described for example, and employ them. For example, the coupling face can be developed to be substantially planar, the dielectric plate configuration with varying thickness with the backside concave when viewed from the process volume and a convex electrode face. Moreover, it is evident to a person skilled in the art that a further layout value for the capacitance distribution explained in FIG. 2 is also the dielectric constant of the dielectric plate configuration or its distribution can be applied. By selecting different materials along the dielectric plate configuration, said capacitance distribution, and therewith the potential distribution on the dielectric electrode face, can be affected additionally or alternatively to the distance or thickness variation.
In particular the dielectric electrode face can be planar and parallel to the other electrode defining the process volume in order to realize therewith a plasma process volume of constant depth perpendicularly to the electrode faces. This preferred embodiment results for example thereby that the metallic coupling face, viewed from the process volume, is developed such that it is concave, the backside of the plate configuration planar or thereby that the backside of the dielectric plate configuration, viewed from the process volume, is developed such that it is convex, the coupling face such that it is planar or thereby that along the dielectric plate configuration of electrode face materials having different dielectric constants are employed, with planar metallic coupling face and planar plate backside parallel to it, in the peripheral region, materials having dielectric constants higher than in the center region are applied.
If it is taken into consideration that with the method according to the invention in particular large substrates with an extent of their circumscribed circle of at least 0.5 m are first coated according to the invention and subsequently are subjected to the Hf plasma treatment, it is evident that providing the above dielectric plate configuration with aperture pattern and chamber formation is demanding.
In one embodiment, therefore, the dielectric plate configuration is formed by ceramic tiles. These tiles can be mounted at a spacing in a position central with respect to the metallic coupling face. Consequently, the dielectric electrode face, due to the thermal deformation of the tiles, does not become deformed, which might have a negative effect on the field distribution and possibly the reactive gas supply into the process volume. Furthermore, the tiles of different materials with different dielectric constants, with different thicknesses and thickness profiles can be flexibly employed for the selective formation of desired plate properties. They can be employed by mutual overlapping and multilayer arrangement for the shaping of concave or convex electrode faces or configuration backsides.
It should be emphasized again that—if a chamber is formed—it is essential to prevent that in this chamber formed between metallic coupling face and backside of the dielectric plate configuration parasitic plasma discharges occur, which would eliminate the effect of this chamber as an areally distributed coupling capacitance. As is known to the person skilled in the art, this is ensured by dimensioning the spacing ratio between metallic coupling face and backside of the dielectric plate configuration, in any case less than the dark space distance valid in the particular process.
In a further embodiment of the method according to the invention the distance of the plate configuration backside varies from the metallic coupling face in one, preferably in several steps and/or the thickness of the plate varies in one, preferably in several steps. This development is realized, for example, through the use of overlapping tiles for structuring the dielectric plate configuration or when using several tile layers with locally varying layer number.
In a further embodiment the distance of the plate configuration backside from the metallic coupling face is continuously varied and/or the thickness of the plate configuration is continuously varied. This development is utilized if a substantially planar dielectric plate configuration is employed with constant thickness and the metallic coupling face, viewed from the process volume, is formed in concavely.
In a further embodiment of the production method according to the invention, in particular for solar cells, the dielectric substrate before the treatment in the plasma process volume is coated with an electrically conducting oxide, preferably an electrically conducting and transparent oxide. This coating, which is carried out before the treatment, can take place for example through reactive magnetron sputtering. Further preferred the dielectric substrate is therein coated with at least one of the following materials: ZnO, InO 2 , SnO 2 , therein additionally doped or undoped, with a thickness D to which applies:
10 nm≦D≦5 μm.
The coating of said materials within the stated thickness range fulfills the specific layer properties stated above with respect to the specific resistance and surface resistance R S .
The substrate coated in this manner is subsequently reactive etched and/or coated through treatment in the plasma process volume. Preferably as the reactive gas at least one of the following gases is utilized: NH 3 , N 2 , SF 6 , CF 4 , Cl 2 , O 2 , F 2 , CH 4 , monosilane, disilane, H 2 , phosphine, diborane, trimethylborane, NF 3 .
For example, the following layers are deposited:
Layer Reactive Gas amorphous silicon (a-Si) SiH 4 , H 2 n-doped a-Si SiH 4 , H 2 , PH 3 p-doped a-Si SiH 4 , H 2 , TMB, CH 4 microcrystalline Si SiH 4 , H 2
For reactive etching for example SF 6 mixed with O 2 is employed as the reactive gas.
Furthermore, the electric high-frequency field is preferably excited with a frequency f Hf , to which applies:
10 MHz≦f Hf ≦500 MHz
or
13 MHz≦f Hf ≦70 MHz.
The produced workpieces preferably have further a radius of the circumscribed circle which is at least 0.5 m.
A vacuum treatment installation utilized within the scope of the method according to the invention has
a vacuum receptacle, therein a first planar, metallic electrode face, a second dielectric electrode face opposing the first, which forms the one surface of a dielectric plate configuration, a metallic coupling face facing the backside of the dielectric plate configuration, electric connections on each the coupling and the first electrode face, a gas line system, which opens through the coupling face and a distributed pattern of apertures through the plate configuration, and
is distinguished thereby that the plate configuration is formed by several ceramic tiles.
Embodiments of the vacuum treatment installation utilized according to the invention will readily present themselves to a person skilled in the art in the claims as well as the following description by example of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be described further in the following in conjunction with embodiment examples and figures. Therein depict:
FIG. 1 is a side sectional and schematic view of a known metallic electrode face which is opposite a substrate disposed on another electrode face,
FIG. 2 is a schematic illustration of a known arrangement according to U.S. Pat. No. 6,228,438,
FIG. 3 is a view of the known capacitors C R or C c according to U.S. Pat. No. 6,228,438,
FIG. 4 is a view of a known arrangement where a dielectric is formed by a solid dielectric or by an evacuated or gas-filled hollow volume between a metallic coupling face and a dielectric plate forming the electrode face,
FIG. 5 schematically the sequence of the production method according to the invention in conjunction with a function block diagram,
FIG. 6 in cross section schematically and simplified, an embodiment of a vacuum treatment installation utilized within the scope of the method according to the invention,
FIG. 7 further simplified, the view onto a coupling face utilized in the installation according to FIG. 6 ,
FIG. 8 as a reference example, the resulting layer thickness distribution over the diagonals on a rectangular dielectric substrate with P Hf ECVD coating utilizing conventional opposing planar metallic electrodes,
FIG. 9 as a reference example and depicted analogously to FIG. 8 , the distribution result on a dielectric substrate, positioned directly above a concavely formed-in metallic electrode face,
FIG. 10 further as a reference example and depicted analogously to FIGS. 8 and 9 , the result when proceeding according to FIG. 9 , however on a substrate coated according to the invention with an InO 2 layer,
FIG. 11 the layer thickness distribution profile resulting when using the method according to the invention,
FIG. 12 simplified and schematically an installation according to the invention utilized for carrying out the method according to the invention in a further preferred embodiment,
FIG. 13 a detail from the region denoted by “A” in FIG. 12 to explain a further preferred embodiment,
FIG. 14 represented analogously to that of FIG. 12 a further embodiment of the installation used according to the invention,
FIG. 15( a ) to ( f ) schematically a selection of feasibilities for increasing the electric field peripherally in the process volume through the corresponding shaping of the dielectric plate configuration and the metallic coupling face,
FIG. 16 in detail a preferred mounting of a ceramic tile for forming the dielectric plate configuration on the metallic coupling face, and
FIG. 17 the realization of the feasibilities presented by example in FIG. 15 by structuring the dielectric plate by means of ceramic tiles.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In conjunction with a simplified block diagram the sequence of the method according to the invention is depicted in FIG. 5 . A dielectric substrate 100 is at least partially coated in a first vacuum coating station 102 , for example a station for reactive magnetron sputtering, with a layer whose material has a specific resistance , for which applies
10 −5 Ωcm≦ ≦10 −1 Ωcm
and specifically such, that the resulting surface resistance R S of the layer is in the following range:
0 <R S ≦10 4 Ω □ .
The lower limit can approximate 0, since the surface resistance R S is a function of the thickness of the deposited layer. This thickness D S of the layer is preferably selected as follows:
10 nm≦D S ≦5 μm
especially if the deposited layer material, as is far preferred, is an electrically conducting oxide (CO), optionally a transparent electrically conducting (TCO). For this purpose at least one of the following materials InO 2 , ZnO or SnO 2 is deposited on the dielectric substrate 100 in doped or undoped form. The coated dielectric substrate 104 is subsequently transported to a reactive Hf plasma treatment step in station 105 , namely to a P Hf ECVD treatment step, or to a reactive Hf plasma enhanced etching step. A workpiece 106 results, which is suitable in particular for use as solar cells.
The substrate 100 , and thus also the substrate 106 , resulting according to the invention has therein preferably a radius of the circumscribed circle R U of at least 0.25 m, corresponding to a diameter of the circumscribed circle of 0.5 m, as is depicted in FIG. 5 on a workpiece W formed in any desired shape.
In FIG. 6 , a first embodiment of an inventive station or installation 105 according to FIG. 5 and utilized according to the invention, is shown in cross section and simplified. A metallic vacuum receptacle 105 a has a planar base 3 , which, facing the interior volume, forms a first electrode face EF 1 . Thereon lies the substrate 104 of a dielectric material, coated— 7 —with said layer material.
Opposite the substrate 104 provided with layer 7 or the first electrode face EF 1 , is mounted an electrode configuration 9 . It forms the second electrode face EF 2 .
The second electrode face EF 2 , in the depicted example it is disposed planar opposite the electrode face EF 1 , is formed by the surface of a dielectric plate configuration 27 . The backside ER of the dielectric plate configuration 27 forms together with a metallic coupling face KF a chamber 10 . In the depicted example the coupling face KF is developed as a formation-in 10 , which, viewed from the process volume PR, is concavely worked into a metal plate 14 . As shown schematically in FIG. 7 , the formation-in 10 depicted in the example is rectangular and forms a distance distribution of distance d between coupling face KF and backside ER of the dielectric plate configuration 27 , which abruptly jumps from 0 to the constant distance in the formation-in 10 . The substrate 104 is entered in dashed lines in FIG. 7 . Via the metal plate 14 a high-frequency generator 13 is connected with the coupling face KF, which is further connected with the electrode face EF 1 which is conventionally at reference potential.
From a gas reservoir 15 reactive gas G R or a reactive gas mixture and optionally an working gas G A , such as for example argon, is introduced via a distribution line system 17 into an pre-chamber 19 to the rear of plate 14 . The pre-chamber 19 is, on the one hand, rimmed by a mounting 18 isolating the plate 14 with respect to the receptacle 105 a , on the other hand, formed by the backside of plate 14 and the front wall 21 of the receptacle 105 a facing the metallic electrode face EF 1 . Plate 14 has a pattern of gas line bores 25 led through it.
The gas line apertures 25 in plate 14 continue, preferably aligned, into openings 29 through the dielectric plate configuration 27 . The plate configuration 27 in this example is comprised of a ceramic, for example of Al 2 O 3 .
By means of generator 13 , via the coupling face KF a high-frequency plasma discharge is generated in the process volume PR.
From the metallic coupling face KF via the areally distributed capacitance C, entered in FIG. 6 in dashed lines, at the dielectric electrode face EF 2 a selectively specified potential distribution was realized as has already been explained.
The excitation frequency f Hf is selected as follows:
10 MHz≦f Hf ≦500 MHz
therein especially
13 MHz≦f Hf ≦70 MHz.
The diameter of the circumscribed circle of the substrate 104 is at least 0.5 m and can be entirely up to 5 m and more.
In the embodiment according to FIG. 6 the distance d changes abruptly from 0 to 1 mm.
As stated above, in the embodiment variants of the installation according to the invention yet to be discussed, the chamber 10 is not laid out with a distance d changing abruptly from 0 to a constant value, but rather said distance, which, after all, contributes decisively to the determination of the capacitance distribution which is critical for the field distribution, is optimized and laid out with a specific distribution. This distance d is selected, depending on the frequency, to be between 0.05 mm and 50 mm so that no plasma can form in chamber 10 .
By means of generator 13 a power of 10 to 5000 W/m 2 per substrate area is preferably supplied.
For P Hf ECVD coating of substrate 104 preferably at least one of the following is used as the reactive gas: NH 3 , N 2 , SF 6 , CF 4 , Cl 2 , O 2 , F 2 , CH 4 , monosilane, H 2 , phosphine, diborane or trimethylborane.
Lastly, the total gas flow through the system 15 , 17 from apertures 29 is for example between 0.05 and 10 sim/m 2 per m 2 of substrate area.
The above stated values apply in particular to reactive high-frequency plasma-enhanced coating.
For the subsequent experiments the following values were set:
Process:
P Hf ECVD coating
f Hf :
27 MHz
Substrate dimension:
1.1 × 1.25 m 2
Depth of formation-in d
1 mm
according to FIG. 6:
Total pressure:
0.22 mbar
Power per substrate area:
280 W/m 2
Substrate material:
float glass with specific conductivity:
10 −15 (Ωm) −1
Prior applied coating:
InO 2 doped with tin
Surface resistance R s
3 Ω ▭
of the coating:
Reactive gas:
monosilane with the addition of H 2
Dilution of monosilane in H 2 :
50%
Total gas flow per unit area:
0.75 slm/m 2
The experiments were carried out in the installation configurations according to FIG. 6 or 7 .
As a reference result is shown in FIG. 8 the resulting layer thickness distribution in nanometers with respect to the mean layer thickness value measured over both diagonals of the rectangle of the workpiece, if on the configuration according to FIG. 6 the plate 14 without formation-in 10 with a planar metallic face is employed directly as the electrode face opposite the electrode face EF 1 .
Analogously to the representation in FIG. 8 , in FIG. 9 , furthermore as reference, the result is shown which is obtained if, on the one hand, as the workpiece to be coated an uncoated dielectric substrate 100 according to FIG. 5 , namely a float glass substrate is placed in position.
Furthermore, as was already the case for the measurement according to FIG. 8 , the plate is developed without formation-in 10 and forms one of the electrodes in the process volume PR. However, an formation-in corresponding to the formation-in 10 is provided on the base 3 beneath the substrate.
Again in analogous representation and as a reference, FIG. 10 shows the result if in the installation configuration, such as was also used for the results according to FIG. 9 , i.e. with the formation-in 10 in the base 3 , covered by the substrate and with the development of the second electrode face by the planar surface, exposed to the process volume PR, of plate 14 , the precoated substrate 104 is treated, namely the float glass substrate precoated with InO 2 .
The following results:
From FIG. 8 : that due to the inhomogeneous field distribution in the process volume PR, the resulting coating thickness distribution is unacceptably in homogeneous.
From FIG. 9 : that if the substrate to be treated is purely dielectric, the formation-in on the workpiece-supporting electrode ( 3 ) leads to a significant improvement of the field distribution and therewith to layer thickness distribution homogeneity.
From FIG. 10 : that the configuration, which for a purely dielectric workpiece according to FIG. 9 leads to a significant improvement of the layer thickness distribution, in the case in which the workpiece is comprised of a substrate 104 precoated according to the invention, leads to an unacceptable layer thickness distribution.
But if, according to the invention, said precoated substrate is coated for example with the installation according to FIG. 6 , the good layer thickness distribution shown in FIG. 11 results.
It is evident that, in spite of the high specific resistance of the layer material (InO 2 ), exclusively the process proposed according to the present invention is surprisingly suitable for attaining the homogeneous action distribution on the workpiece.
Additionally simplified and schematically, in FIG. 12 is depicted a further preferred embodiment of the treatment step according to the invention or of the installation 105 according to FIG. 5 employed for this purpose.
The precoated substrate 104 is again placed onto the planar first electrode face EF 1 . The metallic coupling face KF connected with the high-frequency generator 13 is formed in as a continuous concavity.
The dielectric plate configuration 27 forms, on the one hand, the planar dielectric electrode face EF 2 and, of constant thickness, the backside ER which is also planar. In FIG. 12 the aperture pattern through the dielectric plate configuration 27 is not shown. The dielectric plate configuration 27 has a thickness D, to which preferably applies:
0.01 mm≦d≦5 mm.
Definition
By the term dielectric plate configuration is understood in the context of the present invention an areal dielectric formation extending in two dimensions and manifest in the form of films or foils up to plates.
Since the capacitance of the dielectric plate configuration 27 is manifest in series with the capacitance between coupling face KF and backside ER of the dielectric plate, the possibly large plate capacitance resulting in the case of a thin dielectric plate configuration 27 is not significantly capable of affecting the small capacitance across the chamber 10 a.
FIG. 13 shows a detail, encircled at A, of the configuration according to FIG. 12 . It is evident that at least a portion of the bores 25 through the metal plate 14 a in the embodiment according to FIG. 12 , as well as also in all other embodiments according to the invention, can be aligned with apertures 29 (not shown) through the dielectric plate configuration 27 further can at least approximately have identical aperture cross sections.
Although the coupling face KF in FIG. 12 has a continuous curvature, it is readily possibly to realize it formed in one step or in several steps. As the material of the plate configuration 27 , which is exposed to high temperature loading, an aggressive chemical atmosphere, high vacuum and the plasma, as stated, a ceramic, for example Al 2 O 3 can be utilized. Depending on the process, other dielectric materials can optionally also be employed up to high-temperature-resistant dielectric foils with the aperture pattern.
As shown in FIG. 14 , said dielectric plate configuration 27 can be replaced by several plate configurations 27 a , 27 b spaced apart and one disposed above the other, which are positioned relative to one another by dielectric spacers. All of these individual plates 27 a , 27 b have the aperture pattern in analogy to the pattern of the apertures 29 according to FIGS. 6 and 12 and 13 . Its thickness can again be between 0.01 and 5 mm.
In FIG. 15( a ) to ( f ) feasible mutual assignments of metallic coupling face KF and dielectric electrode face EF 2 are shown schematically. All of them lead to the fact that in the process volume PR, the electric field in the peripheral region is intensified with respect to the field in the center region.
In FIG. 15( a ) the metallic coupling face KF is planar. The dielectric plate configuration 27 is convex with respect to the process volume PR and of constant thickness D. Due to its metallic properties, the coupling face KF under the action of a high-frequency potential functions as an equipotential face with φ Hf . As a first approximation the configuration according to FIG. 15( a ) can be viewed as follows: at each volume element dV along chamber 10 the series connection results of a capacitor C 10 and C 27 as shown on the left in the Figure. While the capacitance C 10 is determined by the varying distance between coupling face KF and backside ER of the dielectric plate configuration 27 as well as the dielectric constant of the gas in chamber 10 , the capacitance C 27 is locally constant, due to the constant thickness D and the dielectric constant ∈ of the plate configuration 27 .
The dielectric constant of the plate material is conventionally significantly greater than that of the gas in chamber 10 , wherewith especially with a thin plate configuration 27 , the capacitance C 27 connected in series with C 10 , becomes negligible at least in a first approximation. In the peripheral region of the dielectric electrode face EF 2 , C 10 becomes increasingly greater due to the decreasing distance d, and consequently locally the potential distribution φ EF2 along the electrode face EF 2 as it approaches the peripheral region approximates the potential φ KF of the coupling face KF. Consequently, over the process volume PR lies in the peripheral region of the electrode face EF 2 the approximate entire potential difference between φ KF and the potential applied at the counterelectrode face EF 1 . In the center region of the electrode face EF 2 , due to the greater distanced, C 10 is smaller than in the peripheral region, and thus a greater high-frequency voltage drop occurs thereon and consequently here the potential φ EF2 has a greater decrease relative to potential φ KF . Consequently, over the process volume PR now an electric field is present in this center region which is decreased relative to the peripheral region.
Based on the examination of FIG. 15( a ) and taking into consideration the fact that chamber 10 is a pressure equalization chamber for the reactive gas supplied from the aperture pattern (not shown) through the dielectric plate configuration 27 to the process volume PR, it is evident that by using a foil-like high temperature-resistant plate configuration 27 , the convex shaping can advantageously be generated due to the pressure difference between process volume and chamber 10 .
In FIG. 15( b ) further the metallic coupling face KF is planar. The dielectric plate configuration 27 has a backside ER which with respect to the process volume PR, is formed convex, but a planar electrode face EF 2 parallel to the coupling face KF. Due to the conventionally higher dielectric constant ∈ of the material of the dielectric plate configuration 27 , the capacitance C 27 affects the capacitance C 10 (s. FIG. 15( a )) only insignificantly in the peripheral region, in spite of greater thickness of the configuration 27 , such that in the embodiment according to FIG. 15( b ) the locally varying capacitance C 10 in series connection dominates and, as has been explained, the major effect was exerted on the field distribution in process volume PR.
In the embodiment according to FIG. 15( c ) the coupling face KF is also planar. The dielectric plate configuration 27 has a constant thickness, but, in contrast, is formed by sectionally different materials of differing dielectric constants ∈a to ∈d. Here the chamber 10 can be omitted.
Toward the periphery the dielectric constant ∈ of the plate material increases, and thus, in view of the equivalent circuit diagram in FIG. 15( a ), C 27 increases. In this embodiment the capacitance C 10 formed by the chamber 10 is locally constant. If here the constant thickness of the dielectric plate configuration 27 is sufficiently large, the capacitance C 27 increasing toward the peripheral region in series with C 10 becomes dominant and the already described effect is attained: in the margin region of the electrode face EF 2 the electric field in process volume PR is attenuated less than in the central region, where C 27 with ∈ d is decreased relative to C 27 with ∈ a .
FIG. 15( d ) shows the already explained conditions according to FIG. 6 and FIG. 12 .
FIG. 15( e ) shows a planar coupling face KF. The dielectric plate 27 has a planar backside E parallel to coupling face KF, however, viewed from the process volume PR, a convex dielectric electrode face EF 2 . Based on the explanation up to this point, a person skilled in the art can readily infer that therewith the same field compensation effect can be achieved in the process volume PR as has been explained up to now, according to the selected plate thickness and the plate material dielectric constants.
In FIG. 15( f ) the coupling face KF as well as also the electrode face EF 2 is concave with respect to the process volume PR, however, the backside ER of plate configuration 27 is planar.
If the dielectric constant of the plate configuration 27 is substantially greater than that of the gas in chamber 10 , then C 10 also dominates here and yields the desired field distribution in process volume PR.
Based on FIGS. 15( a ) to ( f ) it is evident that there is a high degree of flexibility especially with respect to the form of the dielectric electrode face EF 2 . As a person skilled in the art recognizes readily, the variants depicted in FIG. 15 can be expanded and combined, as, for example, providing different materials on the plate configuration 27 combined with varying thickness, etc., which further increases the leeway with respect to layout. As was already stated, chamber 10 can be omitted and the capacitance distribution can exclusively be realized through the plate configuration 27 .
If it is considered that the reactive gas is introduced into the process volume through the aperture pattern provided on the plate configuration 27 and further that the desired field compensation measures can be largely realized independently of the form of the electrode face EF 2 , it becomes evident that it is possible to optimize simultaneously the direction of the gas injection into the process volume PR as well as affecting the field in the process volume PR.
In realizing the dielectric plate configuration 27 it must be taken into consideration that it is exposed during the treatment process especially to high temperatures. Therewith thermal differences of expansion between dielectric plate configuration 27 and, via its securement, the plate 14 forming the coupling face KF. It must further be considered that with the described installation large, even very large, substrates 104 are to be treated. The realization of a dielectric plate configuration of this size as well as its mounting in a manner that thermal expansions and contractions can in every case be absorbed without deformations, represents problems especially if the configuration 27 is not of foil type, but rather as a rigid dielectric plate is comprised for example of a ceramic, such as Al 2 3 .
In an embodiment preferred in this case the solid configuration 27 , as will be explained in conjunction with FIG. 16 , is composed of a large number of dielectric, preferably ceramic, tiles. In FIG. 16 a view of such a tile and its mounting is shown and depicted in cross section. The particular tile 50 , which, as shown, is preferably rectangular or square and fabricated of a ceramic material, such as for example Al 2 O 3 , is positioned substantially centrally relative to the coupling face KF on plate 104 by means of a dielectric spacer bolt 52 , such as for example a ceramic bolt, as well as by means of a dielectric washer 54 . Thereby the relevant distance between face KF and backside ER of the tiles 50 forming the plate configuration 27 is ensured. So that the tiles 50 are peripherally supported and yet can nevertheless freely expand without tension on all sides under thermal loading, they are guided on support pins 56 with respect to the coupling face KF. The tiles 50 are secured against twisting by means of a guide pin 58 in a slot guidance 59 . The tiles 50 are provided with the aperture pattern not shown in FIG. 16 , which, if necessary, is supplemented by gaps between the tiles 50 . The tiles 50 can optionally also overlap. One or several layers of such tiles can be provided, optionally locally varying, and different ceramic materials, especially with differing dielectric constants can be employed in different regions. Therewith flexibly different formations and material profiles can be realized on the dielectric plate configuration 27 .
In FIG. 17( a ) to ( f ) the configurations according to FIG. 15( a ) to ( f ) are shown schematically, which are structured by means of tiles preferably as explained in conjunction with FIG. 16 . Only the tiles disposed directly opposite the coupling face KF according to FIG. 17 must be supported, layers of tiles adjacent on the side of the process volume are mounted on the subjacent tiles. When examining FIGS. 17( a ) to ( f ) a person skilled in the art readily understands the manner of said preferred tile structuring of the configurations according to FIGS. 15( a ) to ( f ). In accordance with said aperture pattern, the gas injection into the process volume distributed to the desired extent, must be ensured, be that by utilizing the labyrinth channels remaining between the tiles and/or by providing additional bores or apertures through the tiles 50 (not shown).
The thickness of the ceramic tiles D K is preferably
0.1 mm≦D K ≦2 mm.
With the production method according to the invention or the installation utilized according to the invention, homogeneously large, even very large, dielectric substrates can be, first, coated with special conducting layers, subsequently be surface-treated, in particular coated, by reactive high-frequency plasma-enhanced methods, whereby in particular large, up to very large, solar cells can be produced on an industrial scale.
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A method for producing a disk shaped workpiece with a dielectric substrate includes treatment in a plasma process volume between two electrode faces bounding a high-frequency plasma discharge. One electrode face is of dielectric material and is at a high-frequency potential with a varying distribution along the face. The other electrode face is metallic. Reactive gas is introduced into the process volume through an aperture pattern. The dielectric substrate, before treatment, is at least regionally coated with a layer material to whose specific resistance applies: 10 −5 Ωcm≦ ≦10 −1 Ωcm, and to the resulting surface resistance R S of the layer applies: 0<R S ≦10 4 Ω. Subsequently, the coated substrate is positioned on the metallic electrode face and is etched or coated reactively under plasma enhancement in the plasma process volume.
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BACKGROUND OF THE INVENTION
1. Related Art Statement
The present invention relates to wear resisting steel, a sliding member for a cylinder in an internal combustion engine, and a ring spring, and more particularly, to high performance wear resisting steel, a sliding member for a cylinder in an internal combustion engine, and a ring spring wherein the wear resisting steel has excellent resistance to wear and scuffing, provides greater strength and greater elongation than cast iron and greater toughness than ultrahigh strength steel or sintered hard alloy, and also provides good machinability.
A piston ring used in an internal combustion engine such as a diesel engine requires properties and characteristics such as wear resistance and anti-scuffing. Conventionally, flake graphite cast iron (hereinafter, referred to as "cast iron") such as Uballoy (trade mark of JAPAN PISTON RING CO., LTD), ultrahigh strength steel with greater hardness, and sintered hard alloy are well known as wear resisting material for such a purpose.
However, cast iron has disadvantages of poor strength and low elongation, and ultrahigh strength steel and sintered hard alloy have also disadvantages of poor toughness, and poor machinability.
By the way, a ring spring is used for a stretcher of a leveler for rolled steel sheets. Since the ring spring requires relatively high strength and toughness, spring steel is conventionally used for the ring spring.
2. Object and Summary of the Invention
It is a first aim of the present invention to provide wear resisting steel having stable anti-scuffing property and a sliding member for a cylinder made of the wear resisting steel.
A ring spring made of conventional material is damaged on its sliding surface so that its life-time is quite short.
It is a second aim of the present invention to keep the characteristics of the ring spring for a long period without considerable damage so as to lengthen product life.
Wear resisting steel according to the present invention consists of:
carbon: equal to or less than 2.2% by weight; silicon: equal to or less than 1.2% by weight; manganese: equal to or more than 0.2% by weight and less than 1.20% by weight, chromium: equal to or less than 16% by weight; phosphorus: equal to or less than 0.08% by weight; sulfur: equal to or more than 0.15% by weight and less than 0.60% by weight; other compositions: equal to or less than 2.0% by weight; and the balance substantially comprising of iron.
The ranges of compositions of preferred wear resisting steels (No. 1 through No. 4) are listed in the following Table 1.
TABLE 1__________________________________________________________________________(wt %)No. of Steel C Si Mn Cr P S others Fe__________________________________________________________________________No. 1 ≦2.2 ≦1.2 1.20 ≧ 0.2 ≦16 ≦0.08 0.60 ≧ 0.15 ≦2.0 bal. No. 2 ≦2.2 ≦1.2 1.20 ≧ 0.2 ≦6.0 ≦0.08 0.60 ≧ 0.15 ≦2.0 bal. No. 3 0.25˜2.0 0.20˜1.20 0.40˜1.20 0.80˜5.50 ≦0.05 0.20˜0.50 ≦1.0 bal. No. 4 0.60˜2.0 0.10˜0.40 0.40˜1.0 11.0˜15.0 ≦0.05 0.20˜0.60 ≦1.0 bal.__________________________________________________________________________
For the following reasons, the compositions of No. 1 steel are limited as shown in Table 1.
C>1.8 (means "C exceeds 1.8% by weight", hereinafter, signs are used in the same manner), Si>1.2, P>0.08, or Cr>16 makes the mechanical properties (material strength, elongation) poor. Particularly, C>2.2 makes the elongation remarkably poor. S<0.15, Mn<0.2 (less than 0.2 % by weight) make the sliding properties (anti-scuffing) poor.
It should be noted that Cr≦6.0 (6.0% by weight or less) such as No. 2 steel improves the mechanical properties.
No. 3 steel and No. 4 steel both offer a good balance between the mechanical properties and the sliding properties thereof.
A sliding member for a cylinder in an internal combustion engine and a ring spring according to the present invention are made of the wear resisting steel as described above.
It is preferable that the surface of the wear resisting steel is sulphurized by electrolysis or is treated by baking molybdenum dioxide after electrolyte sulphurizing.
The sliding member for a cylinder in an internal combustion engine according to the present invention may be a piston ring, a cylinder liner, or a piston skirt.
The ring spring of the present invention comprises inner rings and outer rings wherein at least sliding surfaces of the inner rings and/or outer rings are made of the aforementioned wear resisting steel. Employing the wear resisting steel for the ring spring keeps up the good spring property of the ring spring for long periods, thereby extending the ring spring's life.
The numbers of the inner and outer rings of the ring spring, the inner diameters and so on are not limited. Lubricant (for example MoS 2 grease) is preferably applied on the sliding surfaces between the inner rings and the outer rings.
The wear resisting steel, the sliding member for a cylinder in an internal combustion engine and the ring spring according to the present invention are generally sulphurized after being processed by the following normal heat treatment before use. Laser heat treatment or subzero treatment may be employed besides the following heat treatment.
Method of heat treatment and conditions
Heating (temperature: 780-840 ° C.)→Quenching in oil→Tempering (temperature: 200-600 ° C.)→Air cooling.
The sulphurizing according to the present invention is conducted to form a sulphurized layer (iron sulfide Fe x S) on the surface of the steel by the electrochemical reaction (ionic reaction) by soaking the steel in molten salt in a vessel to electrolyze the steel as anode with the counter electrode as cathode.
It is enough to form the sulphurized layer of 10 μm or less, normally 3-9 μm, preferably 5-8 μm in depth.
The wear resisting steel of the present invention has excellent resistance to wear and scuffing, provides greater strength and greater elongation than cast iron and greater toughness than ultrahigh strength steel or sintered hard alloy, and also provides good machinability.
The wear resisting steel of the present invention is particularly industrially useful as a material of a sliding member for a cylinder in an internal combustion engine such as a piston ring, a cylinder liner, or a piston skirt, and a ring spring.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a dimensional view showing a pin used for scuffing tests;
FIG. 2 is a dimensional view showing a disk used for scuffing tests;
FIG. 3 is a schematic structural view showing a scuffing tester;
FIGS. 4(a) and 4(b) show graphs of the results of the scuffing tests;
FIGS. 5(a) and 5(b) shows graphs of the measurements of friction coefficient μ; and
FIGS. 6(a) and 6(b) shows graphs of the results of ring spring tests.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Here in after, the present invention will now be described more concretely using non-limiting embodiments and comparative examples.
Embodiments 1, 2, and Comparative Examples 1, 2, 3, 4, 5, 6
Scuffing tests are conducted with pins (sometimes, referred to as "test pieces") made of wear resisting steel having following compositions.
TABLE 2______________________________________Com- positions C Si Mn Cr P S Others Fe______________________________________Embodiment 1.00 0.48 0.96 1.13 0.03 0.35 0.29 bal. 1 Embodiment 0.90 0.30 0.60 11.9 0.02 0.30 0.23 bal. 2______________________________________
The pins of wear resisting steel are processed by heat treatment as follows.
Method of heat treatment and conditions
Heating (820° C.)→Quenching in oil→Tempering (200-600° C.)→Air cooling.
It should be noted that, as a result of the heat treatment, the microstructure of the steel became either of tempered troostite and tempered sorbite with cementite.
In Embodiments 1 and 2, after the heat treatment, the pins are sulphurized by electrolysis in molten salt at 190° C. As a result of this, each pin is provided with a sulphurized layer formed in the surface at 8 μm depth.
In Comparative Examples 1 and 2, pins are processed by Ni--P plating of 1 μm in thickness instead of the sulphurizing of Embodiments 1 and 2. In Comparative Examples 3 and 4, pins are ionitrided to form nitrided layers in the surfaces at 40 μm depth, respectively, instead of the sulphurizing of Embodiments 1 and 2.
In Comparative Examples 5 and 6, scuffing tests are conducted with pins processed only by the aforementioned heat treatment without any surface treatment.
Details of the scuffing tests are as follows.
(1) Test piece for scuffing test
1. Pin (Tip)
FIG. 1 shows the configuration and dimensions of a pin 1 used for the scuffing tests (area of the sliding surface=1 cm 2 )
2. Disk
FIG. 2 shows the configuration and dimensions of a disk 2. The test disk was high-phosphorus cast iron with the following composition.
C: 3.23 wt %
Si: 1.93 wt %
Mn: 0.75 wt %
P: 0.22 wt %
S: 0.115 wt %
B: 0.05 wt %
Fe: rest
(2) Method of scuffing test
Measurements of scuffing characteristics were made using an abrasion tester of pin-on-disk type. FIG. 3 shows a schematic view of the tester.
The scuffing tests were made with the pin 1 being fixed and the disk 2 being rotated. As shown in FIG. 3, the disk was rotated through a belt 3 by a servo motor 4. The pin was loaded by a pneumatic load 5.
The diameter of sliding movement of the disk at the center of the test surface was φ120 mm and the sliding speed on the test surface was constant at 5 m/sec. The test lubricating oil was a mixture of lubricating oil SAE #30 and white kerosene at 1:1. The test lubricating oil was applied on the sliding surface of the rotating disk and the disk was rotated under no-load at a speed 5 m/sec for 30 seconds. After that, the disk was loaded to start the test. The setting Load was set to 245 N as an initial load, after 30 minutes, set to 490 N and further increased by 98 N for each 5 minutes.
For the scuffing test, time period until scuffing/load was measured. The anti-scuffing property was evaluated by comparing, in time period until scuffing/load, with a test piece formed of high-phosphorus cast iron or high-phosphorus cast iron treated by Cr plating which is a typical material of DE piston ring for ship, and considering the variation of friction coefficient μ during the scuffing test and the temperature change of the disk.
(3) Observation of scuffing test piece
The appearance and familiarity of the sliding surface before and after the scuffing test were observed by a microscope. The surface condition of the sliding surface before and after the scuffing test was observed by a laser microscope (Laser Microscope 1LM21 manufactured by Laser Tech Corporation) to measure the surface roughness thereof.
(Results of Scuffing Tests)
(1) Time period until scuffing/load
FIGS. 4(a), 4(b) show results of the scuffing tests of pins (time period until scuffing/load). FIG. 4(a) shows test results of the non-treated pin wherein the test was conducted with an initial running-in with load 98N, at sliding speed 5 m/sec, for 30 minutes and FIG. 4(b) shows test results of the nitrided pin, the Ni--P plated pin, the sulphurized pin.
As apparent from FIGS. 4(a), 4(b), wide scatter was observed in the test results of the non-treated pin, even after the running-in (load 98N, sliding speed 5 m/sec, and running time 30 minutes). On the other hand, as shown in FIG. 4(b), smaller scatter was observed in the test results of the nitrided pin, the Ni--P plated pin, the sulphurized pin, in which anti-scuffing properties were all relatively good. The results show that the sulphurizing was the best surface treatment to provide good anti-scuffing property.
(2) Variation of friction coefficient μ during scuffing tests
FIGS. 5(a) and 5(b) show elapsed changes such as friction coefficient μ during the scuffing tests as examples. The sliding speed was constant at 5 m/sec, the vertical axis of the graphs designate friction coefficient μ and load, and the abscissa axis designate time periods during the tests. FIG. 5(a) shows test results of the non-treated pin (with initial running-in) and FIG. 5(b) shows test results of the sulphurized pin.
In the abrasion test, when the friction coefficient μ rises suddenly (μ≧0.5), it is judged as the occurrence of scuffing. During the abrasion test, relatively large variation was observed for the friction coefficient μ of the non-treated pin as shown in FIG. 5(a). However, for the friction coefficient μ of the sulphurized pin and high-phosphorus cast iron disk, no significant variation was observed except at the occurrence of scuffing as shown in FIG. 5(b).
As described above, the wear resisting steel as a parent metal provided not always enough initial break in characteristics. Similarly, since the gas-nitrided pin and the Ni--P plated pin provided not always enough familiarity, relatively large variation was also observed for each friction coefficient μ thereof during the abrasion test. However, no large variation was observed for the friction coefficient μ of the sulphurized test piece and the hardness of the surface was lower than that of thee parent metal. Therefore, it was thought that the initial break in characteristics was improved. The running in characteristics of the wear resisting steel after the initial break in characteristics was also good and, as apparent from the results of the scuffing tests as shown in FIG. 4, the anti-scuffing thereof was excellent.
(3) Appearance of the sliding surface
As a result of observing the appearance of the sliding surface after the scuffing test, a phenomenon that a working face appears partially (hereinafter, referred as "partial working face") was observed in the non-treated pin where time period until scuffing is short. However, as for the Ni--P plated test piece and the nitrided test piece, there is no relation between the time period until scuffing and the partial working face.
On the other hand, for the sulphurized test piece, the sliding surface was damaged without significant partial working face, thereby making the time period until scuffing relatively long. That is, one of effects of the sulphurizing is improvement of the initial break in characteristics on the sliding surface having relatively high hardness.
(4) Picture of sliding surface
As a result of observing the picture of sliding surface before and after the scuffing test by the laser microscope, there was numerically non-significant difference between before and after the scuffing test in the surface roughness of the non-treated pin with the surface roughness after the scuffing test being slightly increased, i.e. the surface roughness was about 1.6 μm and about 2. 0 μm before and after the scuffing test, respectively. Stick-like flaws caused by proceeding of scuffing damage and traces of penetration of lubricating oil were observed on the surface of the test piece after the scuffing test.
As a result of observing the picture of sliding surface of the sulphurized test piece, there is no track caused by machining in the surface of the test piece before the scuffing test because of the sulphurizing. It is thought that the sulphurized test piece is provided with amorphous FexS on the surface thereof. Therefore, though the surface roughness of the test piece was increased to about 14.3 μm, the surface irregularities tended to be smoothed. After the scuffing test, though the surface roughness on a sliding area was reduced (less than about 4.9 μm), a significant scuffing damage was not observed. The test piece was provided with a cavity about 70 μm in diameter and 5 μm in depth formed in the surface thereof due to the sulphurizing. It is thought that the surface irregularities were effective in retaining oil. After the scuffing test, the surface roughness on the area where was completely sliding was reduced (about 2.5 μm) and the sulphurized layer died out. That is, as a result of the scuffing test of the sulphurized test piece, the time period until scuffing was relatively long and the wear resisting steel as the parent metal has relatively high hardness. Therefore, it is thought that as long as the initial break in characteristics is improved, the running in characteristics after that is satisfactory.
(5) Summary
The followings are apparent from Embodiment 1 and Comparative Examples 1 through 3 as described above.
1. Wide scatter was observed in the result of the scuffing test of the non-treated pin and the wear resisting steel as the parent metal thereof provided not always enough initial break in characteristics.
The scatter in the test result was reduced by nitriding, Ni--P plating, or sulphurizing the pin and the anti-scuffing thereof is improved. The results show that the sulphurizing was the best surface treatment to provide good anti-scuffing property.
2. During the abrasion test, no significant variation was observed for the friction coefficient μ of the sulphurized pin except at the occurrence of scuffing.
3. A partial working face was observed in the non-treated pin and stick-like flaws caused by proceeding of scuffing damage and traces of penetration of lubricating oil were observed on the surface of the test piece after the scuffing test. There was numerically non-significant difference between before and after the scuffing test in the surface roughness of the non-treated pin, i.e. about 1.6 μm and about 2.0 μm before and after the scuffing test, respectively.
4. Because of the sulphurizing, the sulphurized test piece is provided with amorphous FexS on the surface thereof, the surface roughness of the test piece was increased (surface roughness=about 14.3 μm), and the surface irregularities tended to be smoothed. The surface irregularities were effective in retaining oil.
After the scuffing test, the surface roughness was reduced (about 2.5 μ m) and the sulphurized layer died out. However, it is thought that as long as the initial break in characteristics is improved, the running in characteristics after that is satisfactory for the wear resisting steel.
The description will now be made as regard to embodiments and comparative examples of the ring spring.
(Embodiments)
A ring spring consisting of combination of four inner rings made of wear resisting steel having compositions of Embodiment 1 shown in Table 1 and five outer rings made of SUP10 steel was prepared. The outer diameter of each outer ring was 100 mm and the inner diameter of each inner ring was 60 mm. The sliding surfaces between the inner rings and the outer rings were applied with MoS 2 grease.
The ring spring was loaded with an alternate compressive load between minimum 1 tons and maximum 10 tons at 0.4 Hz and the strokes thereof were measured. The result is shown in FIG. 6(b).
A ring spring was prepared in the same manner but using wear resisting steel having compositions of Embodiment 2. The result of measuring the strokes thereof was the same as the above case.
(Comparative Examples)
A ring spring was prepared in the same manner but using SUP10 steel for both outer rings and inner rings and the load test was conducted with the ring spring under the same condition. The result of measuring the strokes thereof is shown in FIG. 6(a).
It is apparent from FIGS. 6(a) and 6(b) that the stroke can be kept at a high level for a long period in accordance with the present invention.
As described above, the present invention can provide wear resisting steel having excellent resistance to wear and scuffing, providing high strength and great elongation and high toughness, and further providing good machinability. Such wear resisting steel according to the present invention is particularly useful as a material of a sliding member for a cylinder in an internal combustion engine such as a piston ring, a cylinder liner, or a piston skirt of an internal combustion engine, and a ring spring.
The sliding member and the ring spring of the present invention have excellent wear resistance and high durability.
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Wear resisting steel, a sliding member for a cylinder in an internal combustion engine, and a ring spring consist of: carbon: equal to or less than 2.2% by weight; silicon: equal to or less than 1.2% by weight; manganese: equal to or more than 0.2 % by weight and less than 1.20% by weight; chromium: equal to or less than 16% by weight; phosphorus: equal to or less than 0.08% by weight; sulfur: equal to or more than 0.15% by weight; other compositions: equal to or less than 2.0 % by weiht; and the balance substantially consisting of iron. The surfaces thereof may be sulphurized. The steel has excellent resistance to wear and scuffing, provides high strength, great elongation, and high toughness, and also provides good machinability.
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BACKGROUND OF THE INVENTION
Operators of automobiles are increasingly interested in having a remote starting feature on their vehicles in which the operator has an actuator, which when actuated, causes the engine to be started. Operators find this feature desirable, particularly in cold weather conditions, so that the engine and vehicle cabin are heated prior to the operator entering the vehicle cabin.
At the time of remote starting, the vehicle may be housed in a garage or other enclosed room. Although modern vehicles emit miniscule amounts of carbon monoxide, about one-eighth of the exhaust gas is comprised of carbon dioxide. If the room in which the vehicle is stored is exceptionally well sealed, the concentration of exhaust gases, and carbon dioxide in particular, may exceed desirable levels within the room.
SUMMARY OF THE INVENTION
The inventors of the present invention have recognized that sensors onboard a production vehicle can be used to determine when the concentration of exhaust gases in the room, in which the vehicle is confined, exceeds an acceptable level. If such a situation is determined, engine operation is discontinued.
A method to control an internal combustion engine, which is adapted for remote starting, is disclosed. A measured air/fuel ratio based on fuel flow and air flow is determined. An error is computed based on the measured air/fuel ratio and stoichiometric air/fuel ratio for the particular fuel being supplied to the engine. If the error exceeds a threshold, engine operation is ceased. Engine cessation is based on the engine having been remotely started. In one embodiment, the error is computed when the engine is being operated under closed-loop control based on-a signal from the exhaust gas oxygen sensor. In one embodiment, if the engine is under operator control, the engine is allowed to continue to operate.
The inventors of the present invention have recognized that when the engine is operating under closed loop control based on a signal from the exhaust gas oxygen sensor, the air/fuel ratio based on mass air flow measurements will deviate from the stoichiometric air/fuel ratio when the air being inducted into the engine intake contains significant amount of diluent, e.g., exhaust gas. Modern electronic control units on-board vehicles have the capability of estimating both of these air/fuel ratios. By comparing these, the deviation in the two air/fuel ratios can be determined.
In the present invention, engine operation is discontinued when the error computed based on the two air/fuel ratios exceeds a threshold. By ceasing operation, the amount of exhaust gas concentration of intake gases can no longer increase; thereby, the maximum allowable concentration of exhaust gases in an enclosed space is not exceeded, an advantage of the present invention.
The above advantages, other advantages, and features of the present invention will be readily apparent from the following detailed description of the preferred embodiments when taken in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The advantages described herein will be more fully understood by reading an example of an embodiment in which the invention is used to advantage, referred to herein as the Detailed Description, with reference to the drawings wherein:
FIG. 1 is a schematic of a vehicle equipped with remote starting;
FIG. 2 is a schematic of an internal combustion engine installed in the vehicle;
FIG. 3 is a flowchart of an embodiment of the present invention;
FIG. 4 is a graph showing how air/fuel ratio is affected by the percent diluent in the inducted air; and
FIG. 5 is a flowchart of an embodiment by which engine restart is achieved following an engine shutdown;
FIG. 6 is a graph of the minimum delay time as a function of the time rate of change of measured air/fuel ratio according to an aspect of the invention; and
FIG. 7 is a flowchart of an embodiment of the present invention
DETAILED DESCRIPTION
The present invention relates to a vehicle with the capability of being remotely started. In FIG. 1 , a vehicle 4 is shown in an enclosure 2 , which could be a garage. Vehicle 4 has an internal combustion engine 10 installed within. Engine 10 is electronically coupled to an electronic control unit 40 . Enclosure 1 , which could be a house, has an actuator 8 . When activated, for example, by an operator of vehicle 10 , actuator 8 sends a signal which is sensed by sensor 6 . Sensor 6 is electronically coupled to ECU 40 . When ECU 40 receives the signal that the operator has requested a start of engine 10 via actuator 8 , ECU 40 starts operation of engine 10 . Enclosure 1 is shown by way of example. Enclosure 1 may be detached from enclosure 2 . Alternatively, actuator 8 may not be in an enclosure at all. Engine 10 is coupled to a transmission 5 , which in one embodiment is an automatic transmission. Alternatively, transmission 5 is a manual transmission. Operator controls 3 are coupled to engine 10 , transmission 5 , and ECU 40 . Operator controls include: an ignition switch, a gear shift lever, a throttle pedal, etc.
A four-cylinder internal combustion engine 10 is shown, by way of example, in FIG. 2 . Engine 10 is supplied air through intake manifold 12 and discharges spent gases through exhaust manifold 14 . An intake duct upstream of the intake manifold 12 contains a throttle valve 32 which, when actuated, controls the amount of air flow to engine 10 . Sensors 34 and 36 installed in intake manifold 12 measure air temperature and mass air flow (MAF), respectively. Sensor 31 , located in intake manifold 14 downstream of throttle valve 32 , is a manifold absolute pressure (MAP) sensor. A partially closed throttle valve 32 causes a pressure depression in intake manifold 12 . When a pressure depression exists in intake manifold 12 , exhaust gases are caused to flow through exhaust gas recirculation (EGR) duct 19 , which connects exhaust manifold 14 to intake manifold 12 . Within EGR duct 19 is EGR valve 18 , which is actuated to control EGR flow. Fuel is supplied to engine 10 by fuel injectors 26 . Each cylinder 16 of engine 10 contains a spark plug 28 . A pressure transducer 30 is shown installed in each cylinder 16 . The crankshaft (not shown) of engine 10 is coupled to a toothed wheel 20 . Sensor 22 , placed proximately to toothed wheel 20 , detects engine 10 rotation. Sensor 24 , in exhaust manifold 14 , is an exhaust gas component sensor. Exhaust gas component sensor 24 is an exhaust gas oxygen sensor. Alternatively, exhaust gas component sensor 24 is a wide-range oxygen sensor, a nitrogen oxide sensor, a hydrocarbon sensor, or other gas component sensor as may become available.
Continuing to refer to FIG. 2 , electronic control unit (ECU) 40 is provided to control engine 10 . ECU 40 has a microprocessor 46 , called a central processing unit (CPU), in communication with memory management unit (MMU) 48 . MMU 48 controls the movement of data among the various computer readable storage media and communicates data to and from CPU 46 . The computer readable storage media preferably include volatile and nonvolatile storage in read-only memory (ROM) 50 , random-access memory (RAM) 54 , and keep-alive memory (KAM) 52 , for example. KAM 52 may be used to store various operating variables while CPU 46 is powered down. The computer-readable storage media may be implemented using any of a number of known memory devices such as PROMs (programmable read-only memory), EPROMs (electrically PROM), EEPROMs (electrically erasable PROM), flash memory, or any other electric, magnetic, optical, or combination memory devices capable of storing data, some of which represent executable instructions, used by CPU 46 in controlling the engine or vehicle into which the engine is mounted. The computer-readable storage media may also include floppy disks, CD-ROMs, hard disks, and the like. CPU 46 communicates with various sensors and actuators via an input/output (I/O) interface 44 . Examples of items that are actuated under control by CPU 46 , through I/O interface 44 , are fuel injection timing, fuel injection rate, fuel injection duration, throttle valve 32 position, spark plug 28 timing, EGR valve 18 , etc. Various other sensors 42 and specific sensors (engine speed sensor 22 , cylinder pressure transducer sensor 30 , engine coolant sensor 38 , manifold absolute pressure sensor 31 , exhaust gas component sensor 24 , air temperature sensor 34 , and mass air flow sensor 36 ) communicate input through I/O interface 44 and may indicate engine rotational speed, vehicle speed, coolant temperature, manifold pressure, pedal position, cylinder pressure, throttle valve position, air temperature, exhaust temperature, exhaust stoichiometry, exhaust component concentration, and air flow. Some ECU 40 architectures do not contain MMU 48 . If no MMU 48 is employed, CPU 46 manages data and connects directly to ROM 50 , RAM 54 , and KAM 52 . Of course, the present invention could utilize more than one CPU 46 to provide engine control and ECU 40 may contain multiple ROM 50 , RAM 54 , and KAM 52 coupled to MMU 48 or CPU 46 depending upon the particular application.
A flowchart showing an embodiment of the present invention is shown in FIG. 3 . It is determined whether the engine was remotely started in block 102 . If not, the normal engine control algorithms, which are outside the present invention, are followed. If the engine was remotely started, control passes to block 104 in which it is determined whether the engine is operating in a closed-loop control mode. Closed-loop control will be discussed in more detail below. Briefly, the exhaust gas oxygen sensor, which forms the basis for closed-loop control, provides a reliable signal only when sufficiently warm. Closed-loop control is delayed until such a reliable signal is obtain. When closed-loop control is determined in block 104 , control passes to block 106 in which an air/fuel ratio based on measurements of air flow and fuel flow is computed. Control passes to block 108 in which an error is computed: measured air/fuel ratio minus stoichiometric air/fuel ratio, the latter discussed in more detail below. In block 110 , it is determined whether the error exceeds a threshold. If not, control is passed back to block 106 for continuous monitoring. If a positive result from block 110 is obtained, control passes to block 114 in which it is determined whether the engine is under operator control. If so, normal operation, according to control algorithms outside the present invention, is accessed in block 116 . If the operator has taken over control, it is likely that the operator is about to remove the vehicle from an enclosure thereby taking mitigating action to overcome the issue of the two air/fuel ratios deviating from each other. In an alternative embodiment, blocks 114 and 116 are not included. In this alternative embodiment, a positive result from block 110 feeds into block 118 , in which the engine is shut down.
In block 114 of FIG. 4 , it is determined if the engine is under operator control. In this context, this means has the operator taking over control beyond the initial starting of the engine remotely. Determination of taking over control is based on one of: inserting the key into the ignition, turning the key in the ignition switch, opening the door of the vehicle, moving a gear shift lever, depressing the clutch, as examples.
Modern engines use a catalytic converter to oxidize unburned hydrocarbons and carbon monoxide to water and carbon dioxide and to reduce nitrogen oxides to nitrogen and oxygen. The catalytic converter operates with a high efficiency at carrying out these reactions when it is fed gases at a stoichiometric air/fuel ratio, i.e., the air and fuel fed to the engine are in such a proportion that all of the air and fuel could theoretically react to produce only carbon dioxide, water, and unreacted nitrogen from the air. EGO sensor 24 provides a low voltage when the gases it contacts are lean of stoichiometric and a high voltage when the gases are rich of stoichiometric. By biasing the air/fuel mixture very slightly rich and then very slightly lean, the average air/fuel ratio can be maintained very close to stoichiometric with adjustments to the air/fuel ratio being feedback controlled on EGO sensor 24 signal. Such closed-loop control is used in nearly all production engines and is well known by those skilled in the art.
If vehicle 4 is within a poorly ventilated enclosure 2 , it is possible that the air being inducted into engine 10 becomes substantively diluted. If the inducted air is diluted, more air is required to provide the amount of oxygen needed to provide a stoichiometric mixture. Commonly, during engine idle, the amount of air supplied to the engine is controlled to maintain a desired engine idle speed. Thus, if the air being inducted into the engine does not provide enough oxygen to burn the fuel, the fueling rate would drop slightly causing engine speed to drop. To maintain engine speed, throttle 32 would be caused to open slightly to induct more air. Alternatively, an idle air bypass valve (not shown) would be opened further to supply more air to engine 10 . Under this feedback strategy where air is controlled to maintain engine speed and fuel is controlled to maintain stoichiometric conditions in the exhaust, EGO sensor 24 would continue to indicate that the engine is operating at stoichiometric air/fuel ratio, regardless of the amount of exhaust gas dilution. Stoichiometric air/fuel ratio for gasoline is about 14.6 on a mass basis. A measure of the mass of air and the mass of fuel being supplied to the engine would indicate that the mass of air had increased when there is diluent in the air, thus causing the air/fuel ratio based on such a measurement to increase.
Referring now to FIG. 4 , percent diluent in the induction air (x-axis) is plotted versus air/fuel (y-axis). X % on the x-axis signifies the maximum acceptable diluent fraction. The air/fuel from the EGO sensor is a constant regardless of the amount of diluent. Furthermore, that constant is the stoichiometric air/fuel. The EGO sensor signal is employed in practice to ensure that a stoichiometric amount of air and fuel is supplied to the engine. The EGO sensor has no way of determining that the air is diluted with exhaust gases necessitating a higher mass of the diluted air to be delivered to the engine to provide the same power. Thus, the dashed line in FIG. 4 signifies the constant air/fuel because of feedback control on the EGO sensor. A solid line in FIG. 4 indicates how the air/fuel based on measurement of air and fuel flow increases when the amount of diluent in the air increases. At X % diluent, the deviation in the two air/fuel ratios is shown as e thresh , the threshold error. Error, e, is defined as: e=A/F meas −A/F stoich . As discussed above, the engine is to be shut off when e exceeds e thresh , which indicates that the amount of diluent in the inducted air is greater than X %, the maximum acceptable level of diluent.
Continuing to refer to FIG. 4 , the A/F stoich is the stoichiometric air/fuel, which as discussed above, is 14.6 for gasoline. The stoichiometric air/fuel is other than 14.6 for alternative fuels such as hydrogen, natural gas, liquid petroleum gas, biofuels, alcohols, etc. Either stoichiometric air/fuel is a known quantity, or in the case of gasohols, which could have various percentages of alcohol in gasoline, it is known to use a sensor in the fuel tank or other estimating means to determine the percent of alcohol in the fuel, thereby allowing the computation of the stoichiometric air/fuel.
Typically fuel flow is measured based on the pressure in the fuel injection system and the fuel pulse width, that is, the time that the fuel injector is open. This example is given for illustration purposes only and not intended to be limiting to the present invention. There are two common methods by which mass airflow is measured on production vehicles. These are known by those skilled in the art as speed-density and MAF, for mass-air flow. The former method relies on a measure of the pressure in the intake manifold downstream of throttle 32 and an engine speed sensor 22 . Additionally, the volume of air inducted into engine cylinders each intake event must be known. The mass of air inducted into the engine is computed therefrom. Alternatively, a mass flow sensor 36 is placed upstream of throttle 32 providing the desired quantity directly.
After engine 10 has been shut down due to a deviation in the two air/fuel ratios, the operator of the vehicle may desire to restart the engine and drive the vehicle away. In one embodiment of the present invention, the engine remains disabled for a period of time before restart is allowed. This period of time is based on the time history of the measured air/fuel ratio. That is, if the measured air/fuel ratio rises rapidly, it indicates that vehicle 4 is in a very small and/or very well sealed enclosure 2 . It is likely to take longer, in this situation, for the air in enclosure 2 to be refreshed such that it has significantly less than the acceptable concentration of diluent. Conversely, if the measured air/fuel ratio very slowly rises, indicating that diluent concentration is slowly increasing in the air in enclosure 2 , the time until restart is shorter than the former scenario.
Referring to FIG. 5 , after engine 10 has been shut down (block 118 as shown in both FIGS. 3 and 5 ), control is passed to block 120 in which the time history of the measured air/fuel is analyzed to determine an appropriate delay time. Control then passes to block 122 , in which ECU 40 waits for an operator request for a restart. In block 124 , the actual time delay since engine 10 was shutdown is compared with the minimum delay time computed in block 120 . If the actual delay time exceeds the minimum delay time, a restart is allowed. Otherwise, engine 10 is maintained in the shutdown condition until such minimum delay time has passed.
Referring now to FIG. 6 , one example of how minimum delay time could be computed is provided. In block 120 of FIG. 5 , A/F meas is analyzed. In the particular example of FIG. 6 , the time rate of change of A/F meas is determined. If the slope of A/F meas is high, this indicates a small or well sealed enclosure 2 and that it is likely to take longer for the air in enclosure 2 to return to a concentration of exhausts gases less than the acceptable dilution amount. Thus, the minimum delay time is greater.
Referring now to FIG. 7 , an alternative embodiment is employed for engine restart. Starting with block 118 , the engine is shut down. Control passes to block 130 in which a code in ECU 40 is set indicating that the engine was shut down due to a problem with excess exhaust gas dilution in the air. The operator restarts in block 132 . In block 133 , it is determined whether the code was set in block 130 . If not, control passes to block 116 , normal operation. If the code was set, control passes to block 134 in which an algorithm similar to that in FIG. 3 is followed. That is, the measured air/fuel is determined in block 136 ; the difference between measured and stoichiometric air/fuel is computed in block 138 ; and the difference is compared to a threshold error in block 140 . If greater than the threshold error, control passes to block 118 to shut down the engine. If less than the threshold error, control passes to block 142 to clear the error code and resume normal operation in block 116 .
While several modes for carrying out the invention have been described in detail, those familiar with the art to which this invention relates will recognize alternative designs and embodiments for practicing the invention. The above-described embodiments are intended to be illustrative of the invention, which may be modified within the scope of the following claims.
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Automotive vehicles are increasingly being equipped with remote starting devices. If the vehicle is within a space which is very well sealed, it is possible that the concentration of the exhaust gases may exceed desirable levels. A method and system are disclosed in which a mass-based determination of air/fuel ratio is compared with the air/fuel ratio being maintained by the exhaust gas oxygen sensor. When the air/fuel ratio based on a mass measurement deviates from the air/fuel ratio based on the exhaust gas oxygen sensor by more than a threshold difference, the remotely started vehicle is turned off.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a control technique, and more particularly, to an adaptive control method and related device for controlling a sensing amplifier based on an input clock.
[0003] 2. Description of the Prior Art
[0004] Read procedures of storage devices (e.g. dynamic random access memory (DRAM) or static random access memory (SRAM)) are limited by the timing required for signal transmission. Examples are shown in FIG. 1 and FIG. 2 . FIG. 1 illustrates a portion of a conventional read unit 100 architecture. FIG. 2 illustrates some signals of the conventional read unit 100 . Each time the storage device 100 receives a read command Rd, it takes time tYS from a rising edge of an input clock CK to selecting a proper Y switch 110 by a selection signal YS 0 . After the Y switch 110 is conductive, signals from the data lines (each Y switch is responsible for data of two bits, and four switches are required to control four data lines DL, DL−, DL′ and DL′−, which are respectively the complementary signals of two bits) through the Y switch 110 require time tYS2DLSA until the signals are high enough to be correctly recognized and amplified by a sense amplifier 120 . An amplifier enablement signal SA_EN enables the sensing amplifier 120 to amplify the signals on the data lines (for ease of explanation, only operations of data lines DL and DL− will be explained). The time required to form an internal transmission signal internal_IO from the sensing amplifier to an internal buffer (not shown) of the read unit 100 is tDLSA2DQBUF. Finally, according to an output indication signal CLKOE, the read data signal is transmitted to a driver (off chip driver, not shown) outside the chip to form an output signal Data_pin, which takes time tOCD. Hence, the time required by the read procedure of the storage device will be a sum of times required by the above-mentioned four procedures, which is: tYS+tYS2DLSA+tDLSA2IOBUF+tOCD.
[0005] Times tYS, tDLSA2DQBUF and tOCD cannot be shortened due to certain limitations of design. Time tYS2DLSA cannot be shortened because it is importance to ensure that input differential signals have enough time to develop from zero level to a proper differential level before being processed by the sensing amplifier 120 . Hence, after the Y switch receives the signal, it needs to wait a default time (i.e. tYS2DLSA) before enabling the sensing amplifier. For a faster read unit, which operates with a faster input clock and shorter clock period, a much shorter time is taken to develop the signals from zero level to a proper differential level suitable for the sensing amplifier 110 . That is, the time needed by waiting to receive the signals to enabling the sensing amplifier 110 could be shorter than the default time. If the conventional read unit still enables the sensing amplifier after the default time expires, the process time will be wasted and the overall performance will be degraded.
SUMMARY OF THE INVENTION
[0006] To address the above-mentioned problem, the present invention provides an adaptive control technique based on an input clock, which selectively controls enablement time of a sensing amplifier based on the input clock to improve the overall operating speed.
[0007] According to one exemplary embodiment of the present invention, an adaptive control method based on an input clock is provided. The adaptive control method comprises: performing a read procedure according to the input clock; receiving a read command; receiving a data signal via a data line according to the read command; enabling an amplifying unit according to at least the input clock; and utilizing the amplifying unit to amplify the data signal.
[0008] According to one exemplary embodiment of the present invention, an adaptive control device is provided. The adaptive control device comprises: a read unit, an amplifying unit and a control circuit. The read unit is employed for receiving an input clock, and performing a read procedure according to the input clock. The control circuit is coupled to the amplifying unit and the read unit, and employed for receiving a read command and controlling the read unit to receive a data signal via a data line according to the read command, and enabling the amplifying unit according to the input clock to utilize the amplifying unit to amplify the data signal.
[0009] These and other objectives of the present invention will no doubt become obvious to those of ordinary skill in the art after reading the following detailed description of the preferred embodiment that is illustrated in the various figures and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 illustrates a portion of a conventional read unit architecture.
[0011] FIG. 2 illustrates some signals of a conventional read unit.
[0012] FIG. 3 illustrates a schematic diagram of an adaptive control device according to one exemplary embodiment of the present invention.
[0013] FIG. 4 illustrates some signals of the adaptive control device according to a first exemplary embodiment of the present invention.
[0014] FIG. 5 illustrates some signals of the adaptive control device according to a second exemplary embodiment of the present invention.
[0015] FIG. 6 illustrates some signals of the adaptive control device according to a third exemplary embodiment of the present invention.
[0016] FIG. 7 illustrates some signals of the adaptive control device according to a fourth exemplary embodiment of the present invention.
[0017] FIG. 8 illustrates some signals of the adaptive control device according to a fifth exemplary embodiment of the present invention.
[0018] FIG. 9 illustrates a schematic diagram of an adaptive control device according to another exemplary embodiment of the present invention.
DETAILED DESCRIPTION
[0019] Certain terms are used throughout the following descriptions and claims to refer to particular system components. As one skilled in the art will appreciate, manufacturers may refer to a component by different names. This document does not intend to distinguish between components that differ in name but not differ in functionality. In the following discussion and in the claims, the terms “include”, “including”, “comprise”, and “comprising” are used in an open-ended fashion, and thus should be interpreted to mean “including, but not limited to . . . ” The terms “couple” and “coupled” are intended to mean either an indirect or a direct electrical connection. Thus, if a first device couples to a second device, that connection may be through a direct electrical connection, or through an indirect electrical connection via other devices and connections.
[0020] FIG. 3 illustrates a schematic diagram of an adaptive control device 300 implemented according to one exemplary embodiment of the present invention. The adaptive control device 300 comprises: a read unit 310 , an amplifying unit 320 and a control circuit 330 . The read unit 310 is employed for receiving an input clock CK, and performing a read procedure according to the input clock CK. The control circuit 330 is coupled to the amplifying unit 320 and the read unit 310 , and employed for receiving a read command RD, and according to the read command RD, controlling the read unit 310 to receive a data signal via data lines DL and DL−. Subsequently, the control circuit 330 enables the amplifying unit 320 according to the input clock CK. The amplifying unit 320 is further employed for amplifying the data signal. Note that, in this embodiment, after the control circuit 330 receives the read command RD, the control circuit 330 enables the amplifying unit 320 according to a rising edge of the input clock CK to amplify the data signal on the data lines DL and DL−. According to various embodiments of the present invention, it is feasible to use a falling edge of the input clock CK for the purpose of enabling the amplifying unit 320 . As long as any design uses the input clock CK to enable the amplifying unit 320 , this falls within the scope of the invention. For example, in one embodiment, the control circuit 330 could be implemented with a lock unit (e.g. a phase locked loop, PLL) or a delay lock unit (e.g. delay locked loop, DLL). The control circuit 330 could lock to a frequency of the input clock CK, and generate an adaptive delay time that is directly proportional to a period of the input clock CK according to the frequency of the input clock CK. After the adaptive control device 300 receives the read command Rd, the amplifying unit 320 will be enabled when the adaptive delay time expires. In another embodiment, if the frequency of the input clock CK falls within a predetermined range, after receiving the read command Rd, the adaptive control device 300 will enable the amplifying unit 320 once a default delay time expires. If the frequency of the input clock CK falls outside the predetermined range, the adaptive control device 300 will generate the adaptive delay time that is directly proportional to the period of the input clock CK. After the read command Rd is received, the amplifying unit 320 will be enabled when the adaptive delay time expires. The above-mentioned implementations all fall within the scope of the present invention.
[0021] FIG. 4 illustrates operations and principles of the adaptive control device 300 for further details. FIG. 4 illustrates some signals of the adaptive control device 300 according to a first exemplary embodiment of the present invention. After the adaptive control device 300 receives the read command Rd, the rising edge of the input clock CK will trigger and select one Y switch of the read unit 310 for transmission. Enablement of the amplifying unit 320 (which serves as a sensing amplifier here) of the adaptive control device 300 is controlled by the rising edge of the input clock CK. Thus, the required time from receiving the read command Rd to amplifying the signal by the amplifying unit 320 would be tCK+tDLSA2. In this embodiment, tCK is the period of the input clock CK, while tDLSA2 is default delay time and subsequent to the second rising edge after the read command Rd. In the conventional art shown by FIG. 2 , the required time from receiving the read command Rd to amplifying the signal by the amplifying unit 320 would be tYS+tYS2dlsa, but in this embodiment the required time would be tCK+tDLSA2. In other words, the required time becomes a period of time that is in positive correlation with the input clock, instead of a constant period of time. Hence, the adaptive control device 300 may process the read command faster than the conventional art when receiving high-speed clocks.
[0022] Note that the period of time that is in positive correlation with the input clock is not limited to one period tCK of the input clock. For example, it could be related to 0.5 period, 1.5 periods, 2 periods or the like. The operation of the adaptive control device 300 may lead to the result as shown in FIG. 5 . FIG. 5 illustrates some signals of the adaptive control device 300 according to a second exemplary embodiment of the present invention. After the adaptive control device 300 receives the read command Rd, the rising edge of the input clock CK will trigger and select one Y switch of the read unit 310 for transmission. Enablement of the amplifying unit 320 (which serves as a sensing amplifier here) of the adaptive control device 300 is controlled by a falling edge of the input clock CK at a half period subsequent to triggering the read unit 310 . Thus, the required time from receiving the read command Rd to amplifying the signal by the amplifying unit 320 would be 0.5*tCK+tDLSA2. In this embodiment, tCK is the period of the input clock CK, while tDLSA2 is default delay time and subsequent to the first falling edge after the read command Rd. In the conventional art shown by FIG. 2 , the required time from receiving the read command Rd to amplifying the signal by the amplifying unit 320 would be tYS+tYS2dlsa, but in this embodiment the required time would be 0.5*tCK+tDLSA2. In other words, the required time becomes a period of time that is in positive correlation with the input clock, instead of a constant period of time. Hence, the adaptive control device 300 may process the read command faster than the conventional art when receiving high-speed clocks.
[0023] The operation of the adaptive control device 300 could also lead to the result shown in FIG. 6 . FIG. 6 illustrates some signals of the adaptive control device 300 according to a third exemplary embodiment of the present invention. After the adaptive control device 300 receives the read command Rd, the rising edge of the input clock CK will trigger and select one Y switch of the read unit 310 for transmission. Enablement of the amplifying unit 320 (which serves as a sensing amplifier here) of the adaptive control device 300 is controlled by a second falling edge of the input clock CK at one and a half periods subsequent to triggering the read unit 310 . Thus, the required time from receiving the read command Rd to amplifying the signal by the amplifying unit 320 would be 1.5*tCK+tDLSA2. In this embodiment, tCK is the period of the input clock CK, while tDLSA2 is default delay time and subsequent to the second falling edge after the read command Rd. In the conventional art shown by FIG. 2 , the required time from receiving the read command Rd to amplifying the signal by the amplifying unit 320 would be tYS+tYS2dlsa, but in this embodiment the required time would be 1.5*tCK+tDLSA2. In other words, the required time becomes a period of time that is in positive correlation with the input clock, instead of a constant period of time. Hence, the adaptive control device 300 may process the read command faster than the conventional art when receiving high-speed clocks.
[0024] The operation of the adaptive control device 300 may lead to the result as shown in FIG. 7 . FIG. 7 illustrates some signals of the adaptive control device 300 according to a fourth exemplary embodiment of the present invention. After the adaptive control device 300 receives the read command Rd, the rising edge of the input clock CK will trigger and select one Y switch of the read unit 310 for transmission. Enablement of the amplifying unit 320 (which serves as a sensing amplifier here) of the adaptive control device 300 is controlled by a second rising edge of the input clock CK at two periods subsequent to triggering the read unit 310 . Thus, the required time from receiving the read command Rd to amplifying the signal by the amplifying unit 320 would be 2*tCK+tDLSA2. In this embodiment, tCK is the period of the input clock CK, while tDLSA2 is default delay time and subsequent to the second rising edge after the read command Rd. In the conventional art shown by FIG. 2 , the required time from receiving the read command Rd to amplifying the signal by the amplifying unit 320 would be tYS+tYS2dlsa, but in this embodiment the required time would be 2*tCK+tDLSA2. In other words, the required time becomes a period of time that is in positive correlation with the input clock, instead of a constant period of time. Hence, the adaptive control device 300 may process the read command faster than the conventional art when receiving high-speed clocks.
[0025] It can be understood from the above embodiments that when the control circuit 330 receives the read command RD, it can enable the amplifying unit 320 at a rising edge or a falling edge after multiples of a half period of the input clock CK. For example, the control circuit 330 could enable the amplifying unit 320 according to an edge (rising or falling) at 2.5, 3, or 3.5 periods of the input clock CK, as shown in FIG. 8 .
[0026] FIG. 8 illustrates some signals of the adaptive control device 300 according to a fifth exemplary embodiment of the present invention. After the adaptive control device 300 receives the read command Rd, the rising edge of the input clock CK will trigger and select one Y switch of the read unit 310 for transmission. The enablement of the amplifying unit 320 (which serves as a sensing amplifier) of the adaptive control device 300 could be controlled by signal transition (i.e. the rising edge or the falling edge) at multiples (2.5, 3, or 3.5) of the period after the input clock CK triggers the read unit 310 . Thus, the required time from receiving the read command Rd to amplifying the signal by the amplifying unit 320 would be (2.5, 3, 3.5, . . . )*tCK+tDLSA2. In this embodiment, tCK is the period of the input clock CK, while tDLSA2 is default delay time and fixedly at the occurrence of signal transition at selected multiples of the period after the read command Rd. In the conventional art shown by FIG. 2 , the required time from receiving the read command Rd to amplifying the signal by the amplifying unit 320 would be tYS+tYS2dlsa, but in this embodiment the required time would be (2.5, 3, 3.5, . . . )*tCK+tDLSA2. In other words, the required time becomes a period of time that is in positive correlation with the input clock, instead of a constant period of time. Hence, the adaptive control device 300 may process the read command faster than the conventional art when receiving high-speed clocks.
[0027] FIG. 9 illustrates a schematic diagram of an adaptive control device 900 according to another exemplary embodiment of the present invention. The adaptive control device 900 comprises: a read unit 910 , an amplifying unit 920 , a control circuit 930 , a timer 940 and a selection unit 950 . Functionalities and architecture of the read unit 910 , the amplifying unit 920 , and the control circuit 930 are substantially identical to those of the read unit 310 , the amplifying unit 320 , and the control circuit 330 of FIG. 3 . Hence, the detailed descriptions of the read unit 910 , the amplifying unit 920 and the control circuit 930 are omitted here. The timer 940 is employed for providing a default delay time to the selection unit 950 . After receiving the read command Rd, the selection unit 950 generates an amplifying unit enablement signal SA_EN according to the default delay time or the input clock CK to enable the amplifying unit 920 . The selection unit 950 can be implemented with a simple OR logic gate, a phase/frequency detector or any other similar circuitry. Note that, when the frequency of the input clock CK is lower, the adaptive control device 900 enables the amplifying unit 920 through the path from the timer 940 to the selection unit 950 . Similar to the conventional art, by properly choosing the default delay time, the selection unit 950 waits the time tYS+tYS2DLSA to generate the amplifier unit enablement signal SA_EN to enable the amplifying unit 920 after the timer 940 receives the read command Rd. What is different from the conventional art is that once the frequency of the input clock CK is higher than a threshold, the amplifying unit 820 is enabled through the path from the control circuit 930 to the selection unit 950 to achieve a better performance. Hence, the adaptive control device 900 uses different processing paths according to different input clocks so that the performance can be improved.
[0028] In conclusion, the present invention provides an adaptive control method based on an input clock and related apparatus. The timing of enabling the sensing amplifier may be determined according to the period of the input clock. Hence, the performance of the present invention can be improved as the frequency of the input clock increases.
[0029] Those skilled in the art will readily observe that numerous modifications and alterations of the device and method may be made while retaining the teachings of the invention. Accordingly, the above disclosure should be construed as limited only by the metes and bounds of the appended claims.
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An adaptive control method based on an input clock includes: performing a read process according to the input clock; receiving a read command; receiving a data signal via a data line according to the read command; enabling an amplifier element according to at least the input clock; and utilizing the amplifier element to amplify the data signal.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit under 35 U.S.C. §119 of Korean Patent Application No. 10-2012-0079877, filed Jul. 23, 2012, which is hereby incorporated by reference in its entirety.
BACKGROUND
[0002] The embodiment relates to a lighting apparatus.
[0003] In general, various types of lighting apparatuses such as ceiling-mounting type lamps, scenery lighting lamps, sleeping lamps, and stand lamps exist according to purposes thereof. The lighting apparatuses must irradiate light with sufficient luminance level according to purposes. Accordingly, recently, a light emitting diode (LED) has been used for a lighting apparatus. In comparison with other light sources such as a fluorescent lamp and an incandescent lamp, the LED is advantageous because of low power consumption, a long lifetime, a fast response time, safety, and environment-friendliness. Accordingly, many studies and researches to replace the existing light sources with the light emitting diode have been carried out.
[0004] However, the above lighting apparatuses are turned-on/off by a switch connected to the lighting apparatuses through a cable. Accordingly, a user of the lighting apparatus must inconveniently control the lighting apparatus.
BRIEF SUMMARY
[0005] An embodiment provides a lighting apparatus which can be easily controlled.
[0006] According to the embodiment, there is provided a lighting apparatus including: a control module supplying power; a heat sink receiving the control module; a light source mounted on the heat sink and connected to the control module; and a communication module including a connection terminal inserted into the heat sink and connected to the control module, and an antenna device protruding from the heat sink.
[0007] According to another embodiment, there is provided lighting apparatus including: a control module supplying power; a heat sink receiving the control module; a light source mounted on the heat sink to emit light according to the power; and a communication module receiving a signal for controlling the control module, wherein the communication module includes: a substrate; a connection terminal disposed on the substrate, inserted into the heat sink, and connected to the control module; and an antenna device disposed on the substrate and protruding from the heat sink to be spaced apart from the heat sink.
[0008] The lighting apparatus according to the embodiment has a wireless communication function. In this case, the lighting apparatus may receive a wireless control signal through the communication module. Further, the lighting apparatus may control the light source according to the wireless control signal. Accordingly, the lighting apparatus can be controlled in a wireless scheme. That is, a user of the lighting apparatus can easily control the lighting apparatus. Accordingly, the convenience for a user of the lighting apparatus can be improved.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is an exploded perspective view illustrating a lighting apparatus according to the embodiment.
[0010] FIG. 2 is a perspective view illustrating a coupling structure of the lighting apparatus according to the embodiment.
[0011] FIG. 3 is an exploded perspective view illustrating a communication module shown in FIG. 1 .
[0012] FIG. 4 is a sectional view taken along line A-A′ of FIG. 1 .
DETAILED DESCRIPTION
[0013] Hereinafter, the embodiments will be described in detail with reference to accompanying drawings. In the accompanying drawings, the same components will be assigned with the same reference numerals. In a description of the embodiment, if the function or the structure related to the disclosure and generally known to those skilled in the art make the subject matter of the disclosure unclear, the details of the function or the structure will be omitted.
[0014] In the description of the embodiments, it will be understood that, when each element is referred to as being “on” or “under” another element, it can be “directly” or “indirectly” on or under another element or the other constituent elements may also be present. Such a position of the elements has been described with reference to the drawings.
[0015] FIG. 1 is an exploded perspective view illustrating a lighting apparatus according to the embodiment, FIG. 2 is a perspective view illustrating a coupling structure of the lighting apparatus according to the embodiment, FIG. 3 is an exploded perspective view illustrating a communication module shown in FIG. 1 , and FIG. 4 is a sectional view taken along line A-A′ of FIG. 1 .
[0016] Referring to FIGS. 1 to 4 , the lighting apparatus 100 according to the embodiment includes a light source 110 , a light source coupling part 120 , a light distribution cover 130 , a control module 140 , a housing 150 , a shield cover 160 , a feeding cover 170 , a heat sink 180 , and a communication module 190 .
[0017] The light source 110 generates light. In this case, the light source 110 may include an LED. The light source 110 includes a feeding device 111 , a plurality of feeding wires 113 , a plurality of base substrates 115 , and a plurality of LEDs 117 .
[0018] The feeding device 111 supplies power to the light source 110 . The feeding device 111 may include a printed circuit board (PCB).
[0019] The feeding wires 113 connect the feeding device 111 to the base substrates 115 . In this case, the feeding wires 113 may directly connect the feeding device 111 to the base substrates 115 , respectively. The feeding wires 113 may connect the feeding device 111 to some of the base substrates 115 , and may connect the base substrates 115 to each other. Further, the feeding wires 113 transfer the power from the feeding device 111 to the base substrates 115 .
[0020] The base substrates 115 control driving of the light source 110 . In this case, the base substrates 115 apply the power from the feeding device 111 to the LEDs. The base substrates 115 may include a PCB.
[0021] The LEDs 117 are mounted on the base substrates 115 . In this case, the LEDs 117 may be mounted on each of the base substrates 115 . Further, the LEDs 117 emit the light according to the power from the base substrates 115 . That is, the LEDs 117 output the light.
[0022] The light source coupling unit 120 is coupled with the light source 110 to fix the light source 110 . In this case, at least one first coupling hole 121 and at least one second coupling hole 123 are formed in the light source coupling unit 120 . The first coupling holes 121 receive the base substrates 115 , respectively. The light source coupling part 120 fixes the base substrates 115 and the LEDs 117 at positions of the first coupling holes 121 , respectively. Further, the light coupling part 120 exposes the LEDs 117 through the first coupling holes 121 , respectively. In addition, the second coupling hole 123 receives the feeding device 111 and the communication module 190 . Moreover, the light source coupling part 120 exposes the feeding device 111 and the communication module 190 through the second coupling hole 123 . The communication module 190 extends through the second coupling hole 123 . That is, the communication module 190 protrudes in both directions about the light source coupling part 120 through the second coupling hole 123 . The light source coupling part 120 may include an insulator.
[0023] The light distribution cover 130 surrounds the light source 110 from the top of the light source coupling part 120 . The light distribution cover 130 may have an open bulb shape. Further, the light distribution cover 130 protects the light source 110 , and discharges the light emitted from the light source 110 . In this case, the light distribution cover 130 distributes the light to a front surface or a rear surface of the lighting apparatus. The light distribution cover 130 may include at least one of glass, plastic, polypropylene (PP), and polyethylene (PE). The light distribution cover 130 may include polycarbonate (PC) having good lightfast, heat resistant and impact characteristics. The light distribution cover 130 may include an inner surface on which pigment is coated facing the light source 110 . The pigment may include a diffusing agent to diffuse the light.
[0024] The control module 140 controls an overall operation of the lighting apparatus 100 . In this case, although not shown, the control module 140 may include a main substrate and a plurality of components. The main substrate may include a PCB. The components are mounted on the main substrate and are electrically connected to the main substrate. The components include a converter and a driver. The converter is connected to an external power source through the main substrate. Further, the converter converts AC power of the external power source into DC power. The driver controls driving of the light source 110 .
[0025] In addition, the control module 140 supplies power to the light source 110 . The control module may include a power supply unit (PSU). In this case, the control module 140 may control the light source 110 according to a received wireless control signal. The control module 140 includes a feeding terminal 141 and a coupling terminal 143 .
[0026] The feeding terminal 141 is connected to the light source 110 . The feeding terminal 141 makes contact with the feeding device 111 of the light source 110 . In this case, the feeding terminal 141 protrudes from the control module 140 . The feeding terminal 141 is coupled with the main substrate, and protrudes from the main substrate. Further, the feeding terminal 141 faces the feeding device 111 .
[0027] In addition, the feeding terminal 141 supplies power to the light source 110 . That is, the control module 140 supplies the power to the light source 110 through the feeding device 111 . Further, the feeding terminal 141 transmits a light source control signal for controlling the light source 110 to the light source 110 . That is, the control module 140 transfers the light source control signal to the light source 110 through the feeding device 111 .
[0028] The coupling terminal 143 is connected to the communication module 190 . The coupling terminal 143 is coupled with the communication module 190 . In this case, the coupling terminal 143 may protrude from the control module 140 . The coupling terminal 143 is coupled with the main substrate and protrudes from the main substrate. Further, the coupling terminal 143 may receive the communication module 190 . A coupling groove 145 may be formed in the coupling terminal 143 . The coupling groove 145 may face the communication module 190 . Moreover, the coupling groove 145 may receive the communication module 190 .
[0029] In addition, the coupling terminal 143 supplies the power to the communication module 190 . That is, the control module 140 supplies the power to the communication module 190 through the coupling terminal 143 . Further, the coupling terminal 143 receives a wireless control signal for controlling the control module 140 from the communication module 190 . That is, the control module 140 receives the wireless control signal from the communication module 190 through the coupling terminal 143 .
[0030] The housing 150 receives the control module 140 . A receiving hole 151 is formed in the housing 150 . That is, the housing 150 receives the control module 140 through the receiving hole 151 . In this case, the housing 150 may have a cylindrical shape. Further, the housing 150 may prevent an electrical short between the control module 140 and the heat sink 180 . The housing 150 may include a material having superior insulation and durability. Further, the housing 150 may include a resin material.
[0031] In addition, the housing 150 includes a connection terminal 153 . In this case, the housing 150 is locked with the external power source through the connection terminal 153 . The connection terminal 153 may be locked with the external power source through a socket scheme. Further, the connection terminal 153 may be connected to the external power source. That is, the connection terminal 153 may be electrically connected to the external power source. Further, the connection terminal 153 may electrically connect the control module 140 to the external power source. The connection terminal 153 may include a conductive material.
[0032] The shield cover 160 seals the housing 150 . The shield cover 160 covers the receiving hole 151 of the housing 150 from the top of the housing 150 . In this case, the shield cover 160 may prevent an electrical short between the control module 140 and the heat sink 180 . The shield cover 160 may include a material having superior insulation and durability. Further, the shield cover 160 may include a resin material.
[0033] At least one through hole 161 is formed in the shield cover 160 . The through hole 161 is aligned on the same axis with the second coupling hole 123 . Further, the through hole 161 receives the feeding terminal 141 and the communication module 190 . In this case, the feeding terminal 141 and the communication module 190 extend through the through hole 161 . The shield cover 160 exposes the feeding terminal 141 and the coupling terminal 143 through the through hole 161 . That is, the through hole 161 protrudes the feeding terminal 141 toward the feeding device 111 . Further, the through hole 161 protrudes the communication module 190 toward the coupling terminal 143 .
[0034] The feeding cover 170 seals the housing 150 . The feeding cover 170 covers a receiving hole of the housing 150 from the bottom of the housing 150 . Further, the feeding cover 170 makes contact with the external power source. In this case, the feeding cover 170 electrically connects the control module 140 to the external power source. The feeding cover 170 may include a conductive material.
[0035] The heat sink 180 receives the control module 140 , the housing 150 , and the shield cover 160 . A receiving groove (not shown) is formed in the heat sink 180 . That is, the heat sink 180 receives the control module 140 , the housing 150 , and the shield cover 160 through the receiving groove. Further, the light source 110 is mounted on the heat sink 180 . In addition, the heat sink 180 releases heat generated from the light source 110 , and protects the control module 140 from the heat generated from the light source 110 . In this case, the heat sink 180 includes a first heat sink 181 and a second heat sink 185 .
[0036] The first heat sink 181 is disposed above the shield cover 160 . The first heat sink 181 is coupled with the light distribution cover 130 . In this case, an outer peripheral portion of the first heat sink 181 is coupled with the light distribution cover 130 . Further, the light source 110 and the light source coupling part 120 are mounted above the first heat sink 181 . The first heat sink 181 makes contact with the light source 110 . In this case, the first heat sink 181 moves the heat generated from the light source 110 to the second heat sink 185 . The first heat sink 181 may have a circular shape or a plane shape.
[0037] At least one insertion hole 183 is formed in the first heat sink 181 . The insertion hole 183 is aligned on the same axis with the second coupling hole 123 and the through hole 161 . Further, the insertion hole 183 receives the feeding terminal 141 and the communication module 190 . In this case, the feeding terminal 141 and the communication module 190 extend through the insertion hole 183 . The first heat sink 181 exposes the feeding terminal 141 and the coupling terminal 143 through the insertion hole 183 . That is, the insertion hole 183 protrudes the feeding terminal 141 toward the feeding device 111 . Further, the insertion hole 183 protrudes the communication module 190 toward the coupling terminal 143 .
[0038] The second heat sink 185 surrounds the housing 150 . In this case, the second heat sink 185 exposes the connection terminal 153 . That is, the second heat sink 185 surrounds the housing 150 except for a region of the connection terminal 153 . The second heat sink 185 may have a cylindrical shape. The second heat sink 185 extends downward from the first heat sink 181 . In this case, the second heat sink 185 releases the heat generated from the light source 110 . A diameter of the second heat sink 185 may be gradually reduced downward along a central axis of the first heat sink 181 .
[0039] Further, the second heat sink 185 includes a plurality of heat sink fins. In this case, the second heat sink 185 includes the heat sink fins 186 so that a surface area is increased. The heat sink fins 187 extend downward from the first heat sink 181 . In this case, the heat sink fins 187 may be radially aligned about the central axis of the first heat sink 181 . The heat sink fins 187 may protrude perpendicular to the central axis of the first heat sink 181 .
[0040] The communication module 190 receives a wireless control signal for controlling the lighting apparatus 100 . In this case, the communication module 190 is connected to the control module 140 . The communication module 190 is spaced apart from the light source 110 across the light source coupling part 120 , the heat sink 180 , and the shield cover 160 . In addition, the communication module 190 is coupled with the control module 140 . The communication module 190 includes a substrate 210 , a connection terminal 220 , a ground part 230 , an antenna device 240 , and a protective cover 250 .
[0041] The substrate 210 is provided in the communication module 190 for the purpose of support. In this case, the substrate 210 has a flat plate structure. The substrate 210 may include a PCB. Further, the substrate 210 may include a dielectric substance. The substrate 210 includes a connection region 211 , a driving region 213 , and an antenna region 215 .
[0042] The connection region 211 is placed at one end of the substrate 210 . The connection region 211 is opposed to the control module 140 . In this case, the connection region 211 is opposed to the coupling terminal 143 . The connection region 211 may be opposed to the coupling groove 145 . In addition, the connection region 211 is inserted into the heat sink 180 . In this case, the connection region is received in a receiving groove of the heat sink 180 . Further, the connection region 211 is coupled with the control module 140 . In this case, the connection region 211 is locked with the coupling terminal 143 . The connection region 211 may be inserted into the coupling groove 145 .
[0043] The driving region 213 extends from the connection region 211 . In this case, the driving region 213 is placed at a center of the substrate 210 . The driving region 213 extends across the light source coupling part 120 , the heat sink 180 , and the shield cover 160 . The driving region 213 is inserted into the heat sink 180 . In this case, the driving region 213 is received in the second coupling hole 123 , the insertion hole 183 , the through hole 161 , and a receiving groove of the heat sink 180 which are aligned on the same axis.
[0044] Further, the driving region 213 includes a driving device (not shown). In this case, the driving device is embedded in the substrate 210 , and is disposed in the driving region 213 . The driving device extends from the driving region 213 . In addition, one end of the driving device extends to the connection region 211 , and another end of the driving device extends to the antenna region 215 .
[0045] The antenna region 215 is placed at the other end of the substrate 210 . The antenna region 215 is placed in opposition to the connection region 211 about the driving region 213 . Further, the antenna region 215 is connected to the connection region 211 through the driving region 213 . The antenna region 215 protrudes from the heat sink 180 . The antenna region 215 is exposed from the heat sink 180 . In this case, the antenna region 215 is placed above the light coupling part 120 . The antenna region 215 may be spaced apart from the light source 110 .
[0046] The connection terminal 220 serves as an interface for the control module 140 in the communication module 190 . The connection terminal 200 is disposed at the connection region 211 of the substrate 210 . In this case, the connection terminal 220 is connected to one end of the driving device. Further, the connection terminal 220 is connected to the control module 140 . In this case, the connection terminal 220 is coupled with the coupling terminal 143 together with the connection region 211 and is connected to the coupling terminal 143 . The connection terminal 220 may be inserted into a coupling groove 145 . Power is supplied to the communication module 190 through the connection terminal 220 . That is, the power is supplied from the coupling terminal 143 to the connection terminal 220 .
[0047] The ground part 230 is provided in the communication module 190 for the purpose of grounding. The ground part 230 is disposed at the connection region 211 of the substrate 210 . In this case, the ground part 230 may be spaced apart from the connection terminal 220 . That is, the ground part 230 may not make contact with the connection terminal 220 . Moreover, the ground part 230 may be connected to one end of the driving device.
[0048] The antenna device 240 of the communication module 190 performs a wireless communication function. In this case, the antenna device 240 resonates at a preset frequency band to transmit/receive an electromagnetic wave. The antenna device 240 resonates at preset impedance. In this case, the antenna device 240 is disposed at the antenna region 215 of the substrate 210 . In this case, the antenna device 240 is connected to another end of the driving device. That is, the antenna device 240 is connected to the connection terminal 220 through the driving device. The antenna device 240 may be connected to the ground part 230 through the driving device. One end of the antenna device 240 is connected to the driving device and another end of the antenna device 240 is open.
[0049] In addition, the antenna device 240 protrudes from the heat sink 180 . The antenna device 240 is disposed outside the heat sink 180 . That is, the antenna device 240 is exposed from the heat sink 180 together with the antenna region 215 . Further, the antenna device 240 is spaced apart from the heat sink 180 . A spacing distance d between the antenna device 240 and the heat sink 180 may be approximately 1 mm or more. In this case, the antenna device 240 is placed above the light source coupling part 120 . The antenna device 240 may be spaced apart from the light source 110 .
[0050] Further, the antenna device 240 is driven using power supplied from the connection terminal 220 . In this case, the antenna device 240 receives a wireless control signal for controlling the control module 140 . In addition, the antenna device 240 transmits the wireless control signal to the control module 140 . In this case, the antenna device 240 transmits the wireless control signal to the control module 140 through the connection terminal 220 .
[0051] In this case, an antenna device 240 may be formed in a patch type and then be attached to the antenna region 215 . The antenna device 240 may be drawn with a conductive ink so as to be disposed at the antenna region 215 . The antenna device 240 may be patterned at the antenna region 215 . The antenna device 240 may include at least one of a bar type antenna element, a meander type antenna element, a spiral type antenna element, a step type antenna element, and a loop type antenna element. In this case, the antenna device 240 may include a conductive material. The antenna device 240 may include at least one of silver (Ag), palladium (Pd), platinum (Pt), copper (Cu), gold (Au), and nickel (Ni).
[0052] The protective cover 250 receives the substrate 210 . In this case, the protective cover 250 covers the substrate 210 . The protective cover 250 covers the driving region 213 and the antenna region 215 , and exposes the connection region 211 . The protective cover 250 receives the antenna device 240 , and exposes the connection terminal 220 . That is, the connection terminal 220 protrudes from the protective cover 250 . The protective cover 250 may include at least one of plastic, polypropylene (PP), polyethylene (PE), and polycarbonate (PC). The protective cover 250 includes a first protective cover 251 and a second protective cover 253 .
[0053] The first protective cover 251 surrounds the driving region 213 . The first protective cover 251 , together with the driving region 213 , extends across the light source coupling part 120 , the heat sink 180 , and the shield cover 160 . The protective cover 251 is inserted into the heat sink 180 . In this case, the first protective cover 251 is received in the second coupling hole 123 , the insertion hole 183 , the through hole 161 , and a receiving groove of the heat sink 180 which are aligned on the same axis.
[0054] The second protective cover 253 receives the antenna region 215 . Further, the second protective cover 253 receives the antenna device 240 . The second protective cover 253 extends from the first protective cover 251 . In this case, an insertion groove is formed in the second protective cover 253 . That is, the second protective cover 253 receives the antenna device 240 together with the antenna region 215 through the insertion groove.
[0055] In addition, the second protective cover 253 protrudes from the heat sink 180 . The second protective cover 253 is exposed from the heat sink 180 . In this case, the antenna device 240 is spaced apart from the heat sink 180 by the second protective cover 253 . The second protective cover 253 is placed above the light source coupling part 120 . In addition, the second protective cover 253 is locked with the heat sink 180 . In this case, the second protective cover 253 has a size larger than a size of the insertion hole 183 so that the second protective cover 153 is not inserted into the heat sink 180 .
[0056] According to the embodiment, the lighting apparatus 100 has a wireless communication function. In this case, the lighting apparatus 100 may receive a wireless control signal through the communication module 190 . Further, the lighting apparatus 100 may control the light source 110 according to the wireless control signal. Accordingly, the lighting apparatus 100 can be controlled in a wireless scheme. That is, a user of the lighting apparatus 100 may easily control the lighting apparatus 100 . Accordingly, the convenience for a user of the lighting apparatus 100 can be improved.
[0057] While the invention has been shown and described with reference to certain preferred embodiments thereof, 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 defined by the appended claims.
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Disclosed is a lighting apparatus. The lighting apparatus includes: a control module supplying power; a heat sink receiving the control module; a light source mounted on the heat sink and connected to the control module; and a communication module including a connection terminal inserted into the heat sink and connected to the control module, and an antenna device protruding from the heat sink. Since the lighting apparatus can be controlled in a wireless scheme, a user of the lighting apparatus can easily control the lighting apparatus.
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TECHNICAL FIELD
This invention relates to electronic devices which are encapsulated by means of a polymeric encapsulant and more particularly, to such devices which are encapsulated by means of a silicone resin.
BACKGROUND OF THE INVENTION
Silicone resins have been used in various industrial applications because of their thermal stability, dielectric properties, mechanical properties, chemical resistance and resistance to atmospheric deterioration. One such use is as an encapsulant for electronic devices, e.g., integrated circuit devices and hybrid integrated circuits. However, it has been found in certain applications, e.g., where adhesion is required to a gold or tantalum surface and device processing subsequent to encapsulation includes a cleaning step in solvents such as Freon®, the silicone encapsulant tends not to adhere well to the metal surface and further often exhibits swelling and bleeding. At the present time there are no commercially available screen printable silicone resins which exhibit the desired adhesion to gold and tantalum surfaces especially when processing includes exposure of the encapsulated device to Freon®. I have now discovered a modifier for silicone resins which eliminates the aforementioned problems and allows selective encapsulation over gold or tantalum surfaces by screen printing methods as well as other coating processes.
SUMMARY OF THE INVENTION
An article of manufacture comprises an electronic device having a silicone resin encapsulant thereover, wherein the silicone resin formulation is free of oxime and water and is derived from curing a mixture consisting essentially of a heat curable silicone elastomer prepolymer and a dialkylaminoalkoxysilane. The mixture may also contain fillers and a small amount of curing catalyst and stabilizer.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a photograph of a Freon® treated gold patterned substrate encapsulated in a heat cured silicone resin formulation not including the dialkylaminoalkoxysilane additive;
FIG. 2 represents a similar gold patterned substrate treated in a similar manner but having an encapsulant similar to the above but which includes the dialkylaminoalkoxysilane additive in accordance with this invention; and
FIG. 3 is an elevational cross-sectional view of a typical I.C. encapsulated circuit utilizing a silicone encapsulant.
DETAILED DESCRIPTION
The need for improved silicone resins for encapsulating electronic devices having gold terminal pads and which undergo post encapsulant cleaning in solvents such as Freon TMC (Freon TF® of DuPont Co. and methylene chloride solvent mixture) can best be illustrated with reference to FIG. 1. This figure shows the poor adhesion to a gold surface of a commercially available, heat curable, silicone encapsulant after exposure to the Freon. The problem of adhesion of silicone encapsulants to gold is one that has been recognized in the industry and has limited the use of silicones in certain manufacturing processes. In comparison, referring to FIG. 2, one can see the excellent adhesion to gold of the silicone encapsulant which has been modified in accordance with this invention by the addition of the dialkylaminoalkoxysilane. This surface was exposed to the same Freon treatment as that shown in FIG. 1.
The improvement is achieved by adding a compound having functional groups which act as a cross-linking agent, a catalyst and a promoter to an oxime free and water free heat curable silicone elastomer prepolymer and then heat curing the mixture subsequent to coating or encapsulating the device or substrate to be encapsulated. Suitable compounds are the dialkylaminotrialkoxysilanes, and dialkylaminodialkoxysilanes, particularly those wherein the alkyl and alkoxy groups have from one to four carbon atoms, the amine groups include a secondary and a primary amine nitrogen separated by an alkyl group and wherein an alkyl group separates the secondary amine nitrogen from the silicon atom. A preferred additive is N-2-aminoethyl-3 aminopropyl-trimethoxy silane (NH 2 CH 2 CH 2 NH CH 2 CH 2 CH 2 Si(OCH 3 ) 3 ). Such additives are effective in preventing delamination, blistering and swelling even when present in small quantities, e.g., 0.5 to 3 weight percent. Generally, one weight percent is sufficient when using the preferred compound indicated above.
It has further been discovered that another benefit achieved by the addition of these dialkylaminoalkoxysilanes to a heat curable silicone formulation as set forth herein, is the reduction of the curing temperature. For example, the curing temperature to achieve the same degree of cure over the same time period for DC-649, a Dow Corning hydro-vinyl-function-phenyl methyl siloxane was reduced from 200° C. to 150° C. by the addition of the silane. If longer time periods are tolerable, the resin can now be cured at 120° C., if desired. This reduction in curing temperature is important in maintaining better yields of encapsulated IC devices.
In general, the novel formulations which exhibit the superior adhesion to gold and tantalum metal surfaces, even under severe solvent cleaning conditions employed in the electronics industry, are free of oximes and are heat curable as opposed to room temperature moisture curable and are also free of water. These formulations consist essentially of a heat curable silicone elastomer prepolymer in an amount of from 20 to 25 weight percent and having an average molecular weight of from 400,000 to 600,000, 0.5 to 2.0 weight percent of a dialkylaminoalkoxysilane wherein one amine group is a secondary amine and the other is a primary amine and the amine nitrogen is not directly coupled to the silicon atom; 0 to 80 weight percent filler; 0 to 2 weight percent curing catalyst and 0 to 0.2 weight percent stabilizer. To the above formulation, one may add a solvent to adjust viscosity.
Suitable heat curable silicone elastomers are known in the art and are commercially available. The alkyl groups of the suitable silanes are preferably from 1 to 4 carbon atoms in length and the alkoxy groups are preferably methoxy but can be ethoxy or propoxy. Also, the silane can be a trialkoxy or a dialkoxy silane. When it is a dialkoxysilane, the remaining radical bonded to the silicon atom may be hydrogen or an alkyl group of from 1 to 3 carbon atoms. Preferred materials are hereinafter set forth. The fillers are generally employed to control viscosity and should be limited in amount to allow for good dispersion and desired viscosity control. The fillers should be inert and are generally of fine particle size. Typical fillers are silica and alumina.
While the dialkylaminoalkoxy silane acts to catalyze curing, an additional curing catalyst, e.g., a tri-amino-alkylalkoxysilane may be added as well. Also stabilizers such as metal complexes and phosphites as are known in the art may be employed.
The quantity limits of the additives should be adhered to in order to assure achieving the desired physical, chemical and electrical properties of the cured elastomer.
EXAMPLE 1
A screen printable heat curable silicone resin formulation was prepared in accordance with the following formulation wherein DC-649 is a hydroxy functional phenyl-methyl siloxane made by Dow Corning, Midland, Michigan and BASF-5882 is an organic type pigment.
______________________________________ WeightIngredient Percent______________________________________DC-649 23.9buffered amine catalyst 1silica filler 75pigment 0.1terpinol solvent --______________________________________
The solvent is not included in calculating the weight percent of the components and is employed to the extent necessary to achieve the desired viscosity for the screen printing or other coating technique to be employed. The viscosity can also be adjusted by changing the amount of filler.
The above formulation was printed on a test substrate containing gold plated surfaces and cured at 200° C. for 4-6 hours. The substrates were then processed by exposing them to a Freon TMC cleaning operation wherein, as can be seen in FIG. 1, it was found that the silicone delaminated, swelled and/or bled in the areas over the gold.
EXAMPLE 2
The formulation of Example 1 was modified by adding 1 weight percent N-2-aminoethyl-3-aminopropyltrimethoxysilane. It was found that to reach the same degree of cure in the same time, curing temperatures should be reduced to 150° C. Further, as can be seen in FIG. 2, no delamination, swelling or bleeding occurred on the screen printed gold surfaced substrates even after exposure to the same Freon TLC treatment as previously performed on the samples made from the formulation of Example 1.
Similar results were achieved when the dialkylaminoalkoxy silane of Example 2 was replaced with (aminoethylaminomethyl)-phenethyltrimethoxysilane or N-(2-aminoethyl)-3-aminopropylmethyldimethoxysilane.
The preferred formulations generally include 20 to 25 weight percent heat curable silicone elastomer prepolymer, 0.5 to 2 weight percent dialkylaminoalkoxysilane, 1 to 2 weight percent amine catalyst, 73 to 80 weight percent silica filler and 0.1 to 0.2 weight percent pigment in a viscosity controlling solvent.
In comparison, alternative additives such as silanes containing a single amine group, an oxime group, mercapto groups or where the nitrogen was coupled to the silicon atom and the like, either did not enhance adhesion of the screen printable, heat curable silicones to a gold surface and/or resulted in less than adequate electrical resistivity of the cured encapsulant.
Referring to FIG. 3 there is shown an example of a hybrid integrated circuit 10 having a gold plated electrode pattern 12 thereon for ease of bonding to integrated circuit chips 14 on the device 10. The entire device, in this instance is coated with the novel silicone formulation 16. The circuit chips 14 are bonded to the electrode pattern by means of wire bonds 18. Alternatively, of course, one can coat discrete components or portions of the device by well known screen printing techniques.
It is to be understood that the above-described embodiments are simply illustrative of the principles of the invention. Various other modifications and changes may be devised by those skilled in the art which will embody the principles of the invention and fall within the spirit and scope thereof.
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An article of manufacture comprises an electronic device having a silicone resin encapsulant thereover, wherein the silicone resin is an oxime and water free formulation derived from curing a mixture consisting essentially of a heat curable silicone elastomer prepolymer and a dialkylaminoalkoxysilane. The mixture may also contain fillers and a small amount of curing catalyst and stabilizer.
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The present application claims priority to a U.S. provisional patent application Ser. No. 60/082,125, filed Apr. 17, 1998.
BACKGROUND
This invention relates to equipment, systems and methods for the removal of gaseous and/or substantially gaseous material. Such material includes, but is not limited to aerosol byproducts of surgical procedures, including procedures involving cutting, heating or burning. More particularly, the present invention relates to an evacuator or vacuum head for an evacuation system that efficiently removes smoke, vapor, or plumes released by chemicals or produced by the use of lasers, sonic cutting and/or cautery at a surgical site.
Heating and/or burning of tissue during surgical procedures has become commonplace. An unwanted byproduct of such heating and/or burning, however, is the smoke generated thereby. Smoke plumes can obscure the surgeon's field of vision and the odor generated is unpleasant and distracting to the entire surgical team and to the patient, if awake. Moreover, the smoke plume may contain infectious agents that present a danger to persons in the operating room, and which can leave a lingering contamination within the operating area. Chemical vapor (e.g., such as that produced by the cleaning of computer parts) is, likewise, irritating to the respiratory tract of those who inhale it and may be carcinogenic.
Smoke evacuation and filtering systems have been developed to remove smoke plumes from surgical sites and chemical vapors from the work environment. Such systems typically include a hose connected to a vacuum source or generator and a suction wand connected to the hose. Various filtration systems have been used in conjunction with such vacuum generators to remove odor and infectious agents. Typically, the wand and hoses of known evacuation and filtration systems have required the constant attention or activity of an attendant to hold the wand or the nozzle of the hose close to the surgical site. Another problem is that the flow of air through the hose nozzle and the suction motor are sources of excessive and unwanted noise in the operating room or at the workstation.
More recently, at least in part to address the problems with wands, smoke evacuation systems may include an end effector that can be held in place at a surgical site without the constant attention of a nurse or other attendant. At least one such evacuation system and end effector is disclosed in U.S. Pat. No. 4,921,492 (Schultz et al.), the disclosure of which patent is incorporated herein by reference. Schultz et al. disclose an end effector for removing the gaseous byproducts of laser surgery from a surgical site. The end effector includes a flexible hose and a pliable vacuum head adhesively attachable in airtight relationship around a surgical site. The vacuum head includes a generally annular plenum for drawing plumes away from the surgical site from around a 360° arc. A porous plenum support prevents the flexible plenum from collapsing in the presence of a vacuum, and diffuses the vacuum around the entire periphery of the plenum.
U.S. Pat. No. 5,015,243 (Schifano) discloses another smoke evacuator including a flexible suction head for surrounding an operative site to draw smoke and air from around a perimeter of the site as smoke is produced. In one embodiment, the suction head is a doughnut shaped tubular member including a plurality of radial openings on an interior surface of the tubular member that faces the operative site. Schifano teaches that the tubular ring member may be circular or oval, and that it need not completely surround the operative site as long as air is drawn substantially in a surrounding fashion.
While smoke evacuation systems and end effectors of the Schultz et al. and Schifano type are well-suited for their intended purposes, there is room for improvement. For example, while the end effectors are pliable or flexible to conform to a surface to which they are attached, neither discloses a skeletal stiffening structure or frame for helping to maintain a conformed shape. Such a skeleton or frame would be valuable to adapt end effectors or vacuum heads for smoke evacuation for use on or near irregular physical features such as, for example, the ear, nose, mouth, or in the area of joints. It would also be advantageous if the generally central, site access opening of such end effectors could be varied in size to accommodate different sizes of incisions and different procedures, and if end effectors could be made available with the intake opening or openings in various locations, so that a particular end effector could be selected depending on the procedure to be performed. It would be advantageous if end effectors were available in a generally elongated, tubular shape bendable into a selected configuration by the user, and wherein the shaped or bent effectors would tend to remain in the selected configuration. It would also be advantageous if an end effector or vacuum head could be integrated with the widely used customary surgical drapes or drape material, or incorporated into part of a workstation that would contain noxious chemical fumes.
SUMMARY
The present invention provides an evacuator well-suited for removing or evacuating smoke, chemical vapors, aerosols, gaseous or generally gaseous material and fluids, including fluids with entrained particles or other material. It is well-suited for use in removing such substances from surgical sites, workstations and manufacturing assemblies or processing sites.
The needs outlined above are in large measure solved by a smoke evacuation system and method, including an evacuator, in accordance with the present invention. The embodiments described herein are designed to efficiently and quietly remove smoke or other aerosols, including smoke or bioaerosols generated during surgical procedures, and can be used at a surgical site without constant attention or manipulation by the surgeon or an attendant. They would also remove vapor from the work site.
An improved smoke evacuation system and method for removing gaseous byproducts of surgical or commercial procedures is provided by the present invention. The smoke evacuation system includes a vacuum head positionable at a surgical or other work site. The vacuum head includes a plenum, and a plenum support for preventing the plenum from collapsing when a vacuum or low pressure is established therein, and is adapted to facilitate the use of the system in a variety of surgical procedures at a variety of surgical sites.
In one embodiment, the present invention comprises a vacuum smoke evacuator head for coupling to a vacuum source for withdrawing generally gaseous byproducts, including smoke, fine particulate matter, air and the like, from a surgical or commercial site. The smoke evacuator head is substantially made of a generally pliable or flexible material and defines a plenum. A plenum support is carried within the plenum to provide support to the plenum and to prevent the plenum from collapsing when a vacuum or relatively low pressure area is established therein. The smoke evacuator head includes an open intake facing and/or intake openings, and may be positioned adjacent to or in a surgical site. An adhesive may be carried by the head for maintaining it in a selected position or location relative to the surgical site.
In one embodiment, the smoke evacuator head includes at least one access opening which may be selectively expanded in size. Typically, the access opening may be generally centrally located in the vacuum head, and has an initial peripheral edge which may be moved generally concentrically outwardly by selectively removing one or more removable, generally concentric peripheral portions extending substantially around the opening. Also typically, the opening, whether the initial size or one of the expanded sizes, may be covered or sealed before use by a removable film.
In another embodiment, the smoke evacuator vacuum head includes a skeletal stiffening member or positioning frame whereby the head may be configured and tends to remain in the selected configuration. The skeletal structure may comprise a single, flexible elongated member formed of a suitable material which may be bent or twisted, yet has sufficient rigidity to retain the selected bend or twist. The skeletal structure may be internal or external, and may comprise a single, elongated member, a single annular member, a plurality of axially aligned members, a number of parallel and/or branch members or a combination thereof. This embodiment may be well-suited for use in regions of the body having rather irregular surfaces such as joints, the ear, nose or mouth.
In another embodiment, the smoke evacuator may comprise a generally tubular body having two ends, one of which is adapted to be connected to another smoke evacuator vacuum head or to a coupling, such as a hose, for operably coupling the tubular body to a vacuum source. The other end may be free. The body may have one or more regions comprising openings or an open facing for admitting smoke and the like when a vacuum or low pressure is established in the body. In this embodiment, the body may have a stiffening element or a skeletal structure to allow the body to easily bend and remain in a particular shape for use in different situations. This embodiment of the vacuum head may be well-suited for use, as an adjunct or alone, in deep incisions or wounds during surgical procedures.
In yet another embodiment, the smoke evacuator vacuum head forms a plenum including a substantially open facing portion for being positioned generally adjacent to a smoke or aersol producing site. In one embodiment, wherein the plenum has a top, outwardly facing wall, is generally annular and includes a generally central access opening, the periphery of the opening being formed by an inner wall, the open facing may be formed in and/or adjacent to the inner wall comprising, for example, a bevel and/or a portion of the top wall. This embodiment is well-suited for use in surgical procedures during which a flap or ridge of skin or tissue may be formed, for example, around or as a result of the incision. Such procedures include plastic surgery procedures and mastectomies, for example, where the vacuum induced in the plenum may tend to pull skin flaps or tissue into it, particularly when the skin flap or tissue is held straight up.
In another embodiment, the evacuation system of the present invention comprises an evacuation hose for detachably connecting a vacuum generator or source and a vacuum head that generally surrounds a surgical site. The vacuum head is substantially made of a generally pliable or flexible material and defines a plenum having a generally central opening. A porous plenum supporting material is carried within the plenum to provide a degree of rigidity to the plenum and to prevent the plenum from collapsing when a vacuum or relatively low pressure area is established therein. The plenum includes an open facing region adjacent to the central opening. An adhesive may be carried by the skin contacting wall of the vacuum head for maintaining the vacuum head in place at a surgical site.
An embodiment and feature of the present invention is the concept of a foam supported channel of selectable cross-sectional area incorporated or integrated with a surgical drape, wherein the channel may be used to convey smoke and/or other aerosol debris away from a surgical site.
Any of the embodiments of the smoke evacuation system or vacuum head described herein may be provided in sterile form and in a color acceptable in an operating room environment.
In one embodiment, the smoke evacuation system of the present invention comprises a vacuum head end effector including generally contiguous, concentric areas or regions, which may be oval, formed or separated by generally concentric perforations whereby the areas may be selectively removed to correspond with required length of an incision or procedural area.
In one embodiment, the end effector in accordance with the present invention would have a pre-provided generally central and oval cutout of specific predetermined dimensions, the purpose of which would be to form a primary or initial work area, and to more easily allow the surgeon or attendant to remove surrounding peripheral oval sections to expand the original opening.
In one embodiment, each removable section of the vacuum head may be provided with a paper backed adhesive running on one surface of the sections. The paper backing would be removed once the size of the field or work area is determined, thereby allowing the remaining portion of the vacuum head and/or drape to affix to the patient's prepped skin or to the medical drape covering the intended site of the surgery.
In some embodiments, one or more manifold-like connection handles or tubes would extend from the foam filled channel or vacuum head to convey the smoke and vapor mixture from the operative site into a conduit and then to a collection, filtration and/or deodorization device wherein the mixture may be processed and the air may be returned to the room.
In some embodiments, the skin of the drape may cover the end effector, the manifold and the drape in continuity. In these and other embodiments, the manifold(s) may be provided to include either straight, i.e., parallel, and/or curved extension lips or walls that extend into or on either side of the plenum support that supports the outer walls of the plenum or evacuator vacuum head. The purpose of these lips or walls would be to prevent the possible kinking, narrowing or other form of occlusion by the covering skin of the drape at the plenum support/manifold interface or junction. This occlusion might be caused by the downward force placed on the manifold by the attached tubing that usually trails or falls to the floor of the operating room. In some instances, when suction or reduced pressure is applied without the lip extensions in place, the skin can invaginate and cover the entrance orifice of the manifold.
Another embodiment includes a chamber or gathering site for the evacuated smoke as it leaves the foam-filled channel or the plenum toward the exit site of the manifold or connection nozzle. The chamber is attached to the lip extensions or walls (described in the previous paragraph) at one end and forms or is attached to an exit port at the other end. The chamber and/or exit port may be adapted to increase flow velocities by including an area of decrease cross-sectional area. The exit port from which the smoke mixture leaves the smoke evacuator may be coupled to a typical conduit or hose.
Any of the embodiments disclosed herein may be formed by a wall or skin which may be made of the same as the material of a surgical drape. The skin typically would be fire retardant or resistant, and any of the embodiments may be preferably composed of bio-compatible material and be capable of disposition as such materials are typically disposed of.
It should be appreciated that features of any of the embodiments of the present invention may be selectively combined to adapt the smoke evacuator vacuum head for a variety of situations and surgical procedures.
Other features and advantages of the smoke evacuation device and method of the present invention will become more fully apparent and understood with reference to the following description and appended drawings and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a fragmentary, perspective view of a smoke evacuation system including an vacuum head end effector;
FIG. 2 is a front elevational view of the end effector shown in FIG. 1 , with parts broken away for clarity;
FIG. 3 is a top perspective view of an embodiment of the end effector vacuum head in accordance with the present invention;
FIG. 4 is a side elevational view of the end effector vacuum head depicted in FIG. 3 ;
FIG. 5 is an exploded perspective view of another embodiment of the present invention;
FIG. 6 is a perspective view of the embodiment depicted in FIG. 5 ;
FIG. 7 is a perspective view of another embodiment of the present invention;
FIG. 8 is a fragmentary perspective view of another embodiment of the present invention;
FIG. 9 a is a fragmentary perspective view of another embodiment of the present invention;
FIG. 9 b is a fragmentary perspective view of another embodiment of the present invention;
FIG. 10 is a fragmentary perspective view of another embodiment of the present invention;
FIG. 11 is a perspective view of another embodiment of the present invention;
FIG. 12 is a perspective view of another embodiment of the present invention;
FIG. 13 is a perspective view of another embodiment of the present invention;
FIG. 14 is a perspective view of another embodiment of the present invention;
FIG. 15 is a perspective view of two embodiments of the present invention as they might be used in conjunction;
FIG. 16 is a perspective view of another embodiment of the present invention;
FIG. 17 is a perspective view of another embodiment of the present invention;
FIG. 18 is a perspective view of another embodiment of the present invention; and
FIG. 19 is a perspective view of an embodiment of the invention in use in a workstation.
DETAILED DESCRIPTION
The accompanying Figures and this description depict and describe embodiments of the smoke evacuation system and method of the present invention, including the smoke evacuator vacuum head, and features and components thereof. As used herein, the terms “evacuator”, “smoke evacuator”, “end effector”, “vacuum head” and like terms are intended to encompass a structure or structures into which gaseous or generally gaseous material, such as aerosols, smoke or vapor, is drawn when the structure is operably coupled to a source of low pressure or vacuum and placed generally adjacent to a site producing the gaseous or generally gaseous material. As used herein the term surgical field is intended to encompass places where an incision is to be made in the skin or where other surgical operations or procedures are to be performed. With regard to means for fastening, mounting, attaching or connecting the components of the present invention to form the device and system as a whole, unless specifically described otherwise, such means are intended to encompass conventional fasteners such as machine screws, nut and bolt connectors, machine threaded connectors, snap rings, hose clamps such as screw clamps and the like, rivets, nuts and bolts, toggles, pins and the like. Components may also be connected by adhesives, glues, welding, ultrasonic welding, and friction fitting or deformation, if appropriate. Unless specifically otherwise disclosed or taught, materials for making components of the present invention may be selected from appropriate materials such as metal, metallic alloys, natural and manmade fibers, vinyls, plastics and the like, and appropriate manufacturing or production methods including casting, extruding, molding and machining may be used.
Any references to front and back, right and left, top and bottom and upper and lower are intended for convenience of description, not to limit the present invention or its components to any one positional or spacial orientation.
Referring to FIGS. 1 and 2 , a smoke evacuation system 10 in accordance with the above-noted Schultz et al. patent is depicted. The system includes an end effector 12 detachably connected to a suitable vacuum generator and filtration assembly 14 . In one embodiment, the end effector 12 may include a flexible hose 16 coupled to a vacuum head 18 by a generally tubular manifold-like handle 20 . In one embodiment, the vacuum head 18 includes a generally flat body 22 having a top wall 24 , bottom wall 26 and outer sidewall 27 extending between the top wall 24 and bottom wall 26 . The body 22 is preferably formed from a nonporous, pliable synthetic resin so that it will conform to the surface surrounding the surgical site. The top, bottom, and side walls 24 , 26 , 27 together substantially define a generally annular, internal plenum 28 . The walls form an outer skin of the plenum 28 and may be composed of a medical grade, pliable, substantially non-porous material. The material of choice may be a synthetic, or it may be a natural material, such as fibrous material, e.g., cellulose or cotton fiber based material, such as presently used in surgical drapes and/or towels. The material of choice may be with or without flame-retardant characteristics. Preferred synthetic materials may be selected from open-celled foams, urethane film, spun lace polyester, nonwoven polyurethane tape and the like.
The top wall 24 includes an access aperture 32 , and the bottom wall 26 includes access aperture 34 , typically aligned and/or substantially congruent with the top wall access aperture 32 . Preferably, a layer or adhesive 36 is carried by the top wall 24 , and a clear film 38 is removably carried in place over the top access aperture 32 by the adhesive 36 . Preferably, the bottom wall 26 includes a first adhesive layer 40 and a clear film 42 removably carried by the first adhesive layer 40 . A second adhesive layer 44 , which may have an antiseptic embedded therein, is carried by the bottom wall clear film 42 . A sterile, peel-off shield 46 is removably carried by the antiseptic adhesive layer 44 .
It will be appreciated that, upon application of a vacuum to the body 22 , the top and bottom wall 24 , 26 would be urged together, thereby reducing the volume of the plenum 28 . Therefore, in the end effector 18 depicted in FIGS. 1 and 2 , and in the embodiments of the invention described herein, an inner core plenum support 48 formed from a porous material such as foam urethane, or another appropriate reticulated, open-cell foam material, a supporting matrix, or the like, is carried within plenum 28 , to provide the body 22 with some rigidity without substantially detracting from the flexibility of the vacuum head 18 . The inner core 48 comprises an inner plenum supporting structure 48 that permits the flow of air and smoke into the plenum 28 while blocking the ingress of larger materials such as tissue or surgical materials. Preferably, the inner core support 48 should be made of a synthetic or natural material that is hydrophobic so that it will resist absorption of fluids often present in the operative field. A reticulated open cell foam of a size between 5 and 25 pores per inch (ppi) is well-suited for the inner core. In another embodiment, the plenum support core 48 may be molded and/or may be formed contiguously with the outer skin, and may be provided with a plurality or matrix of airflow shafts or channels.
Whether the shape of vacuum head 18 is generally circular, generally oval or a different shape, it will be noted that the plenum 28 provides for evacuation of generally gaseous material substantially around a complete 360° arc.
FIGS. 3 and 4 depict an embodiment of the smoke evacuator 18 of the present invention, wherein the central access aperture 32 is expandable to form a larger size aperture or opening 50 by removing a peripheral portion 52 of the evacuator vacuum head 18 from around the originally provided access aperture 32 . The top and bottom walls 24 , 26 and the plenum support material 48 may include a line of weakness 56 , be scored, cut or partially cut to define the removable portion 52 and to facilitate its removal. A selected number of generally concentric removable portions may be provided. The line of weakness, scoring, cut or perforations 56 may be substantially concentric and congruent with respect to the initial access aperture 32 , or they may be adapted to expand the initial access aperture in a selected direction or into a selected shape, e.g., they may comprise one or more arcs of weakness beginning and ending at the peripheral edge of the access opening (see, for example, lines of weakness a and b shown in FIG. 6 ). (In describing this and other embodiments, features in common with the end effector depicted in FIGS. 1 and 2 , and with other embodiments of the invention, are and will be commonly referenced.)
FIGS. 5 , 6 and 12 depict another embodiment of the smoke evacuator vacuum head 18 of the present invention, wherein the vacuum head 18 is provided with a variable size access aperture, and is integrated with a surgical drape 60 comprising a relatively large, flexible, generally cloth-like sheet material. Such a drape or drapes are widely used to establish or set off a surgical field, may be generally transparent, and may be formed by a PVC material or the like. They may carry an adhesive on one surface for connection to the skin of a patient, typically, four strips of adhesive to define a periphery. One surface of the drape may have an adhesive thereon for attachment to the vacuum head end effector 18 . Integration of the vacuum head end effector 18 of the present invention may be accomplished by providing a drape or piece of drape material with an opening, placing the end effector 18 over the opening, and attaching or sealing the edges of the end effector 18 to the drape (see FIG. 6 ). The bottom wall of the end effector 18 may be omitted, in which case the top or outside side wall 24 may be joined to the drape, whereby the drape forms the bottom wall, completing the plenum 28 and encompassing the open-cell, reticulated foam forming the plenum support 48 . In use, the integrated drape and end effector 18 may be placed over an intended incision site with the access opening aligned with the site. A tab 64 may be grasped and pulled to permit access to the site. If a larger incision site opening is required initially, or if the incision site needs to be expanded or extended, another tab 66 may be grasped and pulled to remove a peripheral portion 52 , thereby enlarging, specifically lengthening, the opening. As depicted in FIG. 12 , the pre-cut access opening covering is provided with as many tabs as convenient to facilitate grasping and pulling the covering away from the end effector 18 . Pulling one of the tabs releases the pre-perforated covering skin and allows the pre-cut foam 48 to be removed.
FIG. 7 (and others, including FIGS. 15 and 16 ) depict another embodiment of the present invention wherein a wire-like skeletal member 70 is provided. The skeletal member 70 is flexible and bendable to the degree that it may be manipulated, bent or twisted into a desired shape, yet it is inflexible or rigid enough to retain its bent or twisted shape. It may be located in the plenum 28 as shown, or it could be appropriately secured to the exterior of the end effector 18 .
FIG. 7 , and FIGS. 8–10 , depict embodiments of the present invention wherein the walls of the plenum 28 defining the access opening or aperture is an open facing 74 , and wherein the open facing 74 extends into the top wall 24 of the plenum 28 . As shown in FIGS. 7 and 8 , the access opening wall is substantially completely an open facing 74 which extends upwardly at an angle or bevel 76 into the top wall. The bias or angle into the top wall may be from 10 to 60 degrees, with 45 degrees well-suited for many procedures. FIGS. 9 a and 9 b depict two unbeveled embodiments, and FIG. 10 depicts an embodiment wherein the inside wall of the plenum 28 is substantially continuous, only the bevel 76 comprising the open facing portion of the plenum 28 . These embodiments generally are well-suited for use in surgical procedures involving a flap or ridge of tissue which, if the top wall or a portion thereof was not adapted to provide an intake for gaseous material, might occlude the open facing, blocking or at least interfering with the flow of the gaseous material into the plenum 28 . The embodiment depicted in FIG. 10 may be further adapted for particular surgical procedures, such as procedures involving the breast, by providing a sealing means, such as an adhesive, on the inside rim or wall 29 of the plenum 28 so it can be adhered or sealed in place to the breast with a portion of the breast extending through the access opening.
FIG. 11 depicts a drape/smoke evacuator embodiment of the present invention wherein dual vacuum coupling attachment handles are provided. Such an embodiment may be well-suited for procedures requiring large incisions, such as spinal procedures, thoracotomy, large abdominal incisions and the like. In one embodiment, the evacuator embodiment of FIG. 11 may be used as a stand alone device without a drape as depicted in FIG. 11 .
FIGS. 13 and 14 depict another embodiment of the smoke evacuator of the present invention wherein the plenum 28 is formed by a substantially continuous wall, which may be a single piece of extruded material or which may be formed from joined top, bottom and side walls. In this embodiment, the vacuum head 18 and the plenum 28 have a generally tubular, straight, elongated shape with two free ends, one end 80 of which may be closed and the other end 82 which may be adapted to be coupled to another embodiment of the end effector 18 of the invention, as shown in FIG. 14 . The end 82 adapted to be coupled is provided with a sharpened, cannula-like member 84 for penetrating the wall of the plenum 28 as shown in FIG. 14 . The end 82 may be flattened or otherwise adapted to be similarly attached to suction tubing or to the above described channel. In one embodiment (not shown), the cannula-like member 84 is not sharpened as depicted in FIG. 13 . In other embodiments (not shown), this embodiment of the invention may be adapted for direct coupling to a hose or other fitting, or may include or be attached to a manifold or handle 20 generally similar to that shown in FIG. 1 , for coupling to a hose or other fitting. Note that FIG. 14 also depicts that the stiffening skeletal member 70 , shown in two of its possible locations, may be used to configure and position the generally tubular smoke evacuator 18 embodiment, or a portion thereof, in a relatively deep incision or wound.
FIG. 15 depicts an embodiment of the smoke evacuator of the present invention adapted for spinal operations or other procedures wherein a relatively long incision may be used. The plenum 28 is formed in the shape of two generally parallel tubular members 88 , 90 , each having substantially continuous top, bottom, outside and end walls, and an inside wall comprising an open facing 74 . Each embodiment of the invention may include a generally enlarged internal plenum space adjacent to the manifold port or handle 20 . In the evacuator of FIG. 15 , for example, the top wall 24 and bottom wall 26 are extended to form an enlarged plenum space 100 adjacent the manifold port or handle 20 , such that the suction force generated at the manifold or handle 20 is more evenly dispersed, including throughout the plenum and along the open facing 74 . Such a feature may be included in any of the embodiments of the invention described herein. Note that, as in all the embodiments described herein, the malleable, skeletal stiffening member 70 , which might be formed of nitinol or similar “memory” material, may be incorporated to facilitate re configuring this embodiment to, for example, the configuration shown in phantom. This embodiment of the vacuum head 18 may have a single connection manifold or nozzle 20 as shown, or it may be adapted to have two manifolds with a circuit adapter to permit them both flow into a single ⅞″ vacuum hose (see, for example, FIG. 11 ). Such circuit adapters are readily available as standard catalog items for respiratory therapy and anaesthesia.
FIG. 16 depicts an embodiment of the smoke evacuator 18 well-suited for use in dental surgery, e.g., a “bite-block” embodiment. It should be appreciated that the smoke evacuator 18 maybe provided in any configuration suitable for use in or around the mouth, and that substantially the entire skin or walls forming this embodiment would preferably be non-absorbent.
FIGS. 17 and 18 depict an embodiment wherein a generally tubular vacuum head 18 comprises an internal plenum region adjacent to the manifold port or handle 20 and two plenum arms 90 , 92 . The two plenum arms 90 , 92 , which, as in FIGS. 17 and 18 , may be two free arms, may be curled or curved to substantially surround a surgical site. An advantage of this embodiment is that the plenum arms 90 , 92 with their free end are flexible, whereby the head 18 is made more flexible so it may more easily assume and conform to the shape of the underlying tissue. The arms 90 , 92 , and thus the head 18 , may move in various directions according to the layout of adjacent tissues. Because, in one embodiment, one surface of the vacuum head 18 of FIGS. 17 and 18 may have an adhesive attached thereto for attachment to a drape, it may be desirable to have one embodiment wherein the ends 90 , 92 face one direction when viewed from the top and another embodiment wherein the ends 90 , 92 face the other direction. These embodiments may provide for the flexibility needed for various surgical procedures, including procedures on bilateral, mirror image structures or tissues.
In use, it should be understood that operation of all the embodiments disclosed herein may be generally similar. The vacuum head 18 , or the drape 60 with the vacuum head 18 integrated, is detachably affixed to the skin surrounding a surgical site by peeling off the sterile peel-off shield 46 and pressing the adhesive layer 44 carried by the bottom wall 26 of the body 22 against the skin. It will be appreciated that the flexible vacuum head 18 permits a complete, airtight seal of the bottom wall 26 against the skin or any skin covering (such as a clear drape). The films 28 , 42 carried by the top and bottom walls 24 , 26 , respectively, can be entirely removed. Upon actuation of the vacuum source 14 , air is drawn into the plenum 28 , and is transported through the flexible hose 16 and into the filter (not shown) in the vacuum source 14 . The porous plenum support 48 carried within plenum 28 prevents plenum 28 from collapsing under the influence of the vacuum. The plenum support 48 also may be adapted to enhance the effect of diffusing the vacuum around or through the plenum 28 , thereby enhancing the drawing air into the plenum 28 around its entire periphery or open facing, rather than solely in the vicinity of handle 20 . Moreover, drawing air through the larger opening presented by the plenum 28 reduces the noise created by the flow of air into hose 16 . Gaseous or aerosol material produced at the surgical site is thereby drawn into the plenum 28 and evacuated through flexible hose 16 . The plenum support 48 , due to its porous nature, also may act as a filter as the smoke is drawn through it.
Referring back to FIG. 1 , surgical instruments can be manipulated through the tear line T in clear film 38 and/or through the access opening 32 . Alternatively, the clear film 38 can be completely removed. It will be appreciated that the vacuum, and drawing effect, presented by the plenum 28 to the surgical site may be increased by leaving the clear film 38 in place.
The end effector(s) 18 of the present invention may be extruded from a single piece of material, e.g., the body 22 , tubular handle 20 , flexible hose 16 , and in some embodiments, a filter and connector, may be formed from a unitary piece of synthetic resin or similar extrudable material. The end effector(s) 18 of the present invention may be advantageously and hygienically disposed of after a single use, without the necessity of handling contaminated material.
In another use of the invention, the embodiments of the vacuum head 18 may be used at a workstation or the like, or on or in a containment vessel or the like, in order to remove fumes or smoke. Such workstations and vessels may be used, for example, for cleaning components in the computer industry or for performing experiments or tasks in which noxious fumes are emitted. FIG. 19 shows such a use. The workstation 110 may have hand holes 112 , with or without suitable sealing collars 113 or attached gloves (not shown), through which a technician or user may put their gloved or ungloved hands. The vacuum head 18 may be positioned in, adjacent to or on the workstation 110 , for example, as depicted, it may be coupled to an exterior surface of the workstation enclosure adjacent to an opening in the wall defining the workstation. It may also be coupled to an interior surface. When a suction force is applied to the vacuum head 18 , the vacuum head 18 receives smoke or fumes from the inside of the workstation. In one embodiment, an air supply may be pumped into the workstation 110 through a hose 114 to help urge the vapors, aerosols or gaseous material toward the vacuum head 18 . Such an air supply may provide air at any given rate; one such rate for a typical-sized work station may be 30 cubic feet per minute.
The present invention may be embodied in other specific forms without departing from the essential spirit or attributes thereof. The described embodiments should be considered in all respects as illustrative, not restrictive.
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An improved smoke evacuation system ( 10 ), a method for removing gaseous byproducts of surgical procedures, and noxious vapors from chemicals, is provided. The smoke, and vapor evacuation system includes a vacuum head ( 18 ) positioned at a surgical site or incorporated into a workstation. The vacuum head includes a plenum ( 28 ), a plenum support for preventing the plenum from collapsing when a vacuum or low pressure is established therein, and is adapted to facilitate the use of the system in a variety of surgical or commercial procedures at a variety of surgical sites or commercial workstations.
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I. DESCRIPTION
1. Technical Field
The present invention relates to a device for maintaining tension on a band or tape engaged in a tape driving mechanism. Such a device finds application particularly, although not exclusively, in printing machines in which a paper band or tape is displaced through a working zone in front of a printing station by means of a driving mechanism.
2. Background of Prior Art
A variety of machines is known in the existing art in which a material in tape form, of indefinite length, is displaced by means of a driving mechanism, in a continuous or intermittent manner, through a working zone wherein are performed particular operations such as, for example, perforation or imprinting of the material. To obtain a satisfactory quality of the operation performed on this tape, it is essential that this tape should be kept tensioned, at least over its part situated within the working zone.
A variety of tape tensioning devices has been used in the prior art to provide this tension. One type of known tensioning devices is described, for example, in French Patent Application No. 2027826, wherein the component parts of the tensioning device form an integral part of the tape driving mechanism. Such tensioning devices are complex and comparatively expensive. Moreover, the tension applied by such arrangements cannot be modified to a comparatively great extent and they cannot, for this reason, be applied to tension tapes of a material of which the thickness and consequently the rigidity, varies appreciably from one tape to another.
Another known type of tape tensioning devices is described in French Pat. No. 1452691, wherein the component parts of the tensioning device are separate from those of the tape driving mechanism. In this case, the driving mechanism and the tensioning device are situated at either side of the working zone, and the tape which is pulled in one direction by the driving mechanism is kept tensioned by means of the opposed action exerted by the tensioning device. This arrangement tends to draw the tape in the direction opposite to that in which it is actually being displaced by the driving mechanism. Such tensioning devices, which have a simple structure, nevertheless have the disadvantage of complicating the structure of the driving mechanism, because the latter must be equipped with a non-return device intended to prevent the displacement of the tape in the direction opposite to that of its normal travel, due to the action of the tensioning device, when the driving mechanism is no longer energized.
BRIEF SUMMARY OF INVENTION
The present invention overcomes the disadvantages of the prior art, and provides a tape tensioning device which is comparatively simple and inexpensive, of which the component parts are separate from those of the driving mechanism. Furthermore, this tensioning device has the advantage of enabling an operator to adjust the tape tension to a predetermined value comprised within a comparatively wide range of tensions. Furthermore, not only does this tensioning device not cause a complication of the structure of the driving mechanism, but it advantageously does not require any additional control to assure a correct tape tension if the direction of the tape displacement were to be reversed for special conditions of application.
The present invention relates to a device for maintaining a tape in tension, the tape including a first free section arranged to enter a tape driving mechanism and a second free section arranged to leave the driving mechanism, said sections being arranged along a loop-shaped path or track and said device comprises a floating displacement transmission element disposed between the two free sections of the said tape to permit the section emerging from the driving mechanism to be driven, via the floating element, by the section which enters into the driving mechanism, and a tensioning element arranged to control this floating element in such a manner that it exerts a pull on the sections entering into and emerging from the driving mechanism.
BRIEF DESCRIPTION OF DRAWINGS
The invention will now be further described, by way of example, with reference to the accompanying drawings, in which:
FIG. 1 is an overall perspective view of a part of a magnetic printing machine equipped with one form of tape tensioning device constructed in accordance with the invention;
FIG. 2 illustrates a second embodiment of a tape tensioning device which may be used in the machine illustrated in FIG. 1; and
FIG. 3 illustrates a third embodiment of a tape tensioning device which may be used in the machine illustrated in FIG. 1.
DETAILED DESCRIPTION OF INVENTION
The printing machine which is illustrated diagrammatically in FIG. 1 is a magnetic printing machine of known type, similar, for example, to that which has been described and illustrated in U.S. Pat. No. 3,945,343. For simplication, only the elements of this machine which are needed to understand the present invention have been illustrated in FIG. 1.
The magnetic printing machine comprises a recording element formed by a magnetic drum 10 mounted on a horizontal spindle 11 and driven in continuous rotation by means of an electric motor 12, in the direction denoted by the arrow F. In known manner, the symbol or characters which are to be printed are recorded on the drum 10 in the form of latent magnetic images, by means of a recording station (not illustrated) arranged along the drum, parallel to the spindle 11. The portion of the drum on which these latent images are formed then passes in front of a distributor station (also not illustrated) which deposits a developer pigment in powder form on the drum. This pigment which adheres only to the magnetized areas of the drum allows the latent images to be developed, that is to say to be rendered visible. The latent images thus developed than pass in front of a transfer station 13 at which point the pigment particles which have been deposited on the latent images are transferred to a paper tape 14.
In the printing machine illustrated in FIG. 1, this transfer is performed by the pressure applied by a thrust roller 15 which presses the paper tube 14 against the drum 10. Because the drum 10 is driven in rotation by the electric motor 12, paper tape 14 is gripped between drum 14 and the thrust roller 15, and is drawn along in the direction shown by the arrow D in FIG. 1. As is apparent from FIG. 1, paper tape 14 is drawn from a stock of paper 16, normally arranged in zigzag folds, which is situated at the lower part of the machine. The paper tape 14 displaced by the driving mechanism formed by the thrust roller 15, the drum 10 and the electric motor 12, passes over guiding rollers 17, 18, and 19 arranged in such manner that the paper tape 14 consecutively travels along a rising vertical path extending between the paper stock 16 and the driving mechanism, then along a looping path extending between the driving mechanism and the guiding roller 19, and finally after passing over this roller 19, along a descending vertical path. During its travel along this looping path, the paper tape 14 passes through a fusing device 20 which by inducing the melting of the pigment particles which have been transferred from the drum 10 on to tape 14, assures the permanent fixing of the pigment images present on the tape.
The paper tape 14 which is displaced by the driving mechanism formed by the drum 10, the thrust roller 15 and the electric motor 12, has two sections situated at either side of this mechanism. One section 21, which travels along the rising vertical path to be gripped between the drum 10 and the thrust roller 15, will be referred to as the input section. The other section 22, which travels along the looping path and the descending vertical path, will be referred to as the output section. It should be noted that the two sections 21 and 22 are free along the rising and descending vertical paths, meaning that they are not guided by rollers which, like the rollers 17, 18 and 19, constrain the paper tape 14 to follow a clearly defined path, when it is kept tensioned.
The tensioning of the paper tape 14 is provided by a tensioning device which will now be described and which is arranged about the free portions of the sections 21 and 22, and which includes a floating element disposed between the sections 21 and 23. As shown in FIG. 1, this tensioning device comprises a floating element 23 which, by combining the displacements of the sections 21 and 22, enables the output section 22 to be driven by the input section 21 when the latter is drawn up for insertion between the drum 10 and the thrust roller 15. To this end, the floating element 23 comprises a rigid casing formed by two vertical side plates 24 and 25 positioned parallel to each other and spaced apart by means of cross members such as 26. The two side plates 24 and 25 carry two horizontal spindles 27 and 28 which are situated between the side plates 24 and 25 so that they may turn within bearings such as 29 and 30 integral with the side plates. Adjacent to the side plate 25, a belt 31 equipped with spikes 32 is tensioned on two pulleys 33 and 34, each of these being secured on the corresponding spindle 27 and 28. In an analogous manner, a second spiked belt 35 is situated close to the side plate 24 and is tensioned on two other pulleys secured on the corresponding spindles 27 and 28. Only one of these two other pulleys being in part visible in the illustration of FIG. 1.
FIG. 1 also shows that the paper tape 14 is provided along each one of its side edges, with evenly spaced perforations 40 which are engaged by the spikes of the belts 31 and 35. So that the two sections 21 and 22 of the paper tape 14 may remain at least in direct proximity to these two belts 31 and 35, the floating element 23 may be further equipped with four guide plates 41, 42, 43 and 44. The plates 41 and 42 are secured, as shown in FIG. 1, on the opposed vertical edges of the side plate 24. The plates 43 and 44 are secured in analogous manner on the opposed vertical edges of the side plate 25. Each of these guide plates has an opening such as 45, which enable the spikes engaged in the perforations 40 of the paper tape 14 to project beyond the said plate through this opening. The four plates 41, 42, 43 and 44 thus keep the two free portions of the sections 21 and 22 in direct proximity to the spiked belts 31 and 34 and consequently prevent the sections from being separated from the floating element 23, i.e., the two sections pass between guide plates 41, 42, 43, and 44 and bear against their inside surfaces.
The floating element 23 which is disposed between the free sections 21 and 22 exercises, by its weight, a traction on these sections and thus enables tension to be maintained in the potion of the band 14 which is at a level above that of this floating element. Moreover this traction may be adjusted to a convenient value by utilizing an appropriate tensioning means which, acting on the floating element 23, enables it to exert a traction of a predetermined value on the sections 21 and 22. In the embodiment illustrated in FIG. 1, this tensioning means is formed by a weight 46 suspended from the cross member 26 of the floating element 23, but it is to be understood that this tensioning means may be of a different form to that shown in FIG. 1 and may be constituted, for example, by a spring or a pneumatic device.
It is useful to observe that the length of the porton of the tape 14 which is held by the device which has been described always remains constant, both when this tape 14 is at rest and when it is driven in displacement by the driving mechanism formed by the drum 10, the thrust roller 15 and the electric motor 12. In these circumstances, if the input section 21 of this tape is displaced in the rising vertical direction by this driving mechanism, the belts 31 and 35 which have their spikes engaged in the marginal perforations of this section 21 are entrained at the same linear speed as that of the section 21. These belts 31 and 35 for their part then transmit drive via their spikes to the output section 22 of the tape 14, the displacement of this section 22 thus being performed in the descending vertical direction and at the same linear speed as that of the input section 21.
The tensioning device which has been described is intended more particularly to provide tension for a comparatively wide paper tape and, by virtue of this fact, comprises two spiked belts of which the spikes engage in perforations formed along the two longitudinal edges of this tape. It should be observed however that in the case in which the tape were to be in the form of a comparatively narrow ribbon, this tensioning device could comprise only one spiked belt situated or centered at identical distances form the side plates 24 and 25, the spikes of this belt then being engaged in perforations formed along the central axis of the associated ribbon.
In general, the floating element of the tensioning device in accordance with the present invention comprises at least one rotary member installed in slip-free manner between the free sections of the tape, and applicator devices associated with this rotary member for keeping these sections in engagement with this member. In the case illustrated in FIG. 1, this rotary member is formed by a spiked belt (such as 35), whereas the applicator devices are formed by the two plates (such as 41 and 42) which prevent the free sections of the tape from becoming separated from this member.
In the embodiment illustrated in FIG. 2, the rotatable member is formed by a friction cylinder 50 installed free on a spindle 51 integral with a yoke 52. In this case, the applicator devices are formed by two pressure rollers 53 and 54. Each roller 53 and 54 is secured on a corresponding one of the spindles 55 and 56 which pass through elongated openings 57 and 58 formed in the yoke 52 enables this arrangement of the pressure rollers 53 and 54 to move apart from the friction cylinder 50. The pressure rollers 53 and 54 are urged towards the friction cylinders 50 by means of springs 59 and 60, which are connected under tension between the yoke 52 and the spindles 55 and 56. In this manner, the section 21 of the tape is held gripped between the friction cylinder 50 and the thrust roller 54, whereas the section 22 is held gripped between the friction cylinder and the thrust roller 53. In the embodiment of FIG. 2, the tensioning device is formed by a traction spring 61 of which one extremity is attached to the yoke 52 and of which the other extremity is attached to a fixed point 62 of the machine.
In the embodiment illustrated in FIG. 3, the rotatable member is formed by a spiked wheel 70 mounted free on a spindle 71 attached to a plate 72. The spikes 73 of wheel 70 are intended to be engaged in perforations formed in a paper web or tape similar to that which is illustrated in FIG. 1, but which in FIg. 3 is shown only partially in the form of the two sections 21 and 22. In the embodiment illustrated in FIG. 3, the applicator devices which enable the spikes 73 to engage in these perforations are formed by two guide plates 74 and 75 which are urged by the action exerted by the springs 76, arranged as shown in the Figure, against supporting blocks 77 integral with the plate 72. These supporting blocks are machined in such manner as to have sliding surfaces against which the sections 21 and 22 are maintained in contact. The sections 21 and 22 which are thus urged by the plates 74 and 75 against the supporting blocks 77 consequently cannot move away from the wheel 70, so that the spikes 73 of this wheel are constrained to penetrate in step with the passage of the sections 21 and 22, into the consecutive perforations of these sections. It should be pointed out moreover, that the tension of the springs 76 is rated in such a manner, that they do not prevent displacement of the of the sections 21 and 22 with respect to the tensioning device, the tension applied by this device on these sections 21 and 22 being obtainable in known manner, for example as shown in FIG. 3 by means of a weight 78 suspended from the plate 72.
The invention is obviously not limited to the embodiments described and illustrated. On the contrary, it incorporates all means forming technical equivalents to the means described, as well as their combinations if these are executed in the spirit of the invention and applied within the scope of the following claims.
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A tensioning device for materials of tape form particularly adapted for metic printers and comprises a floating element situated between free sections of a paper tape installed in return fashion in a driving mechanism. The floating element is provided with displacement transmission elements formed by spiked belts of which the spikes are engaged in perforations in the tape. The tensioning of the tape is provided by a weight hooked to the floating element such that the tape section emerging from the driving mechanism is driven, via the floating element, by the tape section which enters the driving mechanism.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to apparatus for processing waste material containing components that vary from uncrushable like metallic waste to fabric and plastic waste and intermediate waste of an abrasive character.
2. Description of the Prior Art
The most pertinent prior art is represented by my earlier U S. Pat. Nos. 3,702,682 of Nov. 14, 1972, 4,288,038 of Sept. 8, 1981, 4,337 900 of July 6, 1982, and 4,339,085 of July 13, 1982. Each of these patents discloses apparatus for separating waste materials having materially different characteristics. Materials of this character are typical of domestic and industrial waste containing abrasive substances, rags, glass, metallic objects, discarded paper and cardboard containers, and a whole host of objects that can be processed together or that can be separated out on the basis of specific gravity properties.
Prior art of the above character embodies processing means which vibrates the waste material so that it sorts itself into similar and dissimilar components to make the further processing more responsive to the apparatus called upon to handle such materials. In addition to vibratory devices, the prior art includes a variety of rotary disc screens which, instead of functioning principally on separation by vibration, present a bed of discs having formed peripheral edges which cause the trash to undulate. The discs are mounted to interleave to form a bed having spaces between discs through which desired components of the waste may fall, while larger components travel along the bed to a discharge end. The rotary screen prior art is represented by Bray 622,035 of Mar. 28, 1899, Dunbar 2,966,267 of Dec. 27, 1960, Kuntz 2,974,793 of Mar. 14, 1961, Conway et al 3,028,957 of Apr. 10, 1962, and Wahl et al 4,037,723 of July 26, 1977. In addition applicant has a copending application, Ser. No. 772,041, now U.S. Pat. No. 4,658,964 of Apr. 21, 1987 on a Rotary Disc Screen filed Sept. 3, 1985.
BRIEF DESCRIPTION OF THE INVENTION
An important object of the present invention is to provide apparatus that will be able to process an unclassified collection of waste materials, and extract from that collection of waste material components regarded as abrasive in character, components regarded as uncrushable and difficult to grind, such as metallic bodies, and components which can be reduced by grinding and shredding.
A further important object is to bring together the necessary processing equipment for the handling of widely differing waste materials in one organized composite apparatus.
The invention can have several different arrangements of processing equipment. The differing arrangements include a rotary disc screen which intially processes the arriving waste to separate abrasive shards and granular components such as grit, sand, broken glass and the like. The waste material freed of shards and abrasive components is subjected to gravity separation of waste to remove the hard to reduce materials such as metallics. Finally, the equipment includes a mill suitable for reducing the remainder of the waste to a desired condition for further handling and a subsequent recycling to the disc screen of material incompletely reduced so as to be unable to pass through the usual grate on at least a first try.
In its broad aspects, the present apparatus combines components which function to yield from a common unclassified mass of waste material different subclasses of waste, such as abrasive, uncrushables and shreddables.
BRIEF DESCRIPTION OF THE DRAWINGS
The waste material classifying and reducing apparatus has been disclosed in presently preferred embodiments, wherein:
FIG. 1 is a schematic side elevation of the waste classifying components of a composite system for handling the type of waste material that is encountered from domestic and commercial sources.
FIG. 2 is a further embodiment of waste handling apparatus, disclosed in a side elevational schematic view; and
FIG. 3 is a still further schematic side elevational view of waste handling apparatus.
DETAILED DESCRIPTION OF THE EMBODIMENTS
Referring now to FIG. 1 of the drawings, it can be seen that the material classifying apparatus includes a sheet metal structure 10 which defines a first internal chamber 11 and adjacent to that internal chamber 11 there is a second chamber 12 which is placed in communication with the internal chamber 11 through a flow passage 13 at the upper side, and a discharge passage 14 at the lower side, which passage 14 is controlled by a flop gate 15 that is suitably counterbalanced to seek a closed position until material collecting in the second chamber 12 overcomes the counterbalance force to open the flop gate 15 and return that collected material toward the bottom outlet 16 of the internal chamber 11. The bottom outlet 16 aligns with the inlet of a shredder assembly 17 which is in the form of a ring type hammer mill having a rotor 18 equipped with grate bars 20 which are suitably spaced to control the size of the particles reduced in the mill 17.
As indicated, the reduced material falls onto a suitable belt conveyor 21 for transport to a suitable collecting location.
It will be observed that the second chamber 12 is provided with an outlet port 22 positioned within spaced walls 23, 24 and 25 which surround the outlet 22. The outlet 22 is connected to a conduit 26 which is directed to be connected into the suction side of a blower 27 mounted in a suitable supporting structure 28 adjacent the mill assembly. The blower, driven by a motor 29 is provided with an outlet 30 in the form of a conduit 31 which has an outlet opening 32 directed into the internal chamber 11 so as to deliver air velocity into that chamber for a purpose that will be referred to presently. It is noted that a material trap 33 opens into the side of the air flow conduit 31, and the bottom of the trap 33 is provided with a cleanout door 34 which may be counterbalanced so as to open when a collection of material overcomes the counterbalance. The material collecting in the trap 33 is periodically discharged onto a hopper 35 which directs such material onto a belt conveyor 36 which carries that material to a place of discharge.
The mill structure is provided with a material receiving hopper 37 which directs incoming material falling from the feed belt 38 into the inlet end of a rotary disc screen assembly 39. The disc screen assembly 39 has sides 39A to channel the incoming material along its upper surface to an outlet end 40 which is located directly above the air flow outlet 32 from the conduit 31. The purpose for locating the disc screen outlet 40 as noted is to allow for heavy particles and components to fall into and through the conduit opening 32 against the air flow and gravitate into the trap 33. The material thus trapped would normally consist of heavy components that do not respond to the air flow and thereby gravitate into the trap 33. The rotary disc screen assembly 39 is employed to provide means for screening out abrasive material that may be in the incoming feed, thereby removing such material from getting into the hammer mill 17 which would increase the rate of wear of the rotary hammers. The thus screened out abrasive material falls onto a belt conveyor 41 for delivery to a suitable collecting station.
It can be seen in FIG. 1 that the mill housing structure 10 is intended to be maintained at sub-atmospheric pressure by a conventional cyclone separator unit 42 which is connected by conduit 43 to a blower 44 having its inlet connected by conduit 45 to the space in the mill below the grate bars 20. Any fine waste material that passes through the grate bars 20 may be sucked up by the blower 44 and delivered to the cyclone separator where that material will fall into an outlet port 46, while the thus cleaned air is exhausted into the atmosphere at the hooded top port 47.
The present organization of apparatus is intended to practice a unique method of subjecting a type of waste material that includes abrasive substances, rags, broken glass, metallic objects, discarded paper and cardboard container, and a whole host of discarded objects that are comingled to form a collection of subject materials that can be characterized as typical of domestic and industrial discarded refuse. The apparatus above described is uniquely designed and rendered operative to sort out from the refuse material the abrasive components at the rotary disc screen assembly 39. It is understood, of course, that the rotary disc screen is provided with a separate driving motor which rotates the discs so as to cause the waste material to seek a relatively thin layer on the upper surfaces of the discs, thereby giving the abrasive material, such as broken glass, an opportunity to fall through the spaces between the various discs and be carried away by the belt conveyor 41. The structure of the rotary disc screen per se is disclosed in my copending application Ser. No. 772,041, filed Sept. 3, 1985 and issued as U.S. Pat. No. 4,658,964 on Apr. 21, 1987, and entitled ROTARY DISC SCREEN AND METHOD OF OPERATION. The drive arrangement disclosed in that copending application is incorporated herein by reference, thereby simplifying the drawing disclosure of this application.
The material that passes off the outlet end 40 of the rotary disc screen assembly is subject to the air flow stream from conduit 31 entering the internal chamber 11 so as to separate the various classes of waste material before such material will gravitate or fall toward the hammer mill 17. Subjecting the waste material to an elutriating air stream which facilitates the separation of the components so that the heavy components will gravitate into the trap 33 thereby avoiding subjecting the hammer mill 17 to the presence of such heavy and usually uncrushable components. The remainder of the components is processed in the hammer mill 17 and any of those components that are not immediately reduced are thrown back into the internal chamber 11 and travel along the curved inner wall 48 which divides the internal chamber 11 and the second chamber 12. The material following the wall 48 will recirculate back to the rotary disc screen assembly 39 and return to the internal chamber 11 for further eventual reduction in the hammer mill 17.
It should now be apparent that the present apparatus is unique in its capability of handling typical waste from domestic and industrial sources to classify such waste material into its general components of abrasive material, heavy uncrushable material and material that will respond to reduction in the hammer mill. As a result the abrasive material is conveyed to a collection source by belt conveyor 41. The uncrushable material discharged from the trap 33 will be delivered to a second belt conveyor 36, and the output from the hammer mill 19 is collected on a belt conveyor 21 which passes under the cyclone separator output 36 to back up the solids separated by the cyclone separator and conveyed to a collection station. While the abrasive components and the uncrushable components are not suitable for use as a fuel, the class of material reduced by the hammer mill 17 may be entirely suitable for use as a fuel which then becomes a commercially usable by-product of the operation of the apparatus disclosed in FIG. 1.
Turning now to FIG. 2, a further embodiment of waste material apparatus is seen. The structure of this embodiment is similar to that seen in FIG. 1, and common structure will be identified by the same reference numerals. The sheet metal structure 10A of the apparatus is modified in its configuration of the internal chambers 11 and 12, and the passage 13 at the upper side of chamber 11. The chamber 12 is provided with a discharge passage 14A controlled by a flop gate 15 which releases material collecting at that gate. The structure 10A is provided with a hopper 37A for incoming waste material that is delivered by the conveyor 38. The waste material is dumped upon a rotary disc screen assembly 39 having sides 39A to channel the waste toward the outlet end 40.
The chambered structure 10A is mounted over the inlet 16 of the mill 17 so that material can proceed into the mill from chamber 11 and from the passage 14A at the bottom of chamber 12. The chamber 12 has internal vanes 23 and 24 which surround an outlet port 22 opening into a conduit 26 which is connected to the suction inlet of blower 27A driven by a belted motor 27B. The blower outlet elbow 30 is connected into a conduit 31 having an outlet 32 located within the material drop zone off the end of the rotary disc screen 39. The flow of air (commonly an air knife) at the outlet will pick up that portion of the waste material that is responsive to the force of the air and move it into the chamber 11 where it can be dispursed or broken up before it falls into the mill 17. The components of waste falling off the end 40 of the screen 39 that is non-responsive to the air flow will fall into the conduit 31 and descend into the trap 33 and be released onto a collection belt conveyor 36. The mill 17 has ring hammers 18 rotating over grate bars 20 which reduce the waste material to a size that will pass through the spaces between the grate bars 20.
The material reduced by the mill 17 (FIG. 2) will be collected in two ways. The larger components will fall through and be collected by the conveyor 21. The lighter components will be sucked out of the space below the grate bars 20 and pass through the enclosing hood 50 and into conduit 51 to a cyclone 52 where the blower 53 will exhaust the air and the components collected in the bottom 54 will be released through the rotary gate device 55 to a conveyor 56. In this apparatus, the rotary disc screen operates as the first stage separator to extract by gravity the small abrasive and other elements which fall on the conveyor 41. The heavy uncrushables will fall into the trap 33, and the remainder will migrate toward the mill 17. Control over the migratory material in chamber 11 is obtained by gate means 57 and 58 located in the area leading to the mill 17. The gate 57 has an exterior counterweighted arm (seen in broken outline) at 57A so it will partially close off the passage of waste material into the mill 16 until a sufficient weight of material has collected to overbalance the counterweight 57A. After the material has passed gate 57 the gate will return to its starting position to accumulate more material. Material reaching the mill 17 will be reduced by the ring hammers 18 and certain portions will be thrown up past the gate 58 and along the wall 48 to return to the rotary disc screen where it will return at the end 40 thereof and be sorted out so that the heavy uncrushables fall into the trap 33. In the apparatus of FIG. 2, the rotary disc screen initiates the classification process, and the rest of the apparatus will continue that process to result in the uncrushables reaching conveyor 36, crushables being collected on the conveyor 21, and fines collected on conveyor 56 at cyclone separator outlet 55.
A further embodiment of the present invention is seen in FIG. 3 which varies in certain respects from the foregoing embodiments. In this arrangement the apparatus 60 comprises structure defining a chamber 61 having a shaped wall 62 leading up from a hammer mill 63 and reaching over the outlet end portion 64 of a rotary disc screen assembly 65. The screen has side wall 66 which confines the incoming waste material from the supply conveyor 67 to travel the length of the screen. The screen allows the fine, abrasive material like sand, broken glass, and the like, to fall through and onto a conveyor 68 for movement to a place of disposal (not shown).
The apparatus of FIG. 3 includes an air circulating system made up of a blower 70 having an outlet elbow 71 connected to a conduit 72 which has its outlet 73 located below the screen outlet end 64 so heavy uncrushable material will fall or gravitate into the conduit 72 and fall into a trap 74. The outlet 73 of the conduit is provided with a baffle 76 to close the bottom of the screen 65 to the exterior so air flow into the chamber 61 is not disturbed. The blower 70 has its suction side connected to a conduit 77 extending from the outlet 78 of a cyclone separator 79. The fine material collecting in the separator 79 is released through a rotary valve 80 onto a conveyor 81.
The hammer mill 63 includes the usual hammer rotor 82 operable over a grate 83 made up of a plurality of bars forming the cage in the mill outlet 84 aligned with the conveyor 85. The mill is equipped with breaker plates 86 and 87 capable of being pivoted toward and away from the hammer circle of the rotor 82. These breaker plates are normally adjusted as plate 87 is moved into the hammer path, while plate 86 is moved back to its full line position. This breaker plate setting will allow the rotor hammers to throw difficult material to crush back into chamber 61 where it will usually follow the curved wall 62 and return to the screen assembly 65. The area 88 of the chamber 61 over the screen 65 is connected to an outlet conduit 89 which extends into a connection at the cyclone separator 79. That connection of conduit 89 is protected by a deflector plate 90. The area 88 over the rotary screen is closed by an end wall 91 which can be brought down into close proximity to the rotary screen assembly 65 so that there will be a minimum of blow back.
The circulation system of the assembly is completed by a conduit 92 connected into the mill so as to collect dust and fines and deliver them to the cyclone separator 79 by the conduit 92 being connected into conduit 89 for convenience. As before noted the heavy uncrushables falling into the conduit 72 are diverted into a trap 74 which can be emptied onto conveyor 36 as required.
The foregoing specification has set forth the details of apparatus capable of performing the functions described, and in which improvements have been embodied for effecting the classification process so that preparation of a class of abrasive components can be separated out before reaching the grinding mill. The important feature is seen in the unique arrangement of a rotary disc screen as the initial receptor of the waste material so that the shards and granular class of components do not reach the mill and undergo reduction to create a wear problem. Moreover, the present apparatus combines a number of material handling functions which have been heretofore carried out in separate items of equipment. This combination allows a significant reduction in the size of an enclosure for housing the apparatus.
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Apparatus for processing waste material made up of a mass of comingled abrasive shards and the like, uncrushable and shreddable classes of waste so that the subsequent individual handling of that waste material is made more efficient. The apparatus combines in a common structure rotary disc screen for initially separating the waste material so that the shards and abrasive classes of material are able to drop through the rotary disc screen while the remainder of the material is delivered to the apparatus for gravitational classification as between the uncrushables and shreddables in response to air flow in a controlled atmosphere to promote gravity fall-out separation of the heavier components from the lighter components.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to the conversion of the energy of the wind and subsurface ocean currents into electrical energy. In particular the invention relates to the conversion of pressure energy from these sources into electrical energy.
[0003] 2. The Prior Art
[0004] Wind and subsurface ocean currents are fluids possessing mechanical energy. The two relevant components of mechanical energy are pressure energy and kinetic energy. Up to now only some few efforts hve been made to convert the pressure energy of these fluids into electricity. Yet the pressure energy of these two fluids as they naturally occur is far greater than their kinetic energy.
[0005] Hydroelectric turbine generators are a prime example of devices which convert pressure energy into electrical energy. A pressure head is artificially built up in differentiation with the pressure of the surrounding atmosphere. Theoretical power output is calculated as this pressure difference multiplied by the rate of flow.
[0006] The relevant technology for converting the pressure energy of the wind into electrical energy is U.S. Pat. No. 5,709,419 to Roskey. Pressure energy is converted to kinetic energy by using a Venturi flume with the kinetic energy compounded with the use of a manifold. The manifold lies outside the Venturi flume so the advantage of using a manifold is also minimized since pipe friction can be very great.
[0007] For converting the pressure energy of subsuface ocean currents into electricity the U.S. patent most relevant to this invention is U.S. Pat. No. 6,568,181 B1 to Hassard et al. Here an airflow is drawn through an air turbine ashore through a pipe to an offshore Venturi tube's throat, as may sometimes be observed with a manometer. The speed of the current as it is accellerated through the throat determines the speed of the airflow. But to avoid large energy losses through the airpipe due to friction a large and expensive pipe is needed.
[0008] This problem is overcome by the present invention.
SUMMARY OF THE INVENTION
[0009] There is first of all a teardrop-shaped object elevated into the midst of a fluid current. The object is oriented so its blunt end is made to face the oncoming current. The object is in two separate portions the division being on a plane through the object's widest diameter called an anterior dome and either a posterior cone or a posterior dome. There is sufficient structure to unite the separated parts of the object together. Through the center of the anterior dome shped portion is a hole and by this hole is a tube leading to an atmospheric engine apparatus elsewhere. As fluid flows past this teardrop shaped object fluid tends to be drawn through this hole at high velocity and out between the rims of the anterior and posterior portions of the object at the prevailing current velocity.
[0010] The working fluid within the atmospheric engine is water. The waterline is at the end of the tube near the hole in the anterior dome.
[0011] The first object of this invention is to overcome the stated problem of the prior art.
[0012] The second object is to provide inexpensive and effective electric power from wind and subsurface ocean currents.
[0013] The attainment of the foregoing and related objects, features and advantages should be more readily apparent to those skilled in the relevant arts after a review of the following more detailed description of the invention, taken together with the drawings in which:
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is a perspective view of the invention where the passing fluid is the wind.
[0015] FIG. 2 . is a perspective view of the invention as it applies to subsurface ocean currents.
[0016] FIG. 3 . is a view of the energy conversion apparatus of the invention.
DETAILED DESCRIPTION OF THE INVENTION
FIRST PREFERRED EMBODIMENT
[0017] Turning to FIG. 1 we see base 16 upon which the invention rests. Erected on base 16 is hollow pole 15 . Telescoped over pole 15 is pole 13 upon which teardrop-shaped object 1 is fixedly attached. Thrust bearings 24 alows object 1 and pole 13 to revolve concentricly about pole 15 as governed by the response of fin 2 to the prevailing wind. Races in the wall of pole 13 prevent the vertical motion of hollow object 1 .
[0018] Pipe 4 is concentric with pipes 13 , 15 and has a moveable connection 14 allowing that section of pipe 4 above connection 14 to rotate as teardrop shaped object 1 is made to rotate by the wind. The rims of anterior dome 5 and posterior cone 6 are connected by struts 3 positioned so air can pass through the struts.
[0019] Pipe 4 , which is full of water, is led to atmospheric engine 12 .
SECOND PREFERRED EMBODIMENT
[0020] Turning now to FIG. 2 we see instead of a teardrop shaped object a spherical object 24 fixedly attached to tower 25 which in its turn is fixedly attached to the ocean floor. Anterior dome 5 nd posterior dome 6 as well as pipe 4 and struts 3 exist as in the First Preferred Embodiment.
[0021] Ashore pipe 4 is led into energy conversion apparatus 44 . In FIG. 3 all the parts of energy conversion apparatus 44 are shown. Atmospheric engine 12 contains piston 26 which in its turn has two passages through it, each containing a check valve 27 a , 27 b. These valves each allow water to pass in opposite directions. Arrow directions show the flow of water in operation of the invention. Items 29 , 32 are also check valves, pipes 28 , 30 are led into the volume of the engine to the left of piston 26 and pipes 31 , 33 are led into the volume of the engine to the right of piston 26 Pipe 35 is an air inlet and pipe 4 leads to the object.
[0022] Both pipes are filled with water to the same level. Valve control may be effectuated by mechanical devices as in U.S. Pat. No. 32,455(Shaw) or U.S. Pat. No. 170,813(Burger) or by electronic devices which are not a part of this invention. Shaft 36 is driven by piston 26 and is connected to shaft 37 to be mde to rotate cam 38 . Shafts 39 , 41 , drive gear transmission 40 and D.C. generator 34 , which is connected to output cable 20 and battery 42 .
[0023] In operation,water current flowing past sphere 24 draws water through inlet 43 at a faster rate than the velocity of the current. This lowers the water pressure in pipe 4 providing an energy sink to drive atmospheric engine 12 . To move piston 26 to the right valves 29 , 34 a are opened and valves 32 , 34 b are closed.
[0024] Once the maximum pressure differential is established valve 34 a is closed. Or valve 34 b at this point in the cycle if motion of piston 26 is to be to the left.
[0025] Pipes 4 , 30 , 31 and 35 as well as the volumes on both sides of piston 26 are water-filled. Assuming a water current flowing past sphere 24 the absolute water pressure of the volume of wter to the right of piston 26 as shown in FIG. 3 will fall below atmospheric pressure. But the water in the volume to the left of piston 26 will be maintained at atmospheric pressure. The size of the valve openings 27 a,b must be controlled to be such that as piston 26 is forced to the right by the uneven pressure on either side of piston 26 the resulting displacement of water through valve 27 b will result in no transfer of pressure through valve 27 b.
[0026] Movement of piston 26 to the right causes cam 38 to be made to revolve clockwise crankshaft 39 which in its turn is made to operate D.C. generator 34 causing electricity to be fed into battery 42 . Crankshaft 39 may be connected to other atmospheric engines 12 to insure less fluctuation in power output.
[0027] Motion of piston 26 to the left is accomplished by opening vlves 32 , 34 b and simultaneously closing valves 29 , 34 a.
[0028] If the teardrop shaped object 1 is placed in the wind then the working fluid of the atmospheric engine remains water. The water-line is near hole 43 .
[0029] From the above description it is apparent that the preferred embodiments achieve the object of the present invention. Alternative embodiments and various modifications of the depicted embodiments will be apparent to those skilled in the relevant arts.
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A new type of diverging nozzle is used to convert wind energy and subsurface ocean current energy into electrical energy. A new design for an atmospheric engine uses a pressure energy sink created by fluid flow through the small end of the diverging nozzle. An esthetically pleasing and economical way is presented to convert wind energy into electricity. Offshore, no moving parts are employed.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The subject invention relates to a composite panel structure mounted to a base surface for absorbing impact loading. In particular, the present invention directs itself to a composite panel formed of laminated members which is adapted for placement over apertures exposed to harsh environmental conditions. Still further, this invention relates to a composite panel which may be used for protection of glass windows, glass doors, or like elements on the exterior of a building structure for use in protecting such exposed areas to harsh external environmental conditions such as hurricanes, monsoons, or the like. Still further, this invention directs itself to a composite panel structure which is mounted directly to building surfaces during times when impact loading may occur and which may then be removed subsequent to such impact loading conditions being relieved. More in particular, this invention directs itself to a composite panel having a first core formed of a plurality of cell members which are contiguously mounted each to the other which define through passages extending in a first direction which is mounted in laminated fashion to a second core formed of a plurality of second cell members having second core through passages extending in a second direction which is perpendicular to the first direction. Further, this invention directs itself to a laminated composite panel structure having first and second cores which are secured to at least one skin sheet adhesively coupled to at least one of the sides of the combined first and second cores. Still further, the subject invention directs itself to a laminated composite panel which has first and second cores having cross-directed flutes or troughs with skin sheets fastened to opposing sides of the combined first and second cores. More in particular, the subject invention directs itself to composite panels which are relatively lightweight with increased impact loading strength conditions and have a thickness amenable to mounting on the exterior surfaces of buildings.
2. Prior Art
Laminated panels are known in the art. In general, such prior art panels include some type of core material with a skin coating. In many instances, the problems of such prior art panels is that the weight of the panels is of such a nature that mounting to exterior surfaces of buildings or the like is an extremely tedious procedure. Obviously, the thicker that such prior art panels are made, the more protection they provide for the exterior of such buildings, however, with increased weight and thickness of prior art panels, the cost of manufacture as well as the weight are increased. It is a purpose of the subject invention to provide a combination of elements making up a laminated composite panel which minimizes the thickness as well as the weight while maximizing the impact loading strength of the composite panel.
SUMMARY OF THE INVENTION
The present invention provides for a composite panel which is adapted to be mounted to a base surface for absorbing impact loading. The composite panel is formed of a first core having a plurality of first cell members contiguously located each to the other defining respective first core through passages which extend in a longitudinal direction. The composite panel further includes a second core formed of a plurality of second cell members contiguously mounted and located each to the other which define respective second core through passages extending in a transverse direction. The first and second cores are secured each to the other to provide a laminated composite panel structure.
It is a principal objective of the subject composite panel to provide a laminated panel structure which is adapted to be mounted to a base surface for absorbing impact loading and protecting the base surface from such force loading considerations.
It is a further objective of the subject composite panel to provide a structure which protects window and door areas of a building structure from the forces associated with harsh environmental conditions such as hurricanes, monsoons, or other like natural phenomena.
It is a further objective of the subject invention to provide composite panel structures which have a low weight for ease of mounting and maximize the force loading characteristics to protect underlying surfaces to which the composite panel is attached.
It is a further objective of the subject invention concept to provide composite panels which may be preformed to particular sizes associated with standard apertures on buildings to thereby eliminate any wasteful cutting or fitting of such composite panels.
It is a still further object of the subject invention to provide a pair of laminated core structures which are grooved in mutually orthogonal relation to provide a structure which maximizes impact loading strength of the overall composite panel.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the subject composite panel shown in exploded perspective view and adapted for mounting to a building structure;
FIG. 2 is an enlarged cross-sectional view of the composite panel partially cut-away along the section lines 2--2 of FIG. 1;
FIG. 3 is an enlarged cross-sectional view of the composite panel partially cut-away taken along the section lines 2--2 of FIG. 1;
FIG. 4 is an exploded view of a composite panel showing first and second cores in association with outer skin members; and,
FIG. 5 is a schematic view of a roller coater and press employed to apply and press adhesive and then to laminate materials together to provide a composite panel structure.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIGS. 1-4, there is shown composite panel 10 adapted for mounting to a base surface 12 used in general to protect an aperture, window area, glass door area 14, or the like. Composite panel 10 is generally although not restrictively associated with protection of vulnerable areas of buildings 16 when such buildings 16 encounter disadvantageous environmental conditions such as hurricanes, monsoons, or other environmental conditions which would have high winds associated therewith.
In particular, composite panel 10 is so constructed to provide protection and absorb impact loading which may occur due to high wind forces driving various members, elements, or debris against the sides of buildings 16 where glass filled apertures would be vulnerable to impact loading considerations.
Composite panel 10 may be mounted to base surfaces 12 through threaded securement such as composite panel bolts 18 or some like removable mechanism not important to the inventive concept as herein described, with the exception that the mechanism through which composite panel 10 is mounted to base surface 12 be sufficient to maintain securement of composite panel 10 to base surface 12 of building or other structure 16.
As is more clearly seen in FIGS. 2, 3, and 4, composite panel 10 includes first core 20 formed of a plurality of first cell members 22 which are contiguously located each to the other defining first core through passages 32 which extend in longitudinal direction 24 as is seen in FIGS. 3 and 4. First core 20 is defined by the plurality of first cell members 22 located or positioned adjacent each to the other in contiguous manner to provide a lightweight, and deflectable overall element which would absorb impact loading. Each of first cell members 22 includes opposing first cell member top and bottom members 34 and 36, as is seen in FIG. 4, and further includes opposing first cell member side members 38 with each of the side members 38 forming a side member of a next consecutively spaced first cell member 22, as is seen in FIGS. 2-4.
In general, first core 20 may be formed in a one-piece formation defining an overall first core top member 40 and a first core bottom member 42. First core 20 may be formed of a plastic composition and in particular may be formed of a closed cell plastic composition such as polypropylene. In this manner, first core 20 may be molded in one-piece formation to provide a unitarily formed first core 20. As can be seen in FIGS. 2-4, first core through passages 32 in cross-section may be formed in a rectangular contour and extend in longitudinal direction 24. In this manner, first core 20 allows for added flexure about transverse direction 30 while maintaining a relatively stiff structural resistance about longitudinal direction 24.
Referring now to FIG. 2, it is seen that second core 26 is formed in substantially the same manner being formed of second cell members 28 contiguously mounted each to the other defining respective second core through passages 44 extending in transverse direction 30. Each of second cell members 28 is formed of a second cell top member 46, a second cell bottom member 48, and a pair of second cell opposing side members 50, as is seen. Each of second cell members 28 are formed adjacent and contiguous each next to the other forming a second core top member 52 and a second core bottom member 54. As was the case with first core 20, second core 26 may be formed of plastic composition and specifically polypropylene or other closed cell type plastic composition. Second core through passages 44 extend in transverse direction 30 and provide for relatively stiff structural integrity about transverse direction 30 while allowing a deflection about longitudinal direction 24. Second core 26 may be formed through molding or some like technique to provide a unitary body.
The orientation of first core 20 and second core 26 is of importance and as is seen in the Figures, the core members 20 and 26 are oriented orthogonal each to the other when taken with respect to longitudinal direction 24 and transverse direction 30. As can be seen, an axis line of second core through passages 44 extends in a direction which is orthogonal or perpendicular to an axis line of first core through passages 32 when composite panel 10 is formed into an overall composite structure.
In the overall construction of composite panel 10, there is a mechanism for securing first core 20 to second core 26 to provide an overall laminated composite panel 10. The mechanism for securing first core 20 to second core 26 may be through adhesion using an adhesive composition between first and second core members 20 and 26. The particular adhesive composition or glue is not important to the inventive concept as herein defined, with the exception that first core 20 and second core 26 be maintained in secured relation each to the other. The adhesive composition may be a urethane complex or some like adhesive composition. One particular adhesive composition used effectively in securing first core 20 to second core 26 is a glue composition manufactured by Morton International having a designation MOR-AD858-3.
The overall thickness of each of cores 20 and 26 approximate 7/16 ths of an inch with interior side members 38 and 50 being displaced each from the other approximately by a dimension of 7/16 ths of an inch. Through the use of closed cell polypropylene, the weight of the combined first and second cores 20 and 26 approximates 0.41 lbs. per square foot.
Composite panel 10 may include a first core skin 56 secured to first core top member 40 and may be formed of a fiberglass reinforced plastic which may be used in combination with laminated first and second cores 20 and 26 to form a laminated composite panel 10 having a single core skin 56.
In a preferred embodiment of panel 10, first and second cores 20 and 26 include respective first core skin 56 and second core skin 58 mounted in contiguous relation to first core top member 40 and second core bottom member 54, as is seen in FIG. 4. First core skin 56 may be formed of a fiberglass reinforced plastic having a thickness approximating 0.5 inches or greater. Such fiberglass reinforced plastic type sheeting is commercially available and provides for structural integrity of the overall composite panel 10 while maintaining a deflection sufficient to absorb impact loading.
Second core 26 may include a second core skin 58 formed of aluminum which may include a crystal coating to provide weatherability with respect to the external environment. Second core skin 58 may be formed of aluminum having a thickness approximating 0.03 inches or greater with a crystal coating to enhance weatherability. Obviously, aesthetic considerations may be taken into account and such may be stucco embossed or other designs may be formed thereon. In some cases, only first core skin 56 or second core skin 58 may be employed in the construction of composite panel 10. Alternatively, it may be desirable in some cases to only use an aluminum skin and in other cases, the fiberglass reinforced plastic skin.
In the method of forming composite panel 10, and in particular relation to FIG. 5, first and second cores 20 and 26 having respective through passages 32 and 44 are initially cut to a predetermined size. Cores 20 and 26 are machine spreaded with polyurethane adhesive to a thickness approximating 0.006-0.008 inches on one side of cores 20 and 26, as is seen in FIG. 5 by a commercially available roll coater 60. First and second cores 20 and 26 are oriented in a manner such that first core through passages 32 extend in a direction which is orthogonal with respect to second core through passages 44.
Cores 20 and 26 are then placed in pneumatic press 62 for curing. Such presses are commercially available, and one such press which has been used is manufactured by Black Brothers having a Model Number ACR POD PRESS. Curing takes approximately 4-8 hours dependent upon material temperature with pneumatic press 62 exerting a pressure approximating 8.0 lbs. per square inch. Temperature considerations during the curing process are maintained at ambient temperature generally between 60° F.-80° F.
In this manner, first and second cores 20 and 26 have been laminated into a one-piece structure. Once the cross-lamination of cores 20 and 26 has been completed, the structure now defined by the secured cores 20 and 26 is removed from pneumatic press 62 and once again run through adhesive spreader or roll coater 60 to allow a spreading of adhesive between 0.006-0.008 inches on each side. First core skin 56 and second core skin 58 are mounted on the cores and the skins are run through the rubbery press to distribute the adhesive. Finally, the overall structure including first core skin 56, first core 20, second core 26, and second core skin 58 are mounted in pneumatic press 62 for further curing to provide overall composite panel 10.
Although this invention has been described in connection with specific forms and embodiment thereof, it will be appreciated that various modifications other than those discussed above may be resorted to without departing from the spirit or scope of the invention. For example, functionally equivalent element may be substituted for those specifically shown and described, proportional quantities of the elements shown and described may be varied, and in the formation method steps described, particular steps may be reversed or interposed, all without departing from the spirit or scope of the invention as defined in the appended Claims.
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This invention provides for a composite panel (10) which may be mounted to a base surface (12) of a building structure (16) to allow for absorbing impact or other force loading considerations. The composite panel (10) includes a first core (20) which is made up of a number of first cell members (22) which are located next to each other and form through passageways (32) extending in a longitudinal direction (24). Mounted in adhesive contact with the first core (20) is a second core (26) formed of a number of second cell members (28) which are located next to each other and provide for second core through passageways (44) which extend in a transverse direction to produce a cross-pattern with respect to the first and second through passageways (32 and 44). The first core (20) and the second core (26) are adhesively mounted to each other to provide an overall laminated composite panel structure which blocks access to the window or door areas (14) of the building structure (16).
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CROSS-REFERENCES
The present application is a continuation-in-part application of application Ser. No. 08/063,096 filed May 17, 1993, entitled "THREE NEEDLE STITCH WITH COVER THREAD," now U.S. Pat. No. 5,383,414. This application is incorporated herein by this reference.
BACKGROUND OF THE INVENTION
This invention relates to a new stitch that is formed along and covers the edge of an upper ply that is joined to a second underlying ply. The invention also relates to a method of forming the new stitch, The new stitch is useful in many applications including a pocket facing application.
This invention has particular application in the pocket facing operation on bluejeans. In this operation an upper layer or ply of denim is stitched, along a raw edge of the denim, to a pocket fabric ply.
In the prior art, the pocket facing operation is performed by applying a facing stitch that has two parallel rows of standard Type 401 stitches with a top cover thread interlaced between the two rows of Type 401 stitches. In this prior art pocket facing operation, the stitch extends straight for a short distance, then follows a radius for about 90°, and then extends straight for another short distance. The prior art facing stitch is started with the right needle just to the right of the raw edge of the upper ply of material. As the stitch is formed around the radius the upper ply tends to twist to the right side, thereby sometimes leaving its raw edge uncovered by the facing stitch. As the garment is worn and washed the uncovered raw edge frays and becomes unsightly. In addition, the covered raw edge, located between the two lines of Type 401 stitches, can also fray up to the line of stitches formed by the left needle after the garment is worn and washed. When this occurs the integrity of the stitch is challenged.
SUMMARY OF THE INVENTION
In accordance with the present invention there is provided a stitch for securing together two superimposed workpieces along an edge of one of the workpieces. The stitch comprises three needle threads, three looper threads and a spreader thread. Corresponding needle and looper threads form three parallel rows of standard Type 401 stitches. The spreader thread lies along the upper surface of the fabric and is interwoven between and connects the three rows of Type 401 stitches. When using this stitch in a pocket facing operation, the row of Type 401 stitch to the right is applied to the right of the edge of the upper ply of fabric so that the stitch covers the edge of the fabric. The stitch of the present invention is produced by employing three fabric-penetrating thread-carrying needles, which are positioned with the left and right needles equally spaced from the center needle.
The three needles lie within a vertical plane which is at an acute angle to the direction of material feed such that the right needle trails the central needle and the central needle trails the left needle. The point of the left and center needles are on the same horizontal plane and the point of the right needle is about 1/8 of an inch above this horizontal plane. As a result of the point of the right needle being above the point of the other two needles, the left and center needles penetrate the fabric simultaneously while the right and center needles penetrate the fabric sequentially rather than simultaneously. The three thread-carrying needles introduce first, second and third needle threads through the workpiece. The respective needle threads are formed into first, second and third needle thread loops which are formed on the underside of the workpiece. Three oscillating thread-carrying loopers interloop looper threads with the first, second and third needle loops for securing the latter in the workpiece thereby uniting or joining the superimposed workpieces.
In a preferred embodiment, the point of the right needle is disposed in a horizontal plane that is above the horizontal plane of the points of the center and left needles. The staggered arrangement of the needle points is compensated for by arranging the oscillating loopers to be at levels corresponding to the needle points.
A modified spreader, an auxiliary spreaders a spreader thread eyelet and a spreader thread guide are coordinated to lay a cover thread on the top surface of the workpiece plies. In this operation, the cover thread interweaves between the three rows of the 401 Type stitch and thus covers the edge of the upper ply.
The new stitch of this invention provides superior coverage to the raw edge of the denim and increases the seam strength as a result of the additional row of Type 401 stitch, which increases the width of the stitch by 50%, from 1/4 inch to 3/8 inch. An important advantage of this stitch, especially when used in the pocket facing operation on bluejeans, is that fraying of the margin of the raw denim edge that is located between the left and middle rows of Type 401 stitches is prevented. Fraying of the margin of the raw denim edge located between the middle and right rows of the Type 401 stitches is also reduced since the raw edge need not be positioned as closely to the right needle in the sewing operation as required in conjunction with the two-needle facing stitch. Henceforth, the likelihood of sections of the raw denim edge protruding over the right row of Type 401 stitches is also minimized which in turn inhibits fraying. This not only strengthens the seam but also improves its appearance.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view of the stitch applied to overlapping plies of material.
FIG. 2 is a three-dimensional rendering of the threads comprising the stitch.
FIG. 3 is a perspective view of a sewing machine of the type that could produce the stitch.
FIG. 4 is a composite view of the oscillating loopers used to produce the stitch.
FIG. 4a is an isolated perspective view of the feed dog and needle guard.
FIG. 4b is an isolated perspective view of the looper rocker with the three loopers displaced away from the rocker.
FIG. 5 is a composite view of stitch-forming components that are above the work support surface.
FIG. 5a is an isolated perspective view of the needle head.
FIG. 5b is an isolated perspective view of the spreader thread guide and its mounting plate.
FIG. 5c is an isolated perspective view of the spreader and auxiliary spreader and its holder.
FIG. 5d is an isolated perspective view of the presser foot shank.
FIG. 5e is an isolated perspective view of the presser foot bottom including the presser foot keel.
FIG. 5f is an isolated perspective view of the throat plate.
FIG. 6 is a plan view of the start of forward motion of the spreader.
FIG. 7 is a plan view of the middle of forward motion of the spreader.
FIG. 8 is a plan view of the end of forward motion of the spreader.
FIG. 9 is a plan view of the middle of the return motion of the spreader.
FIG. 10 is a plan view of a second embodiment of the stitch applied to overlapping plies of material.
FIG. 11 is a three-dimensional rendering of the second embodiment of the stitch showing the relative position of the threads comprising the stitch.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 is a plan view of a sewn product having the stitch of this invention applied to an overlapping ply of material. During the formation of this stitch, two plies of material to be joined are fed through the machine in overlapping relationship, with an upper ply of material 10 located with its edge 14 extending along a non-edge piece of a lower ply 12. Thus, the upper ply of material extends toward the left of its edge 14 and the lower ply 12 extends to the right and the left of edge 14. The stitch spans the edge 14 of the upper ply of material 10 to secure the upper and lower plies and to cover the edge 14. When applied to bluejeans, the upper ply 10 is denim pocket facing material and the lower ply 12 is pocket lining material.
FIG. 2 is a three-dimensional illustration of the threads comprising the stitch of this invention. The arrow designated A in this view indicates the Direction of Successive Stitch Formation and the arrow designated B indicates the Direction of Feed of Material. The stitch includes three needle threads 18, 20 and 22, three looper threads 48, 50 and 52 and a spreader thread 60. The material plies that are joined by the stitch have not been included in FIG. 2 to better illustrate the stitch formation. The stitch comprises three continuous upper or needle threads 18, 20 and 22 which are formed into right 24, middle 26 and left 28 loops respectively. The needle threads extend along lines that are laterally offset from each other and generally parallel to the edge 14 of the upper ply of material 10.
Referring now to FIGS. 1 and 2, the right loop 24 of right needle thread 18 passes downwardly from its penetration point 30 through the lower ply 12 of material, and extends downwardly to locate the bight portion 32 of the right loop 24 beneath the penetration point 30. The middle loop 26 of middle needle thread 20 passes downwardly from its penetration point 34 through both the upper ply 10 and the lower ply 12 of material, and extends downwardly to locate the bight portion 36 of the middle loop 26 beneath the penetration point 34. The left loop 28 of thread 22 passes downwardly from its penetration point 38 through both the upper ply 10 and the lower ply 12 of material, and extends downwardly to locate the bight portion 40 of the left loop 28 beneath the penetration point 38.
A right looper thread 48 is formed into a loop 42 that passes through the bight portion 32 of the right loop 24 and, as the material is advanced, the bight portion 44 of loop 42 is open and below the penetration point 30 of the next successive stitch of the right needle thread 18. Thus, the bight portion 44 is penetrated by loop 24 of the next stitch formed by thread 18. Thus, the right needle thread 18 and the right looper thread 48 form a standard Type 401 stitch. This first row of Type 401 stitch is formed through only the lower ply 12 of material and follows along the edge 14 of the upper ply of material 10. The middle and left needle threads 20 and 22 cooperate respectively with middle and left looper threads 50 and 52 in the same manner as described above for right needle thread 18 and right looper thread 48 to form standard Type 401 stitches that extend through both the upper 10 and lower 12 plies of material.
A cover or spreader thread 60 is cast on the upper surface of the superimposed workpieces 10 and 12 and interlaced between the needle threads 18, 20 and 22 such that it follows a serpentine path and ties the three standard Type 401 stitches together. As the stitch is being sewn, the spreader thread 60 is cast such that it is in front of the left needle 82 and center needle 80 and behind the right needle 78. (See FIGS. 5 and 5a) Thus, in the stitch, the spreader thread 60 is located in front of penetration points 38 and 34 for needle threads 22 and 20, and behind penetration point 30 for needle thread 18. The spreader thread pattern ties the three rows of Type 401 stitches together to form a very effective and useful new stitch.
FIG. 3 is a perspective view of a sewing machine 62 of the type that may be used to produce the stitch of this invention. Sewing machine 62 includes a needle head 64, a work supporting surface 66, a reciprocating needle bar 68, a presser foot bar 70 and a throat plate 130. A needle head 64, carrying three needles 78, 80 and 82 (FIG. 5a), is secured to the lower end of the needle bar 68 and a presser foot 76 is carried by the lower end of presser foot bar 70. The looper rocker 142 is located below the work supporting surface 66, and is shown in broken lines in this view to depict its relative location in the sewing machine.
Referring now to FIGS. 4, 4a and 4b, a set of loopers 140 is mounted for reciprocal movement below the work supporting surface 66. In FIG. 4, the assembled set of three loopers, right looper 148, middle looper 150 and left looper 152 are shown mounted on the looper rocker 142. The loopers 148, 150 and 152 are secured in adjusted position in the looper rocker 142 by set screws 144. Looper 152 is the front or first looper when looking in the direction of material travel. The loopers are set at a 3/16 inch looper spacing, that is the lateral distance between the loopers is 3/16th of an inch. Viewing from the top, looper 150 is the middle or second looper and its point is about 3/16 of an inch to the right of the point of looper 152. Looper 148 is the rear or third looper and its point is about 3/16 of an inch to the right of the point of looper 150. Viewing from the front, the point of looper 148 is elevated from the points of loopers 150 and 152 by about 1/8 of an inch.
The looper rocker 142 is mounted for oscillating and rocking motion on the sewing machine frame about a pivot axis X--X. Conventional looper rockers that have complex motions, or an axial motion in addition to an oscillating motion, could also be used. A rocker arm 146 is connected to the looper rocker 142 at threaded bore 154 to impart a rocking and oscillating motion to the looper rocker 142.
FIG. 4b shows the looper rocker 142 isolated from the other mechanism with the loopers 148, 150 and 152 removed. It is apparent in this view that the loopers 148, 150 and 152 are staggered from front to back. Looking into the direction of work material feed, the left looper 152 is in the foreground, the middle looper 150 is behind the left looper 152 and the right looper 148 is behind the middle looper 150.
The sewing needles 78, 80 and 82 are staggered in the direction of the material feed to permit cooperation between each needle and its associated looper during each stitch. (See FIGS. 5 and 5a) Thus, the point of right needle 78 is at a level higher than the points of the left and middle needles 82 and 80 to cooperate with looper 148 which is at a higher level than loopers 150 and 152. As a result, the right needle 78 will penetrate the work material after penetration by the left 82 and middle 80 needles. As a result of the point of the right needle being above the point of the other two needles, the center and right needles penetrate the fabric sequentially rather than simultaneously.
The feed dog 156 in FIG. 4 is located above the set of loopers 140. For simplicity, feed dog 156 is not shown with feed teeth, as in FIG. 4a. Also in FIG. 4, a portion of the needle guard 158 is visible.
In FIG. 4a the feed dog 156 and the needle guard 158 are shown isolated from the stitch-forming mechanism. Feed teeth 160 are located at the top surface of the feed dog 156. The needle guard 158 protects and prevents the needles 78, 80 and 82 from being deflected behind the loopers 148, 150 and 152.
FIGS. 5, 5a, 5b, 5c, 5d, 5e and 5f illustrate the stitch-forming components generally shown in FIG. 3 that are located above the work supporting surface 66. FIG. 5 is a composite view of all these components in assembled condition and FIGS. 5a through 5f are isolated views of individual components. The needle head 64 carries three needles, right needle 78, middle needle 80 and left needle 82. The point of right needle 78 is at a higher elevation than the points of left needle 82 and middle needle 80. As shown in FIG. 5, the needle head 64 is at an acute angle to the direction of material travel, such that right needle 78 is the trailing needle and left needle is the leading needle. A spreader thread eyelet 84, through which spreader thread 60 passes, is carried at the end of a rod 86 that is adjustably carried by the needle head 64. The spreader thread eyelet 84 reciprocates along with the needle bar 68.
As shown in FIG. 5b, a spreader thread guide mounting plate 88 is secured to the sewing head area 72 (see FIG. 3), and functions to mount the spreader thread guide 90 at the end of rod 92. Spreader thread guide 90 has an elongated arcuate shaped slot 94 formed therein. The spreader thread guide 90 remains stationary during the formation of a stitch.
FIG. 5c shows a spreader holder 96 having a vertical cylindrical bore 98, which is mounted for oscillation about a bushing (not shown) within the head of the sewing machine. An oscillator (not shown) causes the spreader holder 96 to oscillate. A lug 100 protrudes radially from the spreader holder 96. The lug 100 has a vertical bore 102 that is sized to receive the top end of the spreader mounting bar 104. A pair of screws 107 is threaded into lug 100 to lock the spreader in a selected position. The spreader 106, is carried at the bottom end of spreader mounting bar 104, and has a generally arcuate shape and lies in a horizontal plane. The spreader 106 has a thread-carrying notch 110 including a point 108 formed thereon. The thread-carrying notch 110 is useful in casting the spreader thread 60 in a serpentine path on the upper surface of the work material.
A mounting hub 112 protrudes upwardly from the spreader 106 and serves to mount an auxiliary spreader 114. The auxiliary spreader comprises a curved wire which extends from mounting hub 112 toward the spreader 106. The auxiliary spreader terminates approximately at thread-carrying notch 110. Screws 116 adjustably secure auxiliary spreader 114 in the mounting hub 112. The operation of the spreader 106 and auxiliary spreader 114 will be explained with reference to FIGS. 6-9.
Referring now to FIGS. 5d and 5e, the presser foot 76, which is mounted for vertical movement, includes a shank 120 and a bottom portion 122 which is mounted on the shank 120 for pivoting about a horizontal pivot axis. The front end of the presser foot bottom portion 122 is inclined and includes a slot 124 that receives the mounting edge of a presser foot keel 126.
The throat plate 130 depicted in FIG. 5f has a plurality of feed dog openings 132 and a set of needle openings 134. The throat plate 130 is set into the work supporting surface 66 and is secured thereto by screws 136 that extend through countersunk holes 138 formed in the throat plate 130.
FIGS. 6, 7, 8, and 9 are a series of views showing the progressive locations of spreader 106 and the auxiliary spreader 114 as the spreader thread 60 is cast along the upper surface of the work material and interlooped with the needle threads 18, 20 and 22. Needles 78, 80 and 82 are shown to illustrate their location relative to the spreader thread 60.
FIG. 6 shows the spreader 106 at its extreme right position when it is about to start its forward motion (to the left). At this point in the cycle, the needle bar 68 is at the bottom of its stroke and the spreader thread 60 extends up from right needle 78, across the front edge of spreader 106, through the arcuate shaped slot 94 in the spreader thread guide 90, through the spreader thread eyelet 84 and from there to its source. The eyelet 84 constrains thread 60 to the end of arcuate shaped slot 94 located at the free end of spreader thread guide 90.
FIG. 7 shows the spreader 106 in the middle of its forward motion and moving to the left as shown by the directional arrow. At this point in the cycle the needle bar 68 is rising and is located between the bottom and top of its stroke. From the position in FIG. 6, the spreader thread 60 has slid along the rear edge of spreader 106 and has encountered thread-carrying notch 110. Notch 110 catches spreader thread 60 and holds it from further movement along the edge of spreader 106. After spreader thread 60 encounters thread-carrying notch 110, further movement to the left by spreader 106 causes the spreader thread 60 to be pulled to the left. At this stage of the cycle, auxiliary spreader 114 has encountered spreader thread 60. The auxiliary spreader 114 causes the thread to slide along the arcuate shaped slot 94, moving thread 60 toward the rear end of slot 94.
FIG. 8 shows the spreader 106 at the end of its forward motion and at its extreme left position. At this point in the cycle the needle bar 68 is at the top of its stroke. The spreader thread 60 remains in contact with the thread-carrying notch 110 of the spreader 106, and the auxiliary spreader 114 has caused the spreader thread 60 to move past the tip of the right needle 78. As the needle bar 68 moved up from its position in FIG. 7, thread 60 passed under the point of needle 78 while in engagement with the front surface of needles 80 and 82. The thread 60 was moved in this manner because the point for needle 78 is at a higher elevation than the point for needles 80 and 82. This movement of the thread 60 beneath needle 78 is caused by the action of the auxiliary spreader 114 directing spreader thread 60 toward the extremity of arcuate shaped slot 94. Immediately after the needles 78, 80 and 82 reach the top of their cycle they reverse direction, and needles 80 and 82 penetrate the work material on one side of thread 60 and needle 78 penetrates the work material on the opposite side thereof. Needles 80 and 82 pierce the fabric first and prevent the thread 60 from being moved to a location on their back side.
FIG. 9 shows the spreader in the middle of its return motion and is moving to the right, as shown by the directional arrow. Here the needle bar 68 is moving down. When the spreader 106 reverses its direction the thread 60 is released from the notch 110. As shown in FIG. 9, thread 60 extends from around needle 78 upwardly through the arcuate shaped slot 94, over the left or rear surface of the auxiliary spreader 114, and through the spreader thread eyelet 84. As the auxiliary spreader 114 sweeps to the right, it engages the thread 60 and allows it to slide along the edge of the arcuate shaped slot 94 toward its terminal end, while motion is caused by the eyelet 84. When the spreader 106 reaches its extreme right position (FIG. 6), the thread 60 will have slid off the terminal end of the auxiliary spreader, and the spreader components will have completed a cycle and will have returned to the positions shown in FIG. 6.
FIGS. 10 and 11 illustrate a second embodiment of the stitch. This embodiment of the stitch can be formed on a sewing machine of the type disclosed in FIGS. 3-9 herein with a few minor changes. To produce this embodiment of the stitch, the middle needle 80 must be raised up to the level of right needle 78. As a result of the points of the middle and right needle being above the point of the left needle, the left 82 and center 80 needles penetrate the fabric sequentially rather than simultaneously, as they do in the first embodiment of the stitch. Also, the middle looper 150 must be raised to the level of right looper 148, which can be accomplished by lengthening the vertical leg of looper 150. The needle guard 158 must be modified slightly, such that the portion that cooperates with middle needle 80 is raised up to the level of the portion that cooperates with needle 78.
FIG. 10 is a plan view of a sewn product having the stitch of this invention applied to overlapping plies of material. During the formation of this stitch, two plies of material to be joined are fed through the machine in overlapping relationship, with an upper ply of material 10' located with its edge 14' extending along a non-edge piece of a lower ply 12'. Thus, the upper ply of material extends toward the left of its edge 14' and the lower ply 12' extends to the right and the left of edge 14'. The stitch spans the edge 14' of the upper ply of material 10' to secure the upper and lower plies and to cover the edge 14'. When applied to bluejeans, the upper ply 10' is denim pocket facing material and the lower ply 12' is pocket lining material.
FIG. 11 is a three-dimensional illustration of the threads comprising the stitch of this invention. The arrow designated A in this view indicates the Direction of Successive Stitch Formation and the arrow designated B indicates the Direction of Feed of Material. This embodiment of the stitch is formed by three needle threads 18', 20' and 22', three looper threads 48', 50' and 52' and a spreader thread 60'. The material plies that are joined by the stitch have not been included in FIG. 11 to better illustrate the stitch formation. The stitch comprises three needle threads 18', 20' and 22' which are formed into right 24', middle 26' and left 28' loops respectively. The needle threads extend along lines that are laterally offset from each other and generally parallel to the edge 14' of the upper ply of material 10'.
Referring now to FIGS. 10 and 11, the right loop 24' of right needle thread 18' passes downwardly from its penetration point 30' through the lower ply 12' of material, and extends downwardly to locate the bight portion 32' of the right loop 24' beneath the penetration point 30'. The middle loop 26' of middle needle thread 20' passes downwardly from its penetration point 34' through both the upper ply 10' and the lower ply 12' of material, and extends downwardly to locate the bight portion 36' of the middle loop 26' beneath the penetration point 34'. The left loop 28' of thread 22' passes downwardly from its penetration point 38' through both the upper ply 10' and the lower ply 12' of material, and extends downwardly to locate the bight portion 40' of the left loop 28' beneath the penetration point 38'.
A lower right looper thread 48' is formed into a loop 42' that passes through the bight portion 32' of the right loop 24' and, as the material is advanced, the bight portion 44' of loop 42' is open and below the penetration point 30' of the next successive stitch of the right needle thread 18'. Thus, the bight portion 44' is penetrated by loop 24' of the next stitch formed by thread 18'. Thus, the right needle thread 18' and the right looper thread 48' form a standard Type 401 stitch. This first row of Type 401 stitch is formed through only the lower ply 12' of material and follows along the edge 14' of the upper ply of material 10'. The middle and left needle threads 20' and 22' cooperate respectively with middle and left looper threads 50' and 52', in the same manner as described above for right needle thread 18' and right looper thread 48', to form standard Type 401 stitches that extend through both the upper 10' and lower 12' plies of material.
A cover or spreader thread 60' is cast on the upper surface of the superimposed workpieces 10' and 12' and interlaced between the needle threads 18', 20' and 22', such that it follows a serpentine path and ties the three standard Type 401 stitches together. As the stitch is being sewn, the spreader thread 60' is cast such that it is in front of the left needle 82 and behind center needle 80 and right needle 78. (See FIGS. 5 and 5a) Thus, in this embodiment of the stitch, the spreader thread 60' is located in front of penetration points 38' for needle thread 22', and behind penetration points 30' and 34' for needle threads 18' and 20' respectively. The spreader thread pattern ties the three rows of Type 401 stitches together to form a very effective and useful new stitch.
While the invention has heretofore been described in detail with particular reference to illustrated apparatus and seams, it is to be understood that variations, modifications and the use of equivalent mechanisms can be effected without departing from the spirit and scope of this invention. It is therefore intended that such changes and modifications be covered by the following claims.
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A method of forming a stitch and the stitch which includes three needle threads and cooperating looper threads for forming three parallel rows of stitches that are joined by a spreader thread that lies on the upper surface of the work piece. The spreader thread follows a serpentine pattern and is configured to lie both forward of and rearward of the penetrating points of the needle threads such that it connects and covers the three parallel rows of stitches.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to antennas capable of both receiving and transmitting high frequency signals. More specifically, this invention relates to beam antennas having a support boom and at least one driver element. Also, this invention relates to antennas that are capable of operating on more than one frequency band using remote tuning. This invention would be particularly useful for amateur radio operators, because amateur radio operators frequently transmit and receive signals on several frequency bands.
2. Discussion of the Related Technology
Conventional beam antennas, such as a Yagi antenna, include at least one driver element tuned to resonate at a desired receive/transmit frequency band and positioned at right angles to a support boom. To increase the directivity of such an antenna, a parasitic reflector element, usually tuned to a frequency slightly higher than the driver resonant frequency, can be placed parallel to the driver element along the boom. For further increased directivity, one or more director elements, usually tuned to frequencies slightly lower than the driver resonant frequency, can be placed at various distances along the boom on the other side of the driver element and parallel to the driver element. The driver and other elements are electromagnetically coupled for maximum gain and directivity and are usually of approximately the same length. In these antennas, the driver and the other elements are basically dipoles which in combination are resonant for a particular frequency band.
Trapped dipole antennas, which are variations of the Yagi antenna, can accommodate up to three transmit/receive frequency bands. Trapped dipole antennas have elements of approximately the same length positioned on a common support boom similar to Yagi antennas. In addition, however, trapped dipole antennas have electrical circuits consisting of wound inductance and capacitance arrangements, commonly called traps, placed near the ends of each element to force each element to resonate at a desired frequency band. Wound inductances, however, have several drawbacks, including high loss and heat generation. Trapped dipole antennas are often used in the amateur radio field where a series of bands are available, because one antenna can be used for several selected frequency bands. In order to use all the frequencies available for amateur radio transmission, however, more than one trapped dipole antenna would be required to obtain maximum efficiency of the transmitted signal.
A theoretical variation on the trapped dipole antenna was described in Les Moxon, HF Antennas for All Locations 122-43 (2d ed. 1992). This variation is similar to the trapped dipole antenna, except that a non-wound inductance/capacitance circuit is placed at the center of each element instead of at the ends of each element. The advantage of this linear resonator variation is that the antenna is electrically two antennas side by side in what is commonly known as a "double Zepp" arrangement. An element of this design exhibits more gain than an element of the trapped dipole design. This antenna has a higher efficiency than a trapped dipole antenna in multi-element form, but it is difficult to construct without increasing weight wind load and using specialized components.
SUMMARY OF THE INVENTION
With the recent assignment of more bands for amateur radio use, the need for multiband antennas has increased. Multiband antennas are needed to transmit on more than one amateur radio frequency band, receive public short wave transmissions, and receive and transmit on frequencies between bands.
The variable capacitance antenna provides a beam antenna arrangement with multiband reception and transmission capabilities. In addition to multiband capabilities, the variable capacitance antenna provides fine multifrequency tuning capabilities. According to one embodiment, a variable capacitance arrangement associated with each antenna dipole element is installed inside the boom of an antenna. Adjusting the capacitance of each dipole element alters the gain, efficiency, and directivity of the antenna as a whole. The antenna capacitance may be remotely tuned to a selected frequency and the antenna remotely rotated to maximize gain and directivity and minimize surface area to reduce wind loading.
Adjusting the dimensions of the variable capacitance antenna makes it applicable for any frequency where resonant dipole elements can be used. Also, the variable capacitance antenna can be used to receive or transmit either horizontally polarized signals, such as amateur radio signals, or vertically polarized signals, such as commercial radio signals.
An advantage of this antenna is that it enables both the receiving and the transmitting of signals in a large number of frequency bands. Another advantage of this antenna is that it has minimal weight and wind load. Another advantage of this antenna is that it supplies high efficiency and high gain yet has a minimal number of "unused" elements. Yet another advantage of this antenna is that it is capable of remote tuning to maximize efficiency for each and every frequency within a frequency band or series of frequency bands. Yet another advantage of this antenna is that it provides tuning such that a desired frequency having a weak signal may be received clearly even if signals on nearby frequencies are strong. Yet another advantage of this antenna is that, by remotely tuning the antenna during broadcast of signals, it minimizes or removes interference with received television signals.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a variable capacitance antenna having three dipole elements.
FIG. 2 shows a cross section of the support boom of a variable capacitance antenna detailing the structure of the variable capacitor portion and the remote tuning portion.
FIG. 3 shows a rack and pinion movement for the remote tuning portion of a variable capacitance antenna.
FIG. 4 shows a variable capacitor portion for use with two elements.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows an embodiment of the variable capacitance antenna having three dipole elements. The director element 1, driver element 2, and reflector element 3 are shown mounted on a common support boom 4. The variable capacitance antenna requires at least one driver element 2, however, there can be any number of directors including zero. In a preferred embodiment, the variable capacitance antenna contains one director element 1 and one reflector element 3, however, reflector elements may also be any number including zero.
Preferably, the three dipole elements are made of light-weight, electrically conductive material, such as aluminum alloy. Each of the dipole elements is approximately of length L, which preferably is approximately half the wavelength of the lowest frequency of interest. If the wavelength of the lowest frequency of interest is between 10 and 20 meters, then each dipole element length L would be approximately 10 meters, or 34 feet. Each element can have any diameter, however, a diameter of 11/2 inches is suggested, with a tapered design for minimal wind load. Each dipole element should be electrically isolated from the boom if the support boom 4 is made of a conductive material.
To provide sufficient strength to support the dipole elements yet weigh a minimal amount, the support boom 4 is preferably a thin wall aluminum alloy tube with an outside diameter of 2 to 3 inches. A fiberglass or fiberglass and aluminum boom, however, is also acceptable. For a four element variable capacitance antenna designed to receive/transmit wavelengths of 10 to 20 meters, the boom length N is preferably 30 to 40 feet. For a two element antenna, the boom length N can be considerably shorter.
Connection of a transmission line to the variable capacitance antenna can be completed by the traditional delta match to the driver element 2 of the antenna at points P and Q shown in FIG. 1. The distance between points P and Q depends on the impedance of the transmission line, but it is expected to be five feet for a 34 foot driver element.
In the center portion of each element is a non-wound inductor/capacitor arrangement, commonly known as a linear resonator. A capacitor portion 20 of a linear resonator is inside the boom 4 and connected to a dipole element using conductive connecting wires 5, 6 such as wire braiding or tubing. A non-wound inductance portion 21 of the linear resonator may be formed at the center of each dipole element, between the connection points of connecting wires 5, 6 on the dipole element. In one embodiment, the inductor portion 21 of the linear resonator is of length M, which can be approximately 7 feet for a dipole element 34 feet long. The structure of an existing Yagi antenna can be modified to include a linear resonator with a variable capacitance portion inside the Yagi antenna boom. For a single element antenna, alternatively, capacitor portion 20 may be placed inside the element. Connecting screws 7, 8 should be spaced 4 inches or more away from inductor portion 21 of the linear resonator to prevent capacitive coupling between the connecting wires and their associated connecting screws 5, 7 and 6, 8 and the inductor portion 21. Connecting screws 7, 8 attach the connecting wires 5, 6 from the inductor portion 21 of a dipole element to the capacitor portion 20 inside the boom 4. Connecting screws 7, 8 are described in detail in FIG. 2.
FIG. 2 shows a cross section of the boom of the variable capacitance antenna detailing the capacitor portion 20 of a linear resonator which includes conductive tubes 9, 13. Tubes 9, 13 are effectively the conductive plates of a variable coaxial cylinder capacitor. Advantageously, tubes 9, 13 are constructed of an aluminum alloy to provide a strong, lightweight, variable capacitor. Preferably, tube 13 has a length of 18 inches. Tube 13 may be slide fit onto a 1/4 inch inner diameter nonconductive tube 12 approximately 20 inches shorter than the length of boom 4. Tube 13 can be secured to tube 12 by a detente 16 made by a center punch.
Tube 13 may be electrically isolated from tube 9 by nonconductor tube 11 having a 3/4 inch inner diameter inside the length of boom 4. For an antenna with a short boom length, however, if nonconducting tube 11 is of sufficient strength and length, then it can take the place of boom 4, i.e., boom 4 is not required (as shown in FIG. 4). Tube 9 should be approximately 2 inches shorter than tube 13, or approximately 16 inches, to enable electrical contact to connecting wire 5. In a preferred embodiment, tubes 9 and 11 are stationary while tube 12 (and associated tube 13) is moveable. Advantageously, nonconductive tubes 11, 12 are constructed of lightweight plastic. The electrical isolation of conductive tubes 9, 13 by nonconductive tube 11 prevents high frequency voltage breakdown and arcing.
Capacitance is measured between electrically conductive connecting screws 7 and 8. Screws 7, 8 are electrically isolated from the boom 4 to prevent stray electrical coupling. Screw 7 makes an electrical connection between connecting wire 5 and conductive tube 9, and screw 8 makes an electrical connection between connecting wire 6 and conductive tube 13. Screw 7 directly connects electrically and mechanically to tubes 9 and 11. Screw 7 provides mechanical coupling between conductive tube 9 and nonconductive tube 11 to prevent movement of either tube 9 or tube 11 inside the boom 4.
Screw 8 connects to conductive tube 13 through tube 10 and contact 15. Preferably, contact 15 is made using a flexible, insulated steel wire spring approximately 1/4 inch wide and 0.010 inches thick in the shape of half a coil. A opening at 45° can be made in nonconducting tube 11 that allows insertion of contact 15 through tube 11 to electrically connect with tube 13. Additionally, screw 8 prevents movement between tube 10 and tube 11. Alternatively, the contact can be made of linear bearings 15A as shown in FIG. 3. Linear bearings provide multiple points of contact to conductive tube 13 and an increased voltage rating for the variable capacitor due to the air gap between tubes 13 and 9 in addition to nonconductive tube 11, however, linear bearings do not provide the desirable scrubbing action that wire contact 15 provides.
Antenna capacitance varies when conductive tube 13 moves relative to conductive tube 9 along the axis of the boom 4. Nonconductive tubes 11, 12 provide a "track" for the movement of conductive tube 13. Positioning the tubes so that stationary conductive tube 9 and moveable conductive tube 13 are maximally coupling (fully overlapping) provides, for example, a capacitance of approximately 100 picofarads. Moving tube 13 so that the conductive tubes 9, 13 are completely decoupled (nonoverlapping) produces zero capacitance and decouples the dipole element associated with the variable capacitor. FIG. 2 shows conductive tubes 9 and 13 completely decoupled. The exact amount of capacitance provided by this arrangement is determined by the surface area of conductive tubes 9, 13, the separation distance between the conductive tubes 9, 13, and the distance of the coupled length thereof. By varying the diameter of tube 9 along its length, capacitance change may be made nonlinear, which can be advantageous for multi-element antennas used for multifrequency purposes.
FIG. 2 represents capacitor portion 20 inside the boom which can be duplicated for each dipole element. Moving the inner conductive tubes along the axis of the boom relative to the outer conductive tubes provides a change of capacitance for each dipole element. This variable capacitance arrangement makes possible fine adjustments to the capacitance of the dipole elements. This change in capacitance varies the resonance frequency of the dipole elements and provides an antenna with high efficiency radiation transfer and gain with directivity. Additionally, the variable capacitor portion 20 enables the antenna to have a sharp frequency focus so that the antenna can receive weak signals on one frequency and reject strong signals on nearby frequencies.
The maximum coupling length of the conductive tubes of the capacitor portion in the reflector element 3 and director element 1 can be varied by +10% and -10%, respectively, compared to the maximum coupling length of the conductive tubes in the capacitor portion of driver element 2. Because the dipole elements are variably tunable, this variable capacitance antenna is capable of receiving and transmitting in more frequency bands with a higher gain for any particular frequency than previous antennas. Each dipole element can also be independently tunable by providing separate, shorter, nonconductive tubes for each dipole element (rather than a single long nonconductive tube 12 for all the dipole elements) as a track for each inner conductive tube 13.
In a preferred embodiment, controlling the movement of tube 13 is accomplished by using a reversible low-speed motor or step motor 17. Motor 17 may be connected near the center of capacitor portion 20 as shown in FIG. 2, or it may be connected near an end of capacitor portion 20 as shown in FIG. 3. As shown in FIG. 2, movement of tube 13 can be attained by winding a cord 19 secured to tube 12 in two places and wrapping the cord 19 around the motor shaft 18A of the motor 17. Tube 11 may be cut away at appropriate points to prevent tube 11 from impeding the movement of the cord 19. Since there is not much friction between tube 11 and tube 13, pulling forces (torque) on the cord 19 can be as low as 15 lbs/in for a 40 foot boom. Reversal of the direction of motor shaft 18A may be accomplished by reversing the electrical connection to the motor 17, which can be controlled remotely along with fine adjustments of the motor speed. Preferably, nonconductive spacers 14 prevent tubes 9, 11, 12, 13 of the capacitor portion 20 from bumping into the inner walls of the boom 4. Advantageously, tube 11 has a low friction interface such as linear bearings 22 on its inner diameter to reduce friction between tube 11 and tube 12 and prevent side thrust forces from slowing or stopping the motor.
High friction assemblies can use more positive methods of movement such as rack and pinion movement between motor 17 and tube 12 as shown in FIG. 3. Rack portion 25 may be attached to or integrated into nonconductive tube 12. The rack portion 25 interacts with pinion motor shaft 18B to provide force to move nonconductive tube 12 and associated conductive tube 13 along the axis of boom 4. Note that FIG. 3 shows conductive tube 13 partially coupled with conductive tube 9.
For a single element vertical antenna, motor 17 may be located at the bottom of the element to allow easy access and provide for nut and screw rotation methods or mobile antenna retraction drive systems to provide axial movement of tube 13 within the driven element.
Varying the capacitance of each dipole element, as opposed to having the same capacitance for each dipole element, will vary the footprint of radiation greatly. If each dipole element is of the same length, making the reflector element 3 (shown in FIG. 1) slightly more capacitive than the driver element 2 (shown in FIG. 1) and the director element 1 (shown in FIG. 1) slightly less capacitive than the driver element 2 produces maximum gain from the direction of the driver element 2 to the director element 1 as per a conventional Yagi antenna design. By varying dipole element lengths, the variable capacitance antenna can provide a reversal of maximum gain direction for some frequencies within the design of the antenna. For additional variability in directivity, the entire antenna structure may be rotatable about its horizontal axis for vertical polarization applications.
FIG. 4 shows a variable capacitor portion without a boom for use with two elements. In this embodiment, two outer conductive tubes 9a, 9b share one inner conductive tube 13. FIG. 4 shows the variable capacitor completely decoupled. However, moving conductive tube 13 toward the right will couple conductive tube 9a and its associated dipole element through connecting wires 5a, 6a. Then, moving conductive tube 13 back toward the left will decouple conductive tube 9a and its associated dipole element and couple conductive tube 9b and its associated dipole element through connecting wires 5b, 6b. This feature is advantageous in that it allows tailoring of the spacing between coupled elements in a multi-element antenna. The spacing of the coupled elements are important in determining the gain, establishing the front to back ratio, and ensuring that element gains or phases are additive rather than subtractive.
This variable capacitance antenna may, of course, be carried out in specific ways other than those set forth here without departing from the spirit and essential characteristics of the invention. Therefore, the presented embodiments should be considered in all respects as illustrative and not restrictive and all modifications falling within the meaning and equivalency range of the appended claims are intended to be embraced therein.
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A variable capacitance antenna allows individual adjustment of linear resonators on a beam antenna. A linear resonator is associated with each dipole element on a common support boom. A variable capacitance is positioned inside the boom and created using an arrangement of two coaxial conductive tubes as capacitive plates. One of the conductive tubes may be axially moved by a motor using a remote drive control. The movement of one conductive tube relative to the other can vary the capacitance from 0 to 100 picofarads, for example. The variable capacitance antenna can be used for both horizontal and vertical signal polarization applications. Such a variable capacitance antenna can receive and transmit electromagnetic signals on multiple frequency bands and in between frequency bands with high gain, high directivity, high efficiency, and low wind loading.
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[0001] The present application claims the benefit of priority under 35 USC §119(e) to U.S. Provisional Patent Application 61/187,302 entitled “Anti-michotic Wallboard Tape”, filed Jun. 16, 2009, which is hereby incorporated, in its entirety, herein by reference.
FIELD OF THE INVENTION
[0002] This invention relates to paper products and/or substrates suitable for being made into wallboard tape (also may be known as joint tape and/or drywall tape) and having improved reduction or inhibition in the growth of microbes, mold and/or fungus. The paper substrate is characterized by its excellent physical properties including cross direction (CD) tensile, machine (MD) tensile, internal bond, wet tensile, hygroexpansivity, curl, bonding properties, bonding of joint tape to joint compound, etc. The paper product of the invention contains a sizing agent and an antimicrobial compound as well as other optional components including without limitation a binder. The paper product of the invention may be produced by contacting the plurality of cellulose fibers with each of the sizing agent, antimicrobial compound, and optional components at any point in the papermaking process, converting process, and/or post-converting process. Finally, the invention relates to methods of using the paper substrate.
BACKGROUND OF THE INVENTION
[0003] Wallboard (also known as drywall) has become the dominant material in the production of interior building partitions. In particular, interior building partitions generally comprise a studwall of spaced parallel vertical members (studs) which are used as a support for preformed panels (wallboard) which are attached to the studwall by screws, nails, adhesive or any other conventional attachment system. Obviously, joints exist between adjacent preformed panels. In order to provide a continuous flat surface to the wall, it is necessary to “finish” the joint between adjacent panels. Generally, such “finishing” may include the building up of multiple layers of a mastic material (joint compound) and the blending of this joint compound and paper substrate suitable for wallboard tape utility into the panel surface so as to form the desired flat and contiguous wall surface. In addition, wallboard tape may be used to bring together a plurality of panels forming a corner which may include but is not limited to corner bead.
[0004] In order to facilitate this finishing of the joints and/or corners, most manufacturers bevel the longitudinal edges of the wallboard panels so as to allow a build-up of mastic material which will then match the level of the major surface area of the preformed panel. Typically, the buildup of the mastic material in the joint area comprises the application of a first layer of mastic material, the embedding of a wallboard tape (for example a paper tape) in the first layer of mastic material and then the overcoating of the tape with one or more, generally two layers of additional mastic material. This finishing of the joints is a time consuming process, since it is generally necessary to wait 24 hours between each application of a coat of mastic material in order to allow the coat to dry before the application of an overcoat of an additional layer of mastic material. Moreover, it is then necessary generally to sand the joint area so as to produce a finish which will match the major portion of the surface area of the wallboard panels. The “finishing” process thus is both time-consuming and labor-intensive.
[0005] In addition to the above, it is desirable to create building materials that are antimicrobial so that they resist or inhibit the growth of microbes such as bacteria, fungus, molds, and mildew.
[0006] Wallboard tape paper is a very challenging paper to make as there is a very narrow window of operation in which to achieve the required high tensile strengths while maintaining other good physical properties such as bonding properties, bonding of joint tape to joint compound, hygroexpansivity, curl, etc. The challenge to the next generation of wallboard tape paper substrate production is to program an addition antimicrobial function into what is already a very specific and stringent set of physical properties such as CD tensile, MD tensile, internal bond, wet tensile, hygroexpansivity, curl, bonding properties, bond of joint tape to joint compound, etc (which are demanded by wallboard tape paper substrate converters and users). Such levels of physical properties such as CD tensile, MD tensile, internal bond, wet tensile, hygroexpansivity, curl, bonding properties, bond of joint tape to joint compound, etc, have been achieved by conventional production of paper substrates under acidic conditions and alkaline conditions. However, an alkaline paper substrate suitable for wallboard tape converting (e.g. have acceptable physical properties such as CD tensile, MD tensile, internal bond, wet tensile, hygroexpansivity, curl, bonding properties, bond of joint tape to joint compound, etc) has been difficult to achieve.
[0007] Despite the considerable efforts, there exists a need for a wallboard tape to satisfy the construction industries' requirements wallboard tape having highly sought after physical properties and maintain sustainable antimicrobial properties.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 : A first schematic cross section of just one exemplified embodiment of the paper substrate that is included in the paper substrate of the present invention.
[0009] FIG. 2 : A second schematic cross section of just one exemplified embodiment of the paper substrate that is included in the paper substrate of the present invention.
[0010] FIG. 3 : A third schematic cross section of just one exemplified embodiment of the paper substrate that is included in the paper substrate of the present invention.
[0011] FIG. 4 : A first pictorial representation of how wallboard and tape samples were tested for antimicrobial performance according to Example 1.
[0012] FIG. 5 : A second pictorial representation of how wallboard and tape samples were tested for antimicrobial performance according to Example 1.
[0013] FIG. 6 : A photograph showing the antimicrobial performance of Sample A after 62 days as measured by the process of Example 1.
[0014] FIG. 7 : A photograph showing the antimicrobial performance of Sample B after 62 days as measured by the process of Example 1.
[0015] FIG. 8 : A photograph showing the antimicrobial performance of Sample C after 62 days as measured by the process of Example 1.
[0016] FIG. 9 : A photograph showing the antimicrobial performance of Sample D after 62 days as measured by the process of Example 1.
[0017] FIG. 10 : A photograph showing the antimicrobial performance of Sample E after 62 days as measured by the process of Example 1.
[0018] FIG. 11 : A photograph showing the antimicrobial performance of Sample F after 62 days as measured by the process of Example 1.
[0019] FIG. 12 : A photograph showing the antimicrobial performance of Sample G after 62 days as measured by the process of Example 1.
[0020] FIG. 13 : A photograph showing the antimicrobial performance of Sample H after 62 days as measured by the process of Example 1.
DETAILED DESCRIPTION OF THE INVENTION
[0021] The present inventors have now discovered a paper substrate which, until now, was unable to meet the stringent physical properties required by the construction industries for useful wallboard tape application that also has sustainable antimicrobial properties, as well as methods of making and using the same.
[0022] The paper substrate of the present invention may contain recycled fibers and/or virgin fibers. Recycled fibers differ from virgin fibers in that the fibers have gone through the drying process at least once.
[0023] The paper substrate of the present invention may contain from 1 to 99 wt % of cellulose fibers based upon the total weight of the substrate, including 1, 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95 and 99 wt %, and including any and all ranges and subranges therein.
[0024] Preferably, the sources of the cellulose fibers are from softwood and/or hardwood. The paper substrate of the present invention may contain from 1 to 99 wt %, preferably from 5 to 95 wt %, cellulose fibers originating from softwood species based upon the total amount of cellulose fibers in the paper substrate. This range includes 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, and 100 wt %, including any and all ranges and subranges therein, based upon the total amount of cellulose fibers in the paper substrate.
[0025] The paper substrate of the present invention may contain from 1 to 99 wt %, preferably from 5 to 95 wt %, cellulose fibers originating from hardwood species based upon the total amount of cellulose fibers in the paper substrate. This range includes 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, and 100 wt %, including any and all ranges and subranges therein, based upon the total amount of cellulose fibers in the paper substrate.
[0026] Further, the softwood and/or hardwood fibers contained by the paper substrate of the present invention may be modified by physical and/or chemical means. Examples of physical means include, but is not limited to, electromagnetic and mechanical means. Means for electrical modification include, but are not limited to, means involving contacting the fibers with an electromagnetic energy source such as light and/or electrical current. Means for mechanical modification include, but are not limited to, means involving contacting an inanimate object with the fibers. Examples of such inanimate objects include those with sharp and/or dull edges. Such means also involve, for example, cutting, kneading, pounding, impaling, etc means.
[0027] Examples of chemical means include, but is not limited to, conventional chemical fiber modification means. Examples of such modification of fibers may be, but is not limited to, those found in the following U.S. Pat. Nos. 6,592,717, 6,582,557, 6,579,415, 6,579,414, 6,506,282, 6,471,824, 6,361,651, 6,146,494, H1,704, 5,698,688, 5,698,074, 5,667,637, 5,662,773, 5,531,728, 5,443,899, 5,360,420, 5,266,250, 5,209,953, 5,160,789, 5,049,235, 4,986,882, 4,496,427, 4,431,481, 4,174,417, 4,166,894, 4,075,136, and 4,022,965, which are hereby incorporated in their entirety by reference.
[0028] The paper substrate of the present invention may contain an antimicrobial compound. The paper substrate's antimicrobial tendency may be measured in part by ASTM standard testing methodologies such as D 2020-92, E 2180-01, G 21-966, C1338, and D2020, all of which can be found as published by ASTM and all of which are hereby incorporated, in their entirety, herein by reference.
[0029] Antimycotics, fungicides are examples of antimicrobial compounds. Antimicrobial compounds may retard, inhibit, reduce, and/or prevent the tendency of microbial growth over time on/in a product containing such compounds as compared to that tendency of microbial growth on/in a product not containing the antimicrobial compounds. The antimicrobial compound when incorporated into the paper substrate of the present invention preferably retards, inhibits, reduces, and/or prevents microbial growth for a time that is at least 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 75, 100, 125, 150, 200, 250, 300, 350, 400, 450, 500, 550, 600, 700, 800, 900, 1000% greater than that of a paper substrate that does not contain an antimicrobial compound, including all ranges and subranges therein.
[0030] Antimycotic compounds are, in part, mold resistant. Fungicide compounds are, in part, fungus resistant. The antimicrobial compound may have other functions and activities than provide either mold resistance and/or fungus resistance to a product containing the same.
[0031] The antimicrobial compound may also be mildew, bacteria and/or virus resistant. A mold specifically targeted, but meant to be non-limiting, is Black mold as applied to the above-mentioned paper substrate of the present invention.
[0032] It is preferable for the antimycotic and/or fungicide to not be highly toxic to humans.
[0033] The antimycotic and/or fungicide may be water insoluble and/or water soluble, most preferably water insoluble. The antimycotic and/or fungicide may be volatile and/or non-volatile, most preferably non-volatile. The antimycotic and/or fungicide may be organic and/or inorganic. The antimycotic and/or fungicide may be polymeric and/or monomeric.
[0034] The antimycotic and/or fungicide may be multivalent which means that the agent may carry one or more active compounds so as to protect against a wider range of mold, mildew and/or fungus species and to protect from evolving defense mechanisms within each species of mold, mildew and/or fungus.
[0035] Any water-soluble salt of pyrithione having antimicrobial properties is useful as the antimicrobial compound. Pyrithione is known by several names, including 2 mercaptopyridine-N-oxide; 2-pyridinethiol-1-oxide (CAS Registry No. 1121-31-9); 1-hydroxypyridine-2-thione and 1 hydroxy-2(1H)-pyridinethione (CAS Registry No. 1121-30-8). The sodium derivative, known as sodium pyrithione (CAS Registry No. 3811-73-2), is one embodiment of this salt that is particularly useful. Pyrithione salts are commercially available from Arch Chemicals, Inc. of Norwalk, Conn., such as Sodium OMADINE or Zinc OMADINE.
[0036] Examples of the antimicrobial compound may include silver-containing compound, zinc-containing compound, an isothiazolone-containing compound, a benzothiazole-containing compound, a triazole-containing compound, an azole-containing compound, a benzimidazol-containing compound, a nitrile containing compound, alcohol-containing compound, a silane-containing compound, a carboxylic acid-containing compound, a glycol-containing compound, a thiol-containing compound or mixtures thereof.
[0037] Additional exemplified commercial antimicrobial compounds may include those from Intace including B-6773 and B-350, those from Progressive Coatings VJ series, those from Buckman Labs including Busan 1218, 1420 and 1200WB, those from Troy Corp including Polyphase 641, those from Clariant Corporation, including Sanitized TB 83-85 and Sanitized Brand T 96-21, and those from Bentech LLC incuding Preservor Coater 36. Others include AgION (silver zeolite) from AgION and Mircroban from Microban International (e.g. Microban additive TZ1, S2470, and PZ2). Further examples include dichloro-octyl-isothiazolone, Tri-n-butylin oxide, borax, G-4, chlorothalonil, organic fungicides, and silver-based fungicides. Any one or more of these agents would be considered satisfactory as an additive in the process of making paper material. Further commercial products may be those from AEGIS Environments (e.g. AEM 5772 Antimicrobial), from BASF Corporation (e.g. propionic acid), from Bayer (e.g. Metasol TK-100, TK-25), those from Bendiner Technologies, LLC, those from Ondei-Nalco (e.g. Nalcon 7645 and 7622), and those from Hercules (e.g. RX 8700, RX 3100, and PR 1912). The MSDS's of each and every commercial product mentioned above is hereby incorporated by reference in its entirety.
[0038] Still further, examples of the antimicrobial compounds may include silver zeolite, dichloro-octyl-isothiazolone, 4,5-dichloro-2-n-octyl-3(2H)-isothiazolone, 5-chloro-2-methyl-4-isothiazolin-3-one, 1,2-benzothiazol-3(2H)-one, poly[oxyethylene(ethylimino)ethylene dichloride], Tri-n-butylin oxide, borax, G-4, chlorothalonil, Alkyl-dimethylbenzyl-ammonium saccharinate, dichloropeyl-propyl-dioxolan-methlyl-triazole, alpha-chlorphenyl, ethyl-dimethylethyl-trazole-ethanol, benzimidazol, 2-(thiocyanomethylhio)benzothiazole, alpha-2(-(4-chlorophenyl)ethyl)-alpha-(1-1-dimethylethyl)-1H-1,2,4-triazole-1-ethanol, (1-[[2-(2,4-dichlorophenyl)-4-propyl-1,3-dioxolan-2-yl]-methyl]-1H-1,2,4-triazole, alkyl dimethylbenzyl ammonium saccharinate, 2-(methoxy-carbamoyl)-benzimidazol, tetracholorisophthalonitrile, P-[(diiodomethyl)sulfonyl]toluol, methyl alcohol, 3-(trimethoxysilyl)propyldimethyl octadecyl ammonium chloride, chloropropyltrimethylsilane, dimethyl octadecyllamine, propionic acid, 2-(4-thiazolyl)benzimidazole, 1,2-benzisothiazolin-3-one,2-N-octyl-4-isthiazolin-3-one, diethylene glycol monoethyl ether, ethylene glycol, propylene glycol, hexylene glycol, tributoxyethyl phosphate, 2-pyridinethio-1-oxide, potassium sorbate, diiodomethyl-p-tolysulfone, citric acid, lemon grass oil, and thiocyanomethylhio-benzothiazole.
[0039] The antimicrobial compound may be present in the paper substrate at amounts from 1 to 5000 ppm dry weight, more preferably, from 100 to 3000 ppm dry weight, most preferably 50 to 1500 ppm dry weight. The amounts of antimycotic and/or fungicide may be 2, 5, 10, 25, 50, 75, 100, 12, 150, 175, 200, 225, 250, 275, 300, 325, 350, 375, 400, 425, 450, 475, 500, 600, 700, 800, 900, 1000, 1100, 1200, 1300, 1400, 1500, 1600, 1700, 1800, 1900, 2000, 2100, 2200, 2300, 2400, 2500, 2600, 2700, 2800, 2900, 3000, 3200, 3500, 3750, 4000, 4250, 4500, 4750, and 5000 ppm dry weight based upon the total weight of the paper substrate, including all ranges and subranges therein. Higher amounts of such antimycotic and/or fungicide may also prove produce an antibacterial paper material and article therefrom as well. These amounts are based upon the total weight of the paper substrate.
[0040] The paper substrate of the present invention may contain at least one sizing agent. Examples of the sizing agent may be, but is not limited to, alkaline sizing agents and acid-based sizing agents. Examples of alkaline sizing agents include without limitation unsaturated hydrocarbon compounds, such as C6 to C24, preferably C18 to C20, unsaturated hydrocarbon compounds and mixtures thereof. Examples of acid-based sizing agents include without limitation alum and rosin-based sizing agents such as Plasmine N-750-P from Pasmine Technology Inc.
[0041] FIGS. 1-3 demonstrate different embodiments of the paper substrate 1 in the paper substrate of the present invention. FIG. 1 demonstrates a paper substrate 1 that has a web of cellulose fibers 3 and a composition containing an antimicrobial compound 2 where the composition containing an antimicrobial compound 2 has minimal interpenetration of the web of cellulose fibers 3 . Such an embodiment may be made, for example, when an antimicrobial compound is coated onto a web of cellulose fibers during or after papermaking and/or during or after converting the substrate to a useful wallboard tape and/or during or after abrading (such as sanding) the surface of the substrate.
[0042] FIG. 2 demonstrates a paper substrate 1 that has a web of cellulose fibers 3 and a composition containing an antimicrobial compound 2 where the composition containing an antimicrobial compound 2 interpenetrates the web of cellulose fibers 3 . The interpenetration layer 4 of the paper substrate 1 defines a region in which at least the antimicrobial compound penetrates into and is among the cellulose fibers. The interpenetration layer may be from 1 to 99% of the entire cross section of at least a portion of the paper substrate, including 1, 2, 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, and 99% of the paper substrate, including any and all ranges and subranges therein. Such an embodiment may be made, for example, when an antimicrobial compound is added to the cellulose fibers prior to a coating method and may be combined with a subsequent coating method if required. Addition points may be at the size press, for example.
[0043] FIG. 3 demonstrates a paper substrate 1 that has a web of cellulose fibers 3 and an antimicrobial compound 2 where the antimicrobial compound 2 is approximately evenly distributed throughout the web of cellulose fibers 3 . Such an embodiment may be made, for example, when an antimicrobial compound is added to the cellulose fibers prior to a coating method and may be combined with a subsequent coating method if required. Exemplified addition points may be at the wet end of the paper making process, the thin stock, and the thick stock.
[0044] The web of cellulose fibers and the antimicrobial compound may be in a multilayered structure. The thicknesses of such layers may be any thickness commonly utilized in the paper making industry for a paper substrate, a coating layer, or the combination of the two. The layers do not have to be of approximate equal size. One layer may be larger than the other. One preferably embodiment is that the layer of cellulose fibers has a greater thickness than that of any layer containing the antimicrobial compound. The layer containing the cellulose fibers may also contain, in part, the antimicrobial compound.
[0045] Further examples of sizing agents that may be incorporated into the present invention may include, but is not limited to, those found in the following patents: U.S. Pat. Nos. 6,595,632, 6,512,146, 6,316,095, 6,273,997, 6,228,219, 6,165,321, 6,126,783, 6,033,526, 6,007,906, 5,766,417, 5,685,815, 5,527,430, 5,011,741, 4,710,422, and 4,184,914, which are hereby incorporated in their entirety by reference. Preferred alkaline sizing agent may be, but not limited to, alkyl ketene dimer, alkenyl ketene dimer and alkenyl succinic anhydride.
[0046] The paper substrate of the present invention may contain from 0.05 to 1.5 wt % of the alkaline sizing agent based upon the total weight of the substrate. This range includes 0.05, 0.06, 0.07, 0.08, 0.09, 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1.0, 1.1, 1.2, 1.3, 1.4, and 1.5 wt %, including any and all ranges and subranges therein.
[0047] The paper substrate of the present invention may have a MD tensile as measured by conventional TAPPI method 494 of from 25 to 100, preferably from 40 to 90 lbf/inch width. This range includes MD tensile of 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, and 100 lbf/inch width, including any and all ranges and subranges therein.
[0048] The paper substrate of the present invention may have a CD tensile as measured by conventional TAPPI method 494 of from 5 to 50, preferably from 20 to 50 lbf/inch width, most preferably 25 to 40 lbf/inch width. This range includes CD tensile of 5, 10, 15, 20, 25, 30, 35, 40, 45, and 50 lbf/inch width, including any and all ranges and subranges therein.
[0049] The paper substrate of the present invention may have a wet strength as measured by conventional TAPPI method 456 of from 5 to 50, preferably from 10 to 25, most preferably from 15 to 25, lb/inch width. This range includes wet strengths of 5, 10, 15, 20, 25, 30, 35, 40, 45, and 50 lb/inch width, including any and all ranges and subranges therein.
[0050] The paper substrate of the present invention may have an internal bond as measured by conventional TAPPI method 541 of from 25 to 350, preferably from 50 to 250, most preferably from 100-200, milli ft-lb/sq. in. This range includes internal bond of 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, 100, 110, 125, 150, 175, 200, 225, 250, 275, 300, 325 and 350 milli ft-lb/sq. in, including any and all ranges and subranges therein.
[0051] The paper substrate of the present invention may have a pH of at least about 1.0 to about 14.0 as measured by any conventional method such as a pH marker/pen and conventional TAPPI methods 252 and 529 (hot extraction test and/or surface pH test). The pH of the paper may be from about 1.0 to 14.0, preferably about 4.0 to 9.0, most preferably from about 6.5 to 8.5. This range includes pHs of 1.0, 2.0, 3.0, 4.0, 5.0, 6.0 6.5, 6.6, 6.7, 6.8, 6.9, 7.0, 7.1, 7.2, 7.3, 7.4, 7.5, 7.6, 7.7, 7.8, 7.9, 8.0, 8.1, 8.2, 8.3, 8.4, 8.5, 8.6, 8.7, 8.8, 8.9, 9.0, 9.2, 9.4, 9.5, 9.6, 9.8, 10.0, 10.5, 11.0, 11.5, 12.0, 12.5, 13.0, 13.5, and 14.0, including any and all ranges and subranges therein.
[0052] The density, basis weight and caliper of the web of this invention may vary widely and conventional basis weights, densities and calipers may be employed depending on the paper-based product formed from the web.
[0053] The paper substrate according to the present invention may be made off of the paper machine having a basis weight of from 50 lb/3000 sq. ft. to 120 lb/3000 sq. ft, preferably from 70 to 120, and most preferably from 80-100 lb/3000 sq. ft. The basis weight of the substrate may be 50, 52, 54, 55, 56, 58, 60, 62, 64, 65, 66, 68, 70, 72, 74, 75, 76, 78, 80, 82, 84, 85, 86, 88, 90, 92, 94, 95, 96, 98, 100, 105, 110, 115 and 120 lb/3000 sq. ft, including any and all ranges and subranges therein.
[0054] The paper substrate according to the present invention may be made off of the paper machine having an apparent density of from 5.0 to 20.0, preferably 9.0 to 13.0, most preferably from 9.5 to 11.5, lb/3000 sq. ft·per 0.001 inch thickness. The apparent density of the substrate may be 5.0, 5.2, 5.4, 5.5, 5.6, 5.8, 6.0, 6.2, 6.4, 6.5, 6.6, 6.8, 7.0, 7.2, 7.4, 7.5, 8.0, 8.5, 9.0, 9.5, 10.0, 10.5, 11.0, 11.5, 12.0, 12.5, 13.0, 13.5, 14.0, 14.5, 15.0, 15.5, 16.0, 16.5, 17.0, 17.5, 18.0, 18.5, 19.0, 19.5 and 20.0 lb/3000 sq. ft·per 0.001 inch thickness, including any and all ranges and subranges therein.
[0055] The paper substrate according to the present invention may have a width off the winder of a paper machine of from 5 to 100 inches and can vary in length. The width of the paper substrate may be 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, 100 inches, including any and all ranges and subranges therein.
[0056] Additionally, the paper substrate according to the present invention may be cut into streamers that have a width of from 1.5 to 3.25 inches wide and may vary in length. The width of the paper substrate streamer may have a width of 1.50, 1.60, 1.70, 1.75, 1.80, 1.85, 1.9, 1.95, 2.00, 2.10, 2.20, 2.30, 2.40, 2.50, 2.60, 2.70, 2.80, 2.90, 3.00, 3.05, 3.10, 3.15, 3.20, and 3.25 inches, including any and all ranges and subranges therein.
[0057] The paper substrate of the present invention may contain optional components as well including but not limited to binders, wet strength additives, and anionic promoters.
[0058] One optional component that is included as one embodiment of the paper substrate of the present invention includes without limitation a binder. Examples of binders include, but are not limited to, polyvinyl alcohol, Amres (a Kymene type), Bayer Parez, polychloride emulsion, modified starch such as hydroxyethyl starch, starch, polyacrylamide, modified polyacrylamide, polyol, polyol carbonyl adduct, ethanedial/polyol condensate, polyamide, epichlorohydrin, glyoxal, glyoxal urea, ethanedial, aliphatic polyisocyanate, isocyanate, 1,6 hexamethylene diisocyanate, diisocyanate, polyisocyanate, polyester, polyester resin, polyacrylate, polyacrylate resin, acrylate, and methacrylate. When the substrate of the present invention contains a binder, preferable binders include without limitation starch and polyvinyl alcohol.
[0059] When the substrate of the present invention contains a binder, the substrate may include any amount of binder including less than 5% of binder, This range includes less than 0.001, 0.002, 0.005, 0.006, 0.008, 0.01, 0.02, 0.03, 0.04, 0.05, 0.1, 0.2, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1, 2, 4, and 5 wt % based on the total weight of the substrate, including any and all ranges and subranges therein.
[0060] One optional component that is included as one embodiment of the paper substrate of the present invention includes without limitation a wet strength additive. The paper substrate of the present invention may contain at least one wet strength additive. The wet strength additive may be cationic, anionic, neutral, and amphoteric. A preferred wet strength additive is cationic and/or contains a basic functional group. Examples of the wet strength additive may be, but is not limited to, polymeric amine epichlorohydrin (PAE), urea formaldehyde, melamine formaldehyde and glyoxylated polyacrylamide resins. Further examples of wet strength additives that may be incorporated in to the present invention may include, but is not limited to, those found in the following patents: U.S. Pat. Nos. 6,355,137 and 6,171,440, which are hereby incorporated in their entirety by reference. Preferred wet strength additives include, but are not limited to, polymeric amine epichlorohydrin (PAE).
[0061] The paper substrate of the present invention may contain from 0.25 to 2.5 wt % of the wet strength additive based upon the total weight of the substrate. This range includes 0.25, 0.30, 0.35, 0.40, 0.45, 0.50, 0.6, 0.7, 0.8, 0.9, 1.0, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, 2.0, 2.1, 2.2, 2.3, 2.4 and 2.5 wt %, including any and all ranges and subranges therein.
[0062] One optional component that is included as one embodiment of the paper substrate of the present invention includes without limitation an anionic promoter. The paper substrate of the present invention may contain at least one anionic promoter. Examples of the anionic promoter may be, but is not limited to, polyacrylates, sulfonates, carboxymethyl celluloses, galactomannan hemicelluloses and polyacrylamides. Preferred anionic promoters include, but are not limited to polyacrylates such as Nalco 64873.
[0063] The paper substrate of the present invention may contain from 0.05 to 1.5 wt % of the anionic promoter based upon the total weight of the substrate. This range includes 0.05, 0.06, 0.07, 0.08, 0.09, 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1.0, 1.1, 1.2, 1.3, 1.4, and 1.5 wt %, including any and all ranges and subranges therein.
[0064] The paper substrate of the present invention may also optionally include inert substances including without limitation fillers, thickeners, and preservatives. Other inert substances include, but are not limited to silicas such as colloids and/or sols. Examples of silicas include, but are not limited to, sodium silicate and/or borosilicates. Another example of inert substances is solvents including but not limited to water. Examples of fillers include, but are not limited to; calcium carbonate, calcium sulfate hemihydrate, and calcium sulfate dehydrate. A preferable filler is calcium carbonate.
[0065] The paper substrate of the present invention may contain from 0.001 to 20 wt % of the inert substances based on the total weight of the substrate, preferably from 0.01 to 10 wt %, most preferably 0.1 to 5.0 wt %, of each of at least one of the inert substances. This range includes 0.001, 0.002, 0.005, 0.006, 0.008, 0.01, 0.02, 0.03, 0.04, 0.05, 0.1, 0.2, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1, 2, 4, 5, 6, 8, 10, 12, 14, 15, 16, 18, and 20 wt % based on the total weight of the substrate, including any and all ranges and subranges therein.
[0066] The paper substrate may be made by contacting a plurality of cellulose fibers with a antimicrobial compound and/or a sizing agent consecutively in any order and/or simultaneously. Further, the contacting may occur in an aqueous environment having a pH of from about 1.0 to about 14.0, preferably from about 6.8 to about 8.5. The pH may be 1.0, 2.0, 3.0, 4.0, 5.0, 6.0 6.5, 6.6, 6.7, 6.8, 6.9, 7.0, 7.1, 7.2, 7.3, 7.4, 7.5, 7.6, 7.7, 7.8, 7.9, 8.0, 8.1, 8.2, 8.3, 8.4, 8.5, 8.6, 8.7, 8.8, 8.9, 9.0, 9.2, 9.4, 9.5, 9.6, 9.8, 10.0, 10.5, 11.0, 11.5, 12.0, 12.5, 13.0, 13.5, and 14.0, including any and all ranges and subranges therein. Accordingly the paper substrate may be made using acidic, near neutral, neutral, or alkaline conditions.
[0067] Still further, the contacting may occur at acceptable concentration levels that provide the paper substrate of the present invention to contain any of the above-mentioned amounts of cellulose fibers, antimicrobial compound, sizing agent, optional components, and/or inert substances isolated or in any combination thereof. The contacting may occur anytime in the papermaking process including, but not limited to the thick stock, thin stock, head box, size press, water box, and coater. The cellulose fibers, antimicrobial compound, sizing agent, optional components, and/or inert substances may be contacted serially, consecutively, and/or simultaneously in any combination with each other. The cellulose fibers, antimicrobial compound, sizing agent, optional components, and/or inert substances may be pre-mixed in any combination before addition to the paper-making process.
[0068] These methods of making the paper substrate of the present invention may be added to any conventional papermaking processes, as well as converting processes, including abrading or sanding to create a fine nap for greater adhesion qualities, slitting, scoring, perforating, sparking, calendaring, sheet finishing, converting, coating, laminating, printing, etc. Preferred conventional processes include those tailored to produce paper substrates capable to be utilized as wallboard tape. Textbooks such as those described in the “Handbook for pulp and paper technologists” by G. A. Smook (1992), Angus Wilde Publications, describe such processes and is hereby incorporated, in its entirety, by reference.
[0069] In one embodiment, the cellulosic fibers and sizing agent may be contacted at anytime during papermaking with or without optional substances or inert substances. In such an embodiment, the cellulosic fibers and sizing agent are contacted at least at the wet end of the paper machine, then the web is dried to make a paper substrate suitable for use as wallboard tape. Optional substances and/or inert substances may optionally be added at anytime during papermaking including without limitation optionally adding the binder to the web using a size press. The substrate may be sanded creating a nap, preferably a fine nap, for greater adhesion qualities. The surface of the substrate carrying the nap may then be contacted with the antimicrobial compound. The contacting may occur using a size press or any coater apparatus including without limitation a spray coater apparatus. Within this embodiment, the optional components and/or inert substances may optionally be contacted with the surface of the substrate at the same time as the antimicrobial compound.
[0070] The present invention is explained in more detail with the aid of the following embodiment example which is not intended to limit the scope of the present invention in any manner.
EXAMPLES
Example 1
Materials:
[0000]
Handsheet Furnish: 100% refined southern softwood collected on Jul. 20, 2007
Sizing Agent: Plasmine N-750-P (40% solids)
Aluminum Sulfate (Alum): (40% consistency)
Wet Strength Agent: Poly(amido-amine)-epichlorohydrin (25% solids)
Antimicrobial Agent (A/M): Intace B350
Starch: Tate & Lyle Pearl
Antimicrobial Gypsum Board: ½″ Dense Armor Plus Mold & Humidity Resistant gypsum panel from Georgia Pacific
Joint Compound: Ready Mixed Sheetrock All Purpose Joint Compound from US Gypsum
Method:
[0079] Two Dynamic Sheet Former (DSF) handsheets were made according to the following experimental design:
[0000]
TABLE 1
DSF Study for paper substrates for use as antimicrobial wallboard tape
DSF
Liquid
Wet
Surface
BDBW
Sizing
Alum
Strength
Sizing
A/M*
Target
I.D.
lb/T
lb/T
lb/T
(Starch)
Agent
gsm
Design:
A
0
20
12
N
N
131.5
B
0
20
12
N
Y
131.5
C
10
20
12
N
N
131.5
D
10
20
12
N
Y
131.5
E
0
20
12
Y
N
125.0
F
0
20
12
Y
Y
125.0
G
10
20
12
Y
N
125.0
H
10
20
12
Y
Y
125.0
[0080] Due to the size of the wet-press felt, all sheets were divided into thirds and then wet-pressed at a pressure of 40 psi before drying on a rotary drum-dryer.
[0081] All sheets were tested for the following physical properties prior to any surface sizing with starch: Basis Weight (TAPPI T-410), Caliper (TAPPI T-411), Gurley Porosity (TAPPI T-460), and HST with 10% formic acid and dye solution (TAPPI T-530).
[0082] Samples E-H were then run through a bench-top puddle size press using the Pearl Starch and dried on a drum-dryer. The pearl starch was cooked in two batches having solids measuring 16.7% and 16.3% yielding an approximate pick up of 110 #/Ton.
[0083] Sheets for samples E-H were tested again for the same physical properties as before. All sheets for samples A-H were manually sanded using a belt sander and 80 grit sand paper.
[0084] Samples B, D, F, and H were manually dipped in a bath of Intace B350 anti-michotic agent to yield an approximate pick up of 2 #/Ton. Then each sheet for those samples was dried on a drum-dryer.
[0085] Samples from each condition A-H were cut into 1″ wide tape strips. Then they were adhered to 3″×3″ squares of anti-microbial gypsum board using joint compound and allowed to air dry.
[0086] Prior to inoculation, 3 samples from each condition (A-H) were soaked in ½″ of sterile water for 1 hour. Each gypsum board square was placed upright on its edge so that the water comes ½″ up the side of the square that has the tape touching the edge as indicated in FIG. 4 .
[0087] Sample squares were placed on 150×25 mm agar plates and inoculated with 0.38 mL of inoculum containing Chaetomium globosum, Aspergillus terreus , and Aspergillus niger . The inoculum was spread along the bottom half of the sample square (as seen in FIG. 5 ), allowing a portion of the tape to remain uninoculated.
[0088] There was also a set of additional tape samples (A-H) that were not bonded to gypsum panels that corresponded to each gypsum board specimen that was tested. The tape was exposed to water in the same manner as the gypsum board samples, but for 2 minutes instead of 1 hour. They were then inoculated over their entire surface with 0.25 mL of the inoculum.
[0089] Growth observations for all samples were recorded at 7, 21, 33, and 62 days after the samples were inoculated. Photographs of a representative sample for each condition were taken on or near each observation date.
[0090] An amended* form of ASTM Method D2020-92 Standard Test Methods for Mildew (Fungus) Resistance of Paper and Paperboard was followed. The amendments included
1) The test substances were wallboard pieces (i.e. gypsum board square) measuring 3 inches by 3 inches (see above and in FIG. 4 ). 2) Prior to inoculation, each wallboard piece was exposed to a ½ inch of sterile water for 1 hour. The test substance pieces were placed on their edge upright so that the water comes ½ inch up the side of the piece that has the tape touching the edge (see FIG. 5 ). 3) After exposure to the water, the test substances pieces were placed on the 150×25 mm agar plates. 4) Each replicate was inoculated with 0.38 mL of the inoculums. The inoculums were spread along the bottom half of the wallboard piece, the bottom being the edge that was immersed. This will allowed a portion of the tape to remain uninoculated. 5) For each wallboard piece, there was a corresponding separate piece of tape. The tape was exposed to the water in the same manner as the wallboard for 2 minutes. The tape pieces were inoculated over their entire surface with 0.25 mL of the inoculums.
Results;
Summary (Observations Until Day 33)
[0000]
A/M Treatment—Application hinders mold growth from day 7 to 33 in all but one sample (Sample F).
Starch Content—Mold growth differences in samples with and without starch in them were not noted until day 33. There is a visual difference on day 20: Samples with starch had noticeably more and larger spore clusters than samples without.
Sizing Content—Mold growth was noticeably smaller in spore size and cluster amounts on samples where sizing was present.
Growth with Increasing Time—For samples with mold growth, regardless of starch or sizing content, sporulation mostly began on the edges of the tape by the first observation day (7 days after inoculation). By the second observation day (21 days after inoculation), mold growth had spread across the surface of the tape.
Time-Specific Observations
[0100] Day 7 Observations
All samples that contain the a/m application show no growth—a/m agent has an effect in prohibiting growth of mold. Most growth initiated at the tape edge for samples where slight growth was noted. At this stage of growth sizing and starch content do not appear to have an effect on mold growth due to the fact that replicates where “heavy” growth was noted in the “soaked” portion of the sample had sizing in one and no sizing in the other. Most samples did not have growth past the inoculation site.
[0105] Day 21 Observations
Growth began to occur in the non-inoculated region where water “wicked” up the drywall portion of the sample during the soaking portion of sample prep. Sizing still does not seem to hinder mold growth at this stage since occurrences of “heavy” growth appeared on samples with and without sizing. The effects of the content of starch are still not seen at this point either because the “heavy” mold growth appeared on samples with and without starch in them. All samples that contain the a/m application still show no growth with the exception of sample F (no starch, no sizing, with a/m). This particular sample is believed to be an outlier. Two replicates for this sample had mold growth on the dry portion of the non-inoculated drywall. Growth is now seen on the surface of all samples that show growth, not just the edge of the tape.
[0110] Day 33 Observations
Still no growth on the samples with the a/m treatment. Most reps have the same mold coverage as day 21 results. Additional mold growth is noted along the edge of the inoculated portion of the tape on samples containing starch but no a/m treatment.-effect of added nutrients (aka starch) now visible.
[0114] Day 62 Observations—
A/M Treatment—all samples show no growth on the tape itself. Sample F (with starch, no sizing, with a/m) has very slight growth on the drywall above the inoculation point only for two of three reps. No other a/m treated samples have growth anywhere on them. Starch Content—For those samples without starch, sporadic mold growth is noted above the inoculation point. Samples that contain starch have evenly spread growth above the inoculation point with slightly larger spores below the inoculation point. Sizing Content—Samples without sizing show consistent growth above and below the inoculation point. Samples with sizing show growth mostly confined to the inoculation area.
[0118] As used throughout, ranges are used as a short hand for describing each and every value that is within the range, including all subranges therein.
[0119] Numerous modifications and variations on the present invention are possible in light of the above teachings. It is, therefore, to be understood that within the scope of the accompanying claims, the invention may be practiced otherwise than as specifically described herein.
[0120] All of the references, as well as their cited references, cited herein are hereby incorporated by reference with respect to relative portions related to the subject matter of the present invention and all of its embodiment
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This invention relates to paper products and/or substrates suitable for being made into wallboard tape (also may be known as joint tape and/or drywall tape) and having improved reduction or inhibition in the growth of microbes, mold and/or fungus. The paper substrate is characterized by its excellent physical properties including cross direction (CD) tensile, machine (MD) tensile, internal bond, wet tensile, hygroexpansivity, curl, bonding properties, bonding of joint tape to joint compound, etc. The paper product of the invention contains a sizing agent and an antimicrobial compound as well as other optional components including without limitation a binder. The paper product of the invention may be produced by contacting the plurality of cellulose fibers with each of the sizing agent, antimicrobial compound, and optional components at any point in the papermaking process, converting process, and/or post-converting process. Finally, the invention relates to methods of using the paper substrate.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional of U.S. Ser. No. 12/796,079 filed Jun. 8, 2010, which is a divisional of U.S. Ser. No. 11/570,102 filed Dec. 6, 2006, which is the National Stage of International Application No. PCT/EP2005/007211 filed Jul. 5, 2005, which claims, the benefit of priority of German Application No. 10 2004 037 739.1 filed Aug. 4, 2004, each of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to a catalyst comprising alkali metal tungstate for the synthesis of alkyl mercaptans from alkanols and hydrogen sulphide, and to a process for preparing this catalyst.
[0003] In this patent application, the term alkali is understood to mean the bound alkali metals of the Periodic Table of the Elements or mixtures of at least two alkali metals bound in the tungstates. In this case, cesium occurs only together with a further element of the alkali metal group.
[0004] Methyl mercaptan in particular is an industrially important intermediate, for example for the synthesis of methionine and for the synthesis of dimethyl sulphoxide and dimethyl sulphone. It is nowadays prepared predominantly from methanol and hydrogen sulphide by reaction over a catalyst composed of aluminium oxide. The methyl mercaptan is synthesized commonly in the gas phase at temperatures between 300 and 500° C. and at pressures between 1 and 25 bar.
[0005] In addition to the methyl mercaptan formed, the reaction mixture comprises the unconverted starting materials and by-products, for example dimethyl sulphide and dimethyl ether, and also the gases which are inert for the purposes of the reaction, for example methane, carbon monoxide, hydrogen and nitrogen. The methyl mercaptan formed is removed from this reaction mixture.
[0006] For the economic viability of the process, a maximum selectivity is required in the catalytic reaction of methanol and hydrogen sulphide to give methyl mercaptan in order to keep the removal of the methyl mercaptan formed from the reaction mixture as uncomplicated and inexpensive as possible. Here, especially the energy demands for the cooling of the reaction gas mixture to condense the methyl mercaptan constitute a large cost factor.
[0007] To increase activity and selectivity, aluminium oxide as a support is typically admixed with potassium tungstate or cesium tungstate. In this case, the tungstate is commonly used in amounts up to 25% by weight based on the total weight of the catalyst. An improvement of activity and selectivity is also obtained by increasing the molar ratio of hydrogen sulphide to methanol. Typically, molar ratios between 1 and 10 are employed.
[0008] However, a high molar ratio also means a high excess of hydrogen sulphide in the reaction mixture and thus the need to conduct large amounts of gas in circulation. To reduce the energy demands required for this purpose, the ratio of hydrogen sulphide to methanol should therefore deviate only slightly from 1.
[0009] U.S. Pat. No. 2,820,062 relates to a process for preparing organic thiols, in which a catalyst composed of active aluminium oxide which is admixed with potassium tungstate in an amount of 1.5 to 15% by weight, based on the weight of the catalyst, is used. With this catalyst, good activities and selectivities are achieved at reaction temperatures of 400° C. and molar ratios of 2. This US patent mentions various possibilities for the introduction of the potassium tungstate into the aluminium oxide. For instance, it is said to be possible to employ impregnation processes, coprecipitations and pure mixtures. Little significance is attributed to the actual preparation of the catalyst for the economic viability of the synthesis process of methyl mercaptan.
[0010] EP 0 832 687 B1 describes the advantages of the use of cesium tungstate (Cs 2 WO 4 ) instead of potassium tungstate (K 2 WO 4 ) as a promoter. For instance, use of cesium tungstate can achieve an enhanced activity with simultaneously good selectivity.
[0011] Increasing the cesium tungstate concentration to up to 40% by weight allows the selectivity for methyl mercaptan to be increased to 92% without the activity being disproportionately worsened.
[0012] According to the general view, the best selectivity is achieved with catalysts for which the alkali metal/tungsten ratio is equal to 2:1 (A. V. Mashkina et al., React. Kinet. Catal. Lett., Vol. 36, No. 1, 159-164 (1988).
SUMMARY OF THE INVENTION
[0013] It is an object of the present invention to specify a catalyst and a process for its preparation, which, at low molar ratios of hydrogen sulphide to methanol, features improved activity and selectivity compared to the known catalysts and thus leads to better economic viability of the process.
[0014] This object is achieved by the provision of a catalyst comprising a catalytically active alkali metal tungstate which contains bound alkali metals and tungsten with a molar ratio of alkali metals to tungsten of <2:1, in particular of <2:1 to 0.9:1, preferably 1.9:1 to 1:1, particularly 1.6:1 to 1:1.
[0015] The oxidic composition can be described with the formula A x WO y in which A is alkali metal and x′ is <2 to 0.9 and y is 3.4 to <4.
[0016] The bound alkali metal constituent of the tungstate can be composed of one or more elements of the alkali metal group. In this case, cesium occurs only in combination with another alkali metal element.
[0017] The catalyst contains the tungstate in an amount of 8 to 45% by weight, in particular 15 to 36% by weight, preferably >25 to 36% by weight. In the case of a coated catalyst, these proportions are based on the composition of the coating.
[0018] The oxidic compounds composed of alkali metal(s) and tungsten may be impregnated directly onto a support body (supported catalyst).
[0019] In the case of the preparation of catalysts in the form of extrudates or mouldings, the pulverulent support is impregnated or mixed with the oxidic composition and the resulting intermediate is subsequently reshaped (unsupported catalyst). When a coated catalyst is prepared, the pulverulent support is impregnated with the catalytically active composition and the resulting mixture is then applied to a preferably inert support core in the form of a coating.
[0020] The alkali metal/W ratio preferably ranges from <1.9:1 to 1:1. The inventive catalysts for the reaction of alkanols with hydrogen sulphide to give alkyl mercaptans thus comprise a superstoichiometric proportion of tungsten compared to the catalyst impregnated with cesium tungstate (Cs 2 WO 4 ) or potassium tungstate (K 2 WO 4 ) according to the prior art.
[0021] It is found that this higher proportion in the tungstate on the aluminium oxide used with preference in comparison to the stoichiometric alkali metal tungstate used exclusively in the prior art imparts to the catalyst an improved activity with simultaneously improved selectivity. While the increase in the concentration of cesium tungstate (Cs 2 WO 4 ) on the catalyst merely brings about an increase in the selectivity with simultaneously lower activity, a further increase in the selectivity with simultaneously increased activity is unexpectedly found in the case of the increase in the tungsten content in relation to the alkali metal content. According to the invention, an excellent activity can be achieved at very high loadings with the promoter without the activity of the catalyst, as known from the prior art, decreasing. In addition, it has also been found that the activity and selectivity of the catalyst can be adjusted precisely via the alkali metal-tungsten ratio and via the selection of the alkali metals. When mixtures of alkali metals are used, it is additionally possible to replace the comparatively more expensive metals such as cesium or rubidium at least partly with less expensive metals, for example potassium or sodium, without the activity or selectivity of the catalyst being impaired.
DETAILED DESCRIPTION OF THE INVENTION
[0022] The catalyst is used in the form of a supported catalyst in which the surface is impregnated with the catalytically active substance, or of a coated catalyst in which a preferably inert core is surrounded with a mixture of catalytically active substance and support material. In addition, extrudates or mouldings in which the catalytically active substance is mixed with the pulverulent support material before the reshaping or is impregnated with it may be used. The support materials used are the known oxidic inorganic compounds, for example SiO 2 , TiO 2 , ZrO 2 and preferably what is known as active aluminium oxide. This material has high specific surface areas between about 10 and 400 m 2 /g, and consists mainly of oxides of the transition series of the crystallographic phases of aluminium oxide (see, for example, Ullmann's Encyclopaedia of Industrial Chemistry of 1985, Vol. A1, pages 561-562). These transition oxides include γ-, δ-, η-, κ-, χ- and θ-aluminium oxide. All of these crystallographic phase are converted on heating of the aluminium oxide to temperatures above 1100° C. to the thermally stable α-aluminium oxide. Active aluminium oxide is supplied commercially for catalytic applications in various qualities and supply forms. Particularly suitable for the preparation of supported catalysts are support bodies composed of granulated or extruded aluminium oxide having particle diameters of 1 to 5 mm, a specific surface area of 180 to 400 m 2 /g, a total pore volume between 0.3 and 1.2 ml/g, and a bulk density of 300 to 900 g/l. For the purposes of the invention, preference is given to using aluminium oxide having a specific surface area of more than 200 m 2 /g, since the catalytic activity of the finished catalyst rises slightly with increasing surface area of the aluminium oxide. This material is used in powder form preferably for the preferred of the coated catalysts, extrudates or mouldings.
[0023] The aqueous impregnation solution for the application of the promoter can be prepared in a simple manner from water-soluble alkali metal and tungsten compounds, in particular tungstic acid (H 2 WO 4 ) and alkali metal hydroxides. To this end, for example, tungstic acid is suspended in water and dissolved with addition of a base and heating. Alkali metal hydroxide or another alkali metal salt is likewise dissolved in water and combined with the solution of tungstic acid (promoter solution). Also advantageously usable are alkali metal salts whose anions can be driven out without residue by heat treatment, for example nitrates, formates, oxalates, acetates or carbonates. Suitable for stabilizing this solution having a pH of 8 to 14 are inorganic and also organic bases. Preference is given to using those bases which can be driven out without residue by a final heat treatment of the catalyst obtained after the impregnation. These bases preferably include ammonium hydroxide and organic bases, in particular amines. Compared to the prior art, the molar ratio of alkali metals and W when the aqueous impregnation solution is prepared is selected in such a way that, in contrasts to cesium tungstate (Cs 2 WO 4 ) or potassium tungstate (K 2 WO 4 ) having an alkali metal/W ratio of 2 to 1, a higher proportion of tungsten, i.e. an alkali metal to W ratio of less than 2 to 1, in particular <1.9:1 to 0.9:1, is present. In comparison to the known catalysts, this leads to a distinctly increased activity and selectivity of the inventive catalysts, in particular at low ratios of hydrogen sulphide and methanol in the reaction gas.
[0024] When mixtures of tungstates with mixed alkali metal fractions are used, they are preferably two different alkali metals of the Periodic Table in a ratio between 0.01:1.0 and 1.0:1.0. In this case, the proportion of the less expensive alkali metal is preferably increased to such an extent and simultaneously that of the comparatively more expensive alkali metal reduced in return that no deterioration in the activity or selectivity of the catalyst occurs.
[0025] For the application of the promoter solution, various impregnation techniques, such as immersion impregnation, spray impregnation, vacuum impregnation and pore volume impregnation may be used, and the impregnation may also be effected repeatedly. In the case of mouldings, the selected impregnation process has to enable the desired loading amount of the promoter to be applied with good uniformity over the total cross section.
[0026] The promoter solution is preferably applied to the shaped bodies by spray or vacuum impregnation in one or two steps. In spray impregnation, the aqueous impregnation solution is sprayed onto the support bodies. In vacuum impregnation, a reduced pressure is generated by means of a vacuum pump in a vessel charged with the shaped bodies. Opening of a hose connection to the aqueous impregnation solution sucks the solution into the vessel until the entire bed of shaped bodies is covered with the solution. After an impregnation time of 0.2 to 2 hours, the solution which has not been absorbed by the material is drained off or poured off.
[0027] Predrying at room temperature for a period of 1 to 10 hours allows the initial concentration gradient over the cross section of the shaped bodies to be substantially balanced. Thus, the uniformity of the impregnation over the cross section of the catalyst particles is improved. Preference is given to drying the thus obtained catalyst precursors to remove the residual moisture at 100 to 200° C., preferably 100 to 140° C., for the period of 1 to 10 hours. There is then a calcination at 300 to 600° C., preferably 420 to 480° C., for the period of 1 to 20 hours, preferably 1 to 5 hours. This fixes the promoter on the aluminium oxide and decomposes and drives off the base of the impregnation solution. Optionally, the bed of support bodies of the catalyst precursors can be flowed through by a gas stream in the course of the predrying, drying and calcinations, which improves the removal of the residual moisture and of the decomposition gases.
[0028] The shaped bodies can also be impregnated in a plurality of stages, in particular two stages.
[0029] In a preferred embodiment, the solution used in the first stage then comprises one to two thirds of the intended total amount of alkali metal and tungsten compounds.
[0030] When the procedure has a plurality of stages, but at least two stages, the precursor obtained in the first step is optionally not calcined.
[0031] Otherwise, the same impregnation, drying and calcination programme as described for the one-stage process proceeds in the second stage.
[0032] This multistage impregnation is viable in particular when high loadings are desired and/or the limited solubility of the promoter mixture does not enable the loading in, one step.
[0033] The possibility also exists of spraying the support bodies repeatedly with the impregnation solution during the impregnation operation (step a from claim 11 ) and, between these treatment steps, in each case removing portions of the residual moisture at a temperature of up to 120° C., before moving on to step b.
[0034] In the preparation of the coated catalyst, the powder to be applied as a coating may be calcined before or after the coating. For example, this catalyst type may be prepared according to EP-B-0 068 193. In the preparation of the extrudates or of the mouldings too, the calcinations may be effected before and/or after the reshaping.
EXAMPLES
Example 1
Comparative Example
[0035] 150 g of aluminium oxide I were impregnated with 21.0% by weight of cesium tungstate (Cs 2.0 WO 4 ) with the aid of vacuum impregnation. To this end, the specific procedure was as follows:
[0036] To prepare the impregnation solution, 55.7 g of tungstic acid were suspended in 44.5 g of water and dissolved by adding 111.4 g of 25% ammonia solution and heating to 50° C. 74.6 g of Cs(OH)·H 2 O were dissolved in 37.3 g of water and mixed with the first solution. The solution was subsequently stirred in a covered beaker for 48 hours. Thereafter, the solution was made up to a volume of 234 ml with 25 g of water.
[0037] The aluminium oxide was initially charged in a glass vessel which was evacuated to 150 mbar. By virtue of the opening of a tap, the impregnation solution was sucked into the evacuated glass vessel until the entire bed of shaped bodies was covered with the solution. After a wait time of 15 minutes and aeration of the glass vessel, the solution which had not been absorbed by the aluminium oxide ran back into the beaker. 79 ml of impregnation solution were absorbed by the aluminium oxide.
[0038] The granules were dried to remove the residual moisture at room temperature in an air current for the period of 1 hour and subsequently at 120° C. for 3 hours. Afterward, the granules were calcined at 455° C. for 3 hours.
Example 2
Comparative Example
[0039] Comparative Example 1 was repeated with 26.3% loading of the aluminium oxide with cesium tungstate (Cs 2.0 WO 4 ).
Example 3
Comparative Example
[0040] Comparative Example 1 was repeated with 19.6% loading of the aluminium oxide with potassium tungstate (K 2.0 WO 4 ) with use of KOH instead of CS(OH)·H 2 O.
Example 4
[0041] 150 g of aluminium oxide (Spheralite 501A) was impregnated in a two-stage impregnation with a total of 26.7% by weight of promoter (K 1.6 WO y ) with the aid of vacuum impregnation. The specific procedure was as follows:
[0042] 64.5 g of tungstic acid were suspended in 50.7 g of water and dissolved by adding 126.9 g of 25% ammonia solution and heating to 50° C. 22.9 g of KOH were dissolved in 11.5 g of water and mixed with the first solution. The solution was subsequently stirred in a covered beaker for 48 hours. Thereafter, the solution, was made up to a volume of 234 ml with 39 g of water. The aluminium oxide was, initially charged in a glass vessel which was evacuated to 150 mbar. By virtue of the opening of a tap, the impregnation was sucked in until the entire bed of mouldings was covered with the solution. After a wait time of 15 minutes and aeration of the glass vessel, the solution which had not been absorbed by the aluminium oxide flowed back into the beaker. 76 ml of impregnation solution were absorbed by the aluminium oxide. Subsequently; the granules were dried at room temperature for 1 hour and at 120° C. for 3 hours, and calcined at 455° C. for 3 hours.
[0043] To carry out the second impregnation, an identical impregnation solution to that in the first step was prepared and applied in the same way by vacuum impregnation to the already laden catalyst from the first step. This was then followed again by drying at room temperature for 1 hour, followed by drying at 120° C. for 3 hours. Finally; the catalyst particles were calcined under air at 455° C. for 4 hours.
Example 5
[0044] 150 g of aluminium oxide (Spheralite 501A) was impregnated in a two-stage impregnation with a total of 30.1% by weight of promoter (Rb 0.9 WO y ) with the aid of vacuum impregnation. The specific procedure was as follows:
[0045] 59.0 g of tungstic acid were suspended in 48.3 g of water and dissolved by adding 110.7 g of 25% ammonia solution and heating to 50° C. 41.5 g of RbOH were dissolved in 17.5 g of water and mixed with the first solution. The solution was subsequently stirred in a covered beaker for 48 hours. Thereafter, the solution was made up to a volume of 234 ml with 25 g of water. The aluminium oxide was initially charged in a glass vessel which was evacuated to 150 mbar. By virtue of the opening of a tap, the impregnation was sucked in until the entire bed of mouldings was covered with the solution. After a wait time of 15 minutes and aeration of the glass vessel, the solution which had not been absorbed by the aluminium oxide flowed back into the beaker. 75 ml of impregnation solution were absorbed by the aluminium oxide. Subsequently, the granules were dried at room temperature for 1 hour and at 120° C. for 3 hours, and calcined at 455° C. for 3 hours.
[0046] To carry out the second impregnation, an identical impregnation solution to that in the first step was prepared and applied in the same way by vacuum impregnation to the already laden catalyst from the first step. This was then followed again by drying at room temperature for 1 hour, followed by drying at 120° C. for 3 hours. Finally, the catalyst particles were calcined under air at 455° C. for 4 hours.
Example 6
[0047] 150 g of aluminium oxide (Spheralite 501A) was impregnated in a two-stage impregnation with a total of 29.4% by weight of promoter (K 0.7 Cs 0.7 WO y ) with the aid of vacuum impregnation. The specific procedure was as follows:
[0048] 61.3 g of tungstic acid were suspended in 49.1 g of water and dissolved by adding 122.7 g of 25% ammonia solution and heating to 50° C. 9.8 g of KOH and 29.0 g of Cs(OH)·H 2 O were dissolved in 14.5 g of water and mixed with the first solution. The solution was subsequently stirred in a covered beaker for 48 hours. Thereafter, the solution was made up to a volume of 234 ml with 47 g of water. The aluminium oxide was initially charged in a glass vessel which was evacuated to 150 mbar. By virtue of the opening of a tap, the impregnation was sucked in until the entire bed of mouldings was covered with the solution. After a wait time of 15 minutes and aeration of the glass vessel, the solution which had not been absorbed by the aluminium oxide flowed back into the beaker. 75 ml of impregnation solution were absorbed by the aluminium oxide. Subsequently, the granules were dried at room temperature for 1 hour and at 120° C. for 3 hours, and calcined at 455° C. for 3 hours.
[0049] To carry out the second impregnation, an identical impregnation solution to that in the first step was prepared and applied in the same way by vacuum impregnation to the already laden catalyst from the first step. This was then followed again by drying at room temperature for 1 hour, followed by drying at 120° C. for 3 hours. Finally, the catalyst particles were calcined under air at 455° C. for 4 hours.
Example 7
[0050] 150 g of aluminium oxide (Spheralite 501A) was impregnated in a two-stage impregnation with a total of 31.0% by weight of promoter (Na 0.3 Cs 1.1 WO y ) with the aid of vacuum impregnation. The specific procedure was as follows:
[0051] 61.1 g of tungstic acid were suspended in 48.9 g of water and dissolved by adding 122.1 g of 25% ammonia solution and heating to 50° C. 3.2 g of NaOH and 44.6 g of Cs(OH)·H 2 O were dissolved in 22.3 g of water and mixed with the first solution. The solution was subsequently stirred in a covered beaker for 48 hours. Thereafter, the solution was made up to a volume of 234 ml with 40 g of water. The aluminium oxide was initially charged in a glass vessel which was evacuated to 150 mbar. By virtue of the opening of a tap, the impregnation was sucked in until the entire bed of mouldings was covered with the solution. After a wait time of 15 minutes and aeration of the glass vessel, the solution which had not been absorbed by the aluminium oxide flowed back into the beaker. 74 ml of impregnation solution were absorbed by the aluminium oxide. Subsequently, the granules were dried at room temperature for 1 hour and at 120° C. for 3 hours, and calcined at 455° C. for 3 hours.
[0052] To carry out the second impregnation, an identical impregnation solution to that in the first step was prepared and applied in the same way by vacuum impregnation to the already laden catalyst from the first step. This was then followed again by drying at room temperature for 1 hour, followed by drying at 120° C. for 3 hours. Finally, the catalyst particles were calcined under air at 455° C. for 4 hours.
Example 8
Use Example
[0053] The catalysts were tested with regard to their performance data in the synthesis of methyl mercaptan from hydrogen sulphide and methanol.
[0054] The synthesis was carried out in a stainless steel tube of internal diameter 18 mm and a length of 500 mm. The catalyst bed of in each case 76 ml was secured in the reaction tube on both sides by inert beds of glass spheres. The reaction tube was heated to the reaction temperature of about 320° C. using a jacket comprising a thermal oil.
[0055] The experimental conditions can be taken from the following list:
[0000] GHSV: 1300 h −1 (based on standard conditions)
LHSV: 0.84 h −1 (based on liquid MeOH)
Reaction temperature: 320° C.
Mass ratio
H 2 S/MeOH: 1.9
Pressure: 9 bar
[0056] The reaction mixture comprising the products methyl mercaptan, dimethyl sulphide and dimethyl ether, and comprising the unconverted starting materials methanol and hydrogen sulphide is analyzed by online gas chromatography.
[0057] When the tungsten fraction in relation to the alkali metal fraction in the catalyst is increased, a distinct increase in activity can be seen with simultaneously improved selectivity. In comparison to the prior art, this leads to a yield increase of up to 10%. The selectivity can be increased to up to ˜96.5% by adjusting the metal-tungstate ratio, and the methanol conversion rises. In the industrial scale synthesis of methyl mercaptan, this also leads to considerable cost savings in the removal of the reaction products from unconverted methanol and by-products.
[0058] In addition, the results of Examples 4 to 7 show that at least a portion of the alkali metals can be exchange for one another in order to selectively adjust the activity and selectivity of the catalyst or in order to save raw material costs in the catalyst synthesis.
[0000]
TABLE 1
Experimental results
mol.
alkali
Loading
Methanol
Catalyst
Alkali
metal:W
[% by
conversion
Selectivity
Yield
Example
metal
ratio
wt.]
[%]
[%]
[%]
CE1
Cs
2:1
21.0
82.4
93.3
76.9
CE2
Cs
2:1
26.3
79.5
94.7
75.2
CE3
K
2:1
19.6
76.0
95.2
72.4
E4* )
K
1.6:1
26.7
85.6
95.1
81.4
E5* )
Rb
0.9:1
30.1
73.2
96.6
70.7
E6* )
K, Cs
1.4:1
29.4
88.5
95.4
84.4
E7* )
Na, Cs
1.4:1
31.0
88.4
95.8
84.7
CE1: Catalyst according to Comparative Example 1
* ) multistage impregnation
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The invention relates to a catalyst containing alkali tungstate for the synthesis of alkylmercaptanes from alkanols and hydrogen sulphide, in addition to a method for the production of said catalyst, wherein the molar ratio of alkali to tungstan is <2:1.
| 1
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CROSS-REFERENCE TO RELATED APPLICATIONS
This is a continuation-in-part of copending application bearing Ser. No. 06/828,031, filed 02/10/86 by the present inventor now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates, generally, to view expansion enclosures, and more particularly relates to a view expansion enclosure with a venting means in the form of a chimney that can be opened and closed as desired to control the flow of air therethrough.
2. Description of the Prior Art
Enclosure structures having transparent sidewalls or roofs in general are known to the construction art. Although they can be ued for structure expansion purposes, they are commonly used as greenhouses. They can be attached to a permanent stucture, such as a house, or they can stand alone.
Examples of building structures with glass walls are shown in U.S. Pat. No. 2,706,538 to Schumann (1955) and U.S. Pat. No. 2,775,794 to Keely (1957).
A 1960 Italian patent to Svenska, No. 606,497, shows a skylight cover in the form of a dome which dome resembles the closure means for the chimney assembly of the present invention.
U.S. Pat. No. 3,562,972 to D'Amato (1971), discloses a greenhouse construction which is attachable to a supporting structure. It is portable and readily assembled.
A convertible, foldable and portable greenhouse is shown in U.S. Pat. No. 3,869,827 to Anderson and others (1975).
A 1976 patent to Smrt, No. 3,987,597, shows a modular structural assembly of the knock down type.
U.S. Pat. No. 4,335,547 to Maxwell (1982), discloses a movable greenhouse construction adapted for use on a balcony or a patio having means for moving the greenhouse laterally with respect to the building to which it is attached.
The prior art structures do not suggest how air flows through the structures could be controlled by means other than the opening of windows or doors.
It is therefore a central object of this invention to provide a view expansion enclosure having window and door-independent means for controlling the flow of air therethrough.
A closely related object is to provide the foregoing means in an embodiment operable by an occupant of the structure from within the structure.
SUMMARY OF THE INVENTION
The invention accomplishes these and other objects by providing a view expansion enclosure that includes a roof having the contour of an inverted funnel.
A mechanical vent valve hereinafter referred to as a chimney is positioned at the apex of the inverted funnel. By adjusting the vertical position of a cap member that overlies and closes the chimney when in its fully closed or down position, the flow of hot air currents flowing from the bottom to the top of the structure are controlled.
The chimney includes a sleeve member having an upper rim upon which the cap member seats when the chimney is closed. Rotation of a gear housing effects axial travel of a vertically aligned worm gear means and hence effects raising and lowering of the cap means dependent upon which direction the gear is advanced.
The cap member has concave bottom walls; when the cap is raised from its seat, a venturi effect is established due to the concave configuration of the cap bottom and the size of the annular space created by separation of the cap from the sleeve.
The novel structure provides several significant features and advantages.
The mechanically openable and closeable chimney, for example, provides a simple yet elegant and accurate means for controlling air currents within the structure.
Moreover, the versatility of the structure renders it suitable for various uses, such as a greenhouse use or use as a leisure area with a substantially unrestricted view of the surrounding environment.
The novel structure can be attached to an existing structure, or it can be built as a free standing structure.
The invention accordingly comprises the features of construction, combination of elements and arrangement of parts that will be exemplified in the construction hereinafter set forth, and the scope of the invention will be indicated in the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
For a fuller understanding of the nature and objects of the invention, reference should be made to the following detailed description, taken in connection with the accompanying drawings, in which:
FIG. 1 is a front elevational view of a structure made in accordance with the teachings of this invention;
FIG. 2 is a top plan view of the structure of FIG. 1;
FIG. 3 is primarily a longitudinal sectional view of the novel chimney assembly, but showing some parts such as a portion of the outer surface of the novel cap member, a portion of the gear housing, and a portion of the screen holder in front elevation;
FIG. 4 is a top plan view of the mating ring assembly
FIG. 4A is a front elevational view of the assembly shown in FIG. 4;
FIG. 5 is a top plan view of a screen used in the assembly of FIG. 3;
FIG. 5A is a front elevational view of the screen shown in FIG. 5;
FIG. 5B is a front elevational view of an alternative embodiment of the latch for the screen holder;
FIG. 6 is a front elevational view of a shroud member of the type that covers the pressure relief and vacuum relief valves shown in FIG. 3;
FIG. 6A is a side elevational view of the shroud shown in FIG. 6; and
FIG. 6B is a top plan view of the shroud shown in FIG. 6.
Similar reference numerals refer to similar parts throughout the several views of the drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1, it will there be seen that an embodiment illustrative of the inventive teachings of the present disclosure is designated by the reference numeral 10 as a whole.
Although the structure may take many forms, such as triangular, square, pentagonal, and so on, in this particular embodiment which is provided for illustrative purposes as aforesaid, the shape is as shown in FIG. 2, i.e., this particular structure has a front wall 12 within which is provided sliding doors 14 (shown in FIG. 1), corner walls 16, 16, side walls 18, 18 and a rear wall denoted 20.
This embodiment has a roof of twelve panels, collectively designated 22. FIG. 1 best depicts the inverted funnel shape of the roof, but FIG. 2 best depicts how the panels converge to a circular chimney means 24. The structure includes no fireplace, and the term "chimney" is used herein to indicate a tubular, air-carrying conduit or sleeve that vents heat from an enclosed space into the atmosphere.
The walls of structure 10 are preferably transparent so that persons within the enclosure may have a substantially unrestricted view of the surrounding environment. Accordingly, glass or a suitable substitute is the preferred material for the walls and roof of the structure 10. Frame members 26 are preferably metallic but those skilled in the art of materials will know other suitable materials that could be used. Moreover, those skilled in the construction arts will know how to build the structure 10 and many variations thereof in view of this disclosure, so no description is contained herein concerning how to mate the glass walls to the metallic frames and so forth since such details of construction are not within the scope of this invention, per se.
However, FIGS. 1 and 2 do depict a very important teaching of this invention, the provision of a roof having the general configuration of an inverted funnel. All of the roof panels 22 direct hot air upwardly toward the chimney means 24, and this is an important feature of the invention.
When structure 10 is built, a circular opening is formed in the roof as suggested by FIG. 2, i.e., the roof panels 22 converge toward one another as depicted but do not meet at the apex of the structure; each roof panel 22 terminates at a ring member 28 the top annular flange of which is shown in FIG. 2 but the structure of which is best understood in connection with FIG. 3 to which FIG. attention should now be directed.
Ring 28 is termed herein the mating ring 28 because it is the foundation to which the roof panels 22 are attached and it is also the foundation which carries the balance of the parts of chimney 24.
It should therefore be understood that the annular surface 30 of mating ring 28 is the surface to which the innermost or uppoermost ends of roof panels 22 are fixedly secured.
Mating ring 28 has an outwardly turned annular flange 29 and an inwardly turned annular flange 31 as is clearly shown in FIG. 3.
The inwardly turned flange 31 slidingly receives and supports cylindrical sleeve member 32.
A first cross bar 34 diametrically extends across sleeve member 32, and a second cross bar 36, positioned orthogonally with respect to first cross bar 34 and spaced downwardly therefrom as shown, also extends diametrically across sleeve member 32.
Both cross bar members 34, 36 are centrally apertured. A rotatably mounted, cylindrical gear housing 38 extends through the central apertures as indicated in FIG. 3.
It will be observed in FIG. 3 that the lowermost end of housing 38 is provided with a bore means 40; this bore means is releasably engaged by a suitable torque rod as shown in the cross-referenced disclosure. Rotation of the torque rod, not shown in the present disclosure, by an occupant of structure 10 while standing therewithin, effects rotation of housing 38 about its vertical axis of symmetry.
Housing 38 houses an elongate worm gear member 42 which has a nut and washer 43 secured to its lowermost end.
Collar member 44 is fixedly secured to or integrally formed with housing 38 at its uppermost end and therefore rotates conjointly therewith.
Collar member 44 is internally threaded and screw-threadly receives worm gear 42; accordingly, rotation of housing 38 and hence collar 44 effects axial travel of worm gear 42.
Friction-reducing bushing members 45, 46, associated with cross bars 34, 36, respectively, are employed for the purpose their name expresses.
Axial travel of gear 42 effects raising or lowering of cap member 48, dependent upon the direction housing 38 is rotated by the person turning the torque rod.
Thus, the cap member 48 does not rotate significantly as it travels up or down.
As is apparent, cap 48 has a generally hemispherical appearance.
An uppermost limit to the travel of cap 48 is set by the nut and washer 43 at the lowermost end of worm gear 42, i.e., washer 43 enters into abutting relation to annular shoulder 49 and prevents further raising of cap 48.
Cap 48 is hollow so that it will be light in weight and thus easy to raise and lower. However, if an occupant were to overly tighten the cap when in its closed position, theoretically cap 48 could be deformed due to its hollow construction. Thus, a sleeve 50 of rigid construction slideably receives the extension 42a of worm gear 42 and resists compressive forces.
An annular seal 52 is fixedly secured to the bottom of cap 48 as shown; seal 52 seats against the upper peripheral rim 53 of sleeve member 32 when cap 48 is closed.
Thus, when cap 48 is in its "down" position, no significant circulation of air can occur within structure 10 if doors 14 are closed.
It has been found that annular seal 52 and rim 53 form an excellent seal especially if cap member 48 is maintained against even minimal amounts of rotation. As mentioned earlier, cap 48 does not rotate significantly since worm gear 42 travels axially to lift or lower said cap 48; however, small amounts of rotation can occur.
The small rotation of cap 48 thus effected could be ignored and the inventive chimney means would still perform its intended function, but careful study has determined that a different sealing relationship is established for each lowering of cap 48 because different sections of annular seal 52 seat against annular rim 53 when small amounts of rotation are tolerated.
An anti-torque rod 54 is thus provided and is shown in FIG. 3. Its upper end is screw-theadedly engaged or otherwise fixedly secured to cap 48 at flat surface 57; rod is vertically deployed and extends through an aperture formed in upper cross bar 34, and boss members 55, 56 help maintain its vertical alignment. It is slideably received within said bosses 55, 56.
In this manner, everytime cap 48 is lowered, anti-torque rod 54 assures that seal 52 will seat on rim 53 at precisely the same location, thereby effecting a hermetic seal.
Since structure 10 may be closed so tightly, it is advisable to provide it with relief ports for both positive and negative pressures, especially in view of the glass construction of the enclosure.
A pressure relief valve means is generally denoted 58 in FIG. 3; it is positioned in registration with an aperture 59 formed in sleeve member 32. Importantly, the aperture has an annular bevel formed therein, contiguous to the outer surface of sleeve 32, as shown in FIG. 3.
A valve member 60 is complementally beveled as shown so that when it is seated on the beveled rim of aperture 59, no air can enter or exit structure 10 through said aperture.
Valve member 60 is carried by valve stem 61 which is elongate as shown; a spring member 62 has a base which abuts a baffle member 64, said baffle member being centrally apertured, carried by valve stem 61 and fixedly secured thereto.
The other end of spring 62 abuts spring support surface 62a. A housing 66 having opening 66a formed therein slideably mounts baffle member 64; opening 66a of housing 66 allows the atmospheric pressure inside structure 10 to bear against baffle member 64. The strength of spring 62 is selected so that when the pressure inside structure 10 is substantially equal to the pressure of the surrounding atmosphere, valve member 60 will be seated against the beveled annular rim of aperture 59.
Thus, when the pressure inside structure 10 exceeds a predetermined threshold, spring 62 compresses under the action of baffle member 64 and valve 60 is unseated so that air can leave structure 10 through aperture 59.
A shroud member 68 is shown protecting pressure relief valve 58 from the elements. The outwardly directed flange 29 of mating ring 28 constrains rain or other elements to execute a return bend as denoted by the arrow 69 to enter the confines of shroud 68. Thus, the elements are effectively prevented from befouling the valve 58 by the cooperation of shroud 68 and flange 29.
A vacuum relief valve of similar construction is also formed in sleeve member 32 and is denoted 71 as a whole. An aperture 70 having an inwardly beveled annular rim provides a seat for valve member 72 carried by elongate stem 73, said bevel being on the inside of sleeve 32 as shown instead of on the outside as was the case with pressure relief valve 58. Spring 74 has a preselected threshold which is overcome by atmospheric pressure outside enclosure 10 when the pressure inside said enclosure falls below a preselected pressure. Housing 75 has opening 75a formed therein to communicate pressure within structure 10 to the inside of said housing.
Both valves have an elongate stem as aforesaid, said stems having ends that extend beyond their respective housings 66, 76. Occupants of the structure 10 can thus operate the valves, by pulling on vacuum valve stem 73 or by pushing on pressure valve stem 61. Thus, if the occupants desire a pressure change that is not within the preselected limits of the springs, manual operation of the valves effects the desired results. The stems could also be pushed or pulled if the springs were to malfunction for any reason. Moreover, maintenance of the valves may require opening and closing of the valves from time to time.
The shroud 78 that protects vacuum valve 71 has the same construction of the pressure relief shroud 68 and also cooperates with the outwardly turned annular flange 29 of mating ring 28 to constrain rain and the like to follow the path indicated by arrow 69.
The shape of the bottom of cap 48 is important; as indicted in FIG. 3, the bottom of cap 48 includes flat central portion 80 and concave sidewalls 82.
The concave walls 82 cause air impinging thereagainst to flow in the direction indicated by the directional arrows 83.
It will be observed that a venturi effect arises from the moment cap 48 is raised from its seat on the annular rim 53 of sleeve member 32, because of the concave shape of the bottom of cap 48.
The volume of air entering sleeve member 32 as indicated by the arrows 85, appearing at the lower end of FIG. 3, will be constrained to exit sleeve member 32 between the gap existing between rim 53 of sleeve member 32 and the bottom of cap 48. When cap 48 is only partially raised as in FIG. 3, a low pressure area in the vicinity of the space denoted by the reference numeral 86 will arise, and the presence of such low pressure area will accelerate the flow of air out of the enclosure.
The hemispherical in configuration top surface 47 of cap 48 overhangs its concave bottom wall 82 to form an annular overhang denoted 81 in FIG. 3; the overhang prevents rain from dripping into sleeve 32.
It is desireable to provide a screen at the lower end of sleeve 32 in order to prevent debris from entering the sleeve which debris could clog the valves or otherwise mar performance of the inventive chimney.
FIG. 4A shows that an annular shoulder member 88 is fixedly secured to or integrally formed with mating ring 28 at its bottom; the screen member 90 shown in FIG. 5 is mounted to said annular shoulder member 88 as is best understood in connection with FIG. 3.
Screen 90 (FIG. 5) is surrounded by tightening band 92 having a latch means 94, which latch means is shown closed in FIG. 3. The securing of latch 94 tightens and thus screen 90 to its annular mount 88 and thus ensures that it will not be dislodged.
The latch allows the screen to be easily removed whenever required for maintenance reasons.
Screen 90 is centrally apertured as at 93 to receive gear housing 38; since gear housing 38 rotates when cap 48 is being raised or lowered, a means must be provided to seal aperture 93 around said housing 38. The chosen means is a pliable seal denoted 96 in FIGS. 5 and 5A.
The invention is thus understood to have numerous inventive features; it represents a significant advance in the art of structures in general, as well as in the art of ventilating means for enclosed structures.
The construction of the preferred embodiment is reliable. Moreover, the chimney means is economical to manufacture and thus its provision does not add appreciably to the cost of the glass enclosure 10.
It will thus be seen that the objects set forth above, and those made apparent from the foregoing description, are efficiently attained and since certain changes may be made in the above construction without departing from the scope of the invention, it is intended that all matters contained in the foregoing description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.
It is also to be understood that the following claims are intended to cover all of the generic and specific features of the invention herein described, and all statements of the scope of the invention which, as a matter of language, might be said to fall therebetween.
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A structure that provides a substantially unrestricted view of the surrounding environment to its occupants. The structure includes a lower portion defined by upstanding transparent walls, and an upper transparent portion having the general appearance of an inverted funnel. The inverted funnel shape of the structure directs rising hot air currents to the inlet of a chimney positioned at the apex of the inverted funnel. The vertical position of a closure member which forms a part of the chimney is adjustable by the occupants of the structure to control air flow within the structure.
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This is a continuation of copending application Ser. No. 07/099,368 filed on Sep. 21, 1987, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to improved impact absorbing compressible composites. These composites can be shaped into smooth compound curves and find application wherever high efficiency impact absorption is called for such as in athletic wear, in seating systems, in vehicle interior padding materials and the like.
2. Background Information
There is a well-recognized need for high performance materials for spreading or absorbing impacts. In recent years, athletes, athletic equipment manufacturers and sports medicine professionals have recognized the need for improved impact absorbing materials in athletic equipment. These materials find application as heel pads and foot sole pads in shoes to absorb the shock of foot strike and as cushioning points under football or hockey pads such as shoulder pads, thigh pads, hip pads and the like to name but a few typical applications. Similar needs may be found in seating systems and in vehicle interiors, to name but a few representative fields in which impact absorption is a major interest.
One common approach to impact absorption in the past has involved using felts or blocks of a soft padding material. Padding materials known heretofore include cotton padding, horsehair padding, foam rubber, foamed plastics, sponge rubber and the like. In these designs, the inherent resilience of the padding material is employed to absorb and disperse the applied impact. These designs have the disadvantage that they often "bottom out" or fully compress on severe impacts of the type regularly encountered during use such as in athletic equipment or in vehicle interiors and thus provide minimal protection. When made thicker to avoid this problem, they become cumbersome and can interfere with the design of the article being padded, and in the case of athletic equipment can interfere with the wearer's freedom and performance.
Impact absorbers have also been proposed which employ fluid-filled bladders such as cushioning air sacks These devices rely upon the compressibility of the enclosed fluid to provide the desired shock absorbing. In some embodiments of these devices, the fluid is fully enclosed and can not escape. In others, the fluid is gradually and controllably forced out of the bladder during the impact with the rate of release being selected to prevent exhaustion of the fluid during the impact event. While effective as shock absorbers, these devices can have the failing of ballooning or otherwise expanding in one region when another region is being compressed. This can lead to discomfort or at minimum give an unnatural or unstable feel to the user. In the case of footwear, this problem can lead to an unstable foot plant with increased opportunity for injury. Another issue with this type of pad has related to problems in forming shapes based on compound curve and to retaining structural integrity with the above-described ballooning.
Representative patents in the field of shock absorbing or impact absorbing devices include U.S. Pat. No. 4,513,449, SHOCK ABSORBING ATHLETIC EQUIPMENT; U.S. Pat. No. 4,370,754, VARIABLE PRESSURE PAD; U.S. Pat. No. 4,453,271, PROTECTIVE GARMENT; U.S. Pat. No. 4,217,705, SELFCONTAINED FLUID PRESSURE FOOT SUPPORT DEVICE, all issued to Donzis, U.S. Pat. No. 4,446,634 for FOOTWEAR HAVING IMPROVED SHOCK ABSORPTION; U.S. Pat. No. 4,397,104 for INFLATABLE SOLE-SHOE; U.S. Pat. No. 2,863,230 for CUSHIONED SOLE AND HEEL FOR SHOES; U.S. Pat. No. 4,229,889 for PRESSURIZED POROUS MATERIAL CUSHION SHOE BASE; U.S. Pat. No. 4,637,716 for METHOD FOR MAKING ELASTOMERIC SHOE SOLES; U.S. Pat. No. 4,635,384 for FOOTWEAR SOLE; U.S. Pat. No. 4,610,099 for SHOCK-ABSORBING SHOE CONSTRUCTION; and U.S. Pat. No. 4,571,853 for SHOE INSERT.
It is an object of the present invention to provide an improved impact absorbing composite. It is desired that this composite provide superior shock absorbing performance and also be capable of being formed into complex compound curve shapes, be durable and hygienic.
STATEMENT OF THE INVENTION
An improved impact absorbing composite has now been found. This composite is capable of dispersing and absorbing impacting forces with high efficiency. The composite is characterized by a structure including a flexible plastic wall (enclosure) defining an internal cavity. This flexible enclosure is made of a material that is generally impermeable to air and is capable of having its internal pressure changed. The internal cavity of the enclosure is filled with a foam core. This core is held in place by the cavity walls. Importantly, the core is intimately adhered (glued, bonded or the like) on substantially all of its external surfaces to the internal surface of the cavity. In preferred embodiments, the wall and the core are prestressed by one another. That is, the core presses out against the wall and the wall pushes in against the core. The intimate adherent contact between the foam core and the outer wall gives rise to an unexpected degree of product integrity and unexpectedly superior impact absorbing capabilities.
In preferred embodiments, the composite has a valve or fitting communicating with the cavity so that the pressure within the cavity can be altered. This permits the composite to be adjusted to accommodate varying impacts. The invention can thus include in combination such a composite together with a device for pressurizing its cavity.
Also in preferred embodiments, the foam core is an open-celled foam or a reticulated foam so that the pressure within the core is uniform. Urethane polymers have been found to be excellent for forming the cavity and the foam and are preferred materials of construction.
In other aspects, the composites of the invention can employ cores having a plurality of different foams arranged parallel or perpendicular to the impact direction. This permits differing densities and impact resistances to be present at different positions on the composite. The impact absorbers of this invention can be used in conjunction with other materials or layers including without limitation, cosmetic or hygienic overlayers, other shock-absorbing layers or the like.
In yet another aspect, this invention provides a variety of methods for fabricating these composites. All of these methods are characterized by creating an adherent bond between the foam core and the outer layer and by pressurizing the core to a value effective to provide efficient impact absorption.
One such method involves shaping the wall surface to create a cavity, sizing and shaping the foam core so as to fully fill the cavity and preferably prestress the wall and core, adhering and enclosing the core within the cavity and adjusting the pressure within the cavity to a value effective to provide efficient impact absorption.
Another fabrication method involves shaping the wall surface to create a cavity, sizing and shaping the core so as to partially fill the cavity, placing the core within the cavity, forming an elastomeric foam and preferably an open-celled or reticulated foam in situ within the cavity so as to fill the space between the preshaped foam and the cavity wall and to adhere the cavity wall to the core and preferably prestress the wall and core, and adjusting the pressure within the cavity to a value effective to provide efficient impact absorption.
Yet another fabrication method involves shaping the wall surface to create a cavity, forming a cavity-wall-adherent open-celled or reticulated foam core in situ within the cavity so as to fill the cavity and preferably prestress the wall and core, and adjusting the pressure within the cavity to a value effective to provide efficient impact absorption.
A further fabrication method involves sizing and shaping the foam core, forming the outer wall in situ around and adherent to the foam core such as by shrinking a film a core-adherent material around the core or by applying a layer of uncured wall material, such as a solution of wall-forming polymer, around and adherent to the core and then curing the uncured wall material, thereby creating a cavity enclosing and preferably prestressing the core, and adjusting the pressure within the cavity to a value effective to provide efficient impact absorption.
The present shock absorbing composites can be employed in a wide range of applications. One excellent application is as heel pads and/or sole pads for shoes, especially sport shoes, where they serve to absorb foot strike impact with high efficiency.
The composites of this invention are characterized by being easily formed in compound curve forms, by being very light weight and by being hygienic. They are further characterized by being adjustable in pressure, and thus in impact cushioning capacity. This permits them to serve in a wide range of applications with widely variable impacts.
DETAILED DESCRIPTION OF THE INVENTION
Brief Description of the Drawings
The present invention will be described herein with reference being made to the accompanying drawings. Where practical in the drawings, a common reference numeral is used for the same part when it appears in more than one Figure. In the drawing:
FIG. 1 is an exploded perspective view of the components of an impact absorber of this invention;
FIG. 2 is an cut away cross-sectional view of a shock absorber of this invention;
FIG. 3 is a partially schematic cross sectional view of an impact absorbing heel pad not embodying this invention. This heel pad has a wall defining a pressure-tight cavity but does not have a foam core adhered to and filling its inner surface. This figure illustrates the flaw in this design that an impact can be absorbed but at the same time ballooning occurs;
FIG. 4 is similar to FIG. 3 but illustrates that with the present invention ballooning is prevented;
FIG. 5 is a perspective view of an alternative foam core for use in this invention. This core has a plurality of differing compression strength foams arranged parallel to the impact force;
FIG. 6 is a cut away cross-sectional view of another alternative embodiment of the impact absorber of this invention in which the wall material defining the cavity is further shaped to provide a supportive column;
FIG. 7 is another cross sectional view of the absorber shown in FIG. 6 taken along line 7--7';
FIG. 8 is an exploded perspective view of the components of the absorber of FIGS. 6 and 7;
FIG. 9 is a perspective view of an alternative embodiment of the impact absorber of this invention. This embodiment employs a core which has a plurality of differing compression strength foams arranged perpendicular to the impact force;
FIG. 10 is a phantom top view of a core configuration for use with closed cell foam materials;
FIG. 11 is a cross sectional view of the core shown in FIG. 10 taken along line 11--11';
FIG. 12 is a phantom top view of another core configuration for use with closed cell foam materials;
FIG. 13 is a cross sectional view of the core shown in FIG. 12 taken along line 13--13';
FIG. 14 is a cut away cross sectional view of a shoe containing a shock absorber of the present invention and additionally having a pump for pressurizing the core of the absorber;
FIG. 15 is a cross sectional view of an automotive dash board incorporating an impact absorber of this invention;
FIGS. 16 and 17 are two views of an additional representative application for the shock absorbers of this invention as a foot pad;
FIG. 18 is a perspective view of a shoulder pad under pad application for the shock absorbers of this invention; and
FIGS. 19 and 20 are graphs illustrating the effectiveness of the impact absorbers of this invention and their adaption to various body weights and to various impacts.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIGS. 1 and 2 in more detail, these figures illustrate an impact absorber 10. Impact absorber 10 includes a foam core 11 and top and bottom wall sections 12 and 14 which when joined define a cavity 15. A layer of adhesive 16 is present between essentially all of the inner surface of cavity 15 and the outer surface of foam core 11. This layer is shown on core 11 but could as well be on the inside surface of the wall or on both the core and the wall as desired. When wall sections 12 and 14 are joined, the cavity which they define is pressure tight. It is possible to equip the impact absorber with a valve or fitting such as valve 16. Valve 16 is a "Halkey-Roberts" type urethane valve which is shown in FIG. 1 in its pre-assembly form. After incorporation, the top end of valve 16 is cut off flush with the surface of the shock absorber as shown in FIG. 2. Any equivalent form of valve or pressure control aperture can be used, if desired. This valve allows the pressure in the interior (cavity 15) of the impact absorber to be adjusted, as desired, by adding or removing fluid from the cavity.
The outer wall of the impact absorber is formed of flexible plastic. The materials used to form the wall can be selected from the film-forming flexible plastics. Virtually any plastic can be used so long as it is resistant to bacterial attack, flexible and shapable into the forms and configurations desired. Useful film-forming plastics include poly(urethane)s both of the poly(ether) and the poly(ester) form, poly(ester)s such as poly(ethylene terphthalate), flexible poly(vinyl)s, elastomeric poly(olefin)s such as poly(isoprene), poly(isobutylene), and neoprene, low density poly(ethylene)s and the like.
In the embodiment shown in FIGS. 1 and 2, the outer wall is preshaped into the desired configuration and then the foam core is adhered to it. In another embodiment, the outer wall can be formed around the foam core. One way to accomplish this is to use a liquid polymer precure solution or suspension which is applied to the outer surface of the core and then cured. Another way to accomplish this is to use plastic sheet stock and laminate it to the core or shrink it around the core. In any of these alternative modes of construction, it is essential that there be a strong adherent bond between the wall and essentially the entire outer surface of the core.
Of the plastics useful in forming the films, preference is given to the flexible poly(urethane)s because of their ready availability. These materials are available from J. P. Stevens Company and Deerfield Urethane, Inc., to name but two regular suppliers. Representative useful plastic films include the Deerfield "Dureflex" poly(urethane) films. These materials can be preformed, as in FIGS. 1 and 2 or they can be used as stock goods. When a liquid is used to apply the outer wall, it is typically a solution of a prepolymer or resole resin. Vinyl films can be used in this application. A typical vinyl film is the vinyl adhesive sealant produced by W. R. Grace and marketed by Eclectic Products as Eclectic 6000 adhesive sealant. These materials are solvented in halocarbons such as perchloroethylene and the like. A preferred liquid coating is based on the polyurethanes. Again, the nonrigid urethane polymers are preferred. The solutions known in the art for forming flexible urethane films are very suitable for this application. Typical urethane polymer solutions include the reaction product of a diisocyanate such as toluene diisocyanate or hexamethylene diisocyanate with a polyol such as a polyether polyol. These reaction products are commonly produced in a mixed solvent system such as a polar solvent (for example, Butyl Cellosolve, Cellosolve Acetate, butyl Carbitol, or diacetone alcohol or the like) in combination with an aromatic solvent such as toluene, benzene, or hydrocarbon distillate fractions heavy in aromatics and having a boiling range in the range of from about 140° to 240° C. This outer wall, when applied as a liquid can be dried (solvent removed) and cured by the application of heat and/or the application of a curing catalyst such as an amine. Other curing modalities such as photocuring can be employed as well, if appropriate. The liquid wall-forming compositions can contain plasticizers and builders and the like, if desired. The particular conditions used for forming the outer wall are conventional for processing polymers such as the urethanes which are preferred and are known to those of skill in the polymer arts.
The outer wall, whether supplied as a preformed structure, a cured liquid overcoat or a shrunk or adhered layer of stock goods is commonly from about 1 to 200 mils in thickness with thicknesses in the range of from about 2 to 50 mils being preferred and excellent results being attained with thicknesses of from about 3 to about 35 mils.
The core of the impact absorber is a foam. This foam is preferably an open-celled foam, that is a foam in which the various cells are in communication with each other and with the outer surface of the foam. Similar properties are achieved with a reticulated foam, that is a foam which has been treated to break down membranes which separated various cells. Foam rubber, foamed latex, vinyl foams and the like can be used. The preferred foam material for use in the core is poly(urethane) foam. Representative foams include the "Ensolite" foams sold by Uniroyal Plastics Co., Inc. and the flexible urethane foams sold by the E. R. Carpenter Company.
Typical densities for the foam core range from between about 0.5 to about 15 pounds per cubic foot. Preferred foam densities are from about 2 to 10 pounds per cubic foot.
It will be appreciated that because the foam core is adhered to the outer wall it is in effect a structural member. The adhered foam serves to prevent the ballooning of the device as previously described. This duty puts strain upon the foam of the core. If the foam separates under this strain it can result in a loss of integrity of the device. With this potential problem in mind, it is possible to reinforce the foam by including filaments or fibers or fabrics in it. Typical reinforcements can be inorganic materials such as fiberglass or carbon fiber; natural organic fibers such as silk, cotton, wool or the like or synthetic organic fibers such as urethane fibers, nylon filaments, nylon fabrics, aramid filaments and fabrics, and the like. This reinforcement can be laminated into the foam, incorporated into the foam or otherwise compounded into the foam as is known by those skilled in the art.
In the embodiment shown in FIGS. 1 and 2, the internal foam core is preshaped to fit tightly within the outer wall of the impact absorber.
This intimate fit may be accomplished in other ways as well. For one, the core can be foamed in place within the wall structure using injectable flexible foam forming materials known in the art. With the preferred urethane foams, a typical foaming mixture can include a polyether polyol, a diisocyanate such as toluene diisocyanate, water, and amine and organotin catalysts. This mixture generally contains polymeric fillers and flexibilizers (plasticizers) as well. The added water reacts with the isocyanates to produce an amine plus carbon dioxide gas which foams the liquid. Other foaming agents such as gases including carbon dioxide, nitrogen, air or the like as well as low boiling liquids, (commonly low-boiling fluorocarbons and the like) can also be added. By controlling the amount of foaming material added and the cure conditions, the core so formed can, if desired, prestress the outer wall as is preferred. The in situ cores can be closed-cell foams, open-celled foams or reticulated foams as desired.
In a hybrid form of construction, the foam core can be a composite of a preshaped foam body which does not completely fill the cavity created by the outer wall and an added foam-in-place layer between the wall and the preshaped body. This form of fabrication has the advantage that the desired intimate fit is achieved with a minimum of preshaping and fitting while at the same time the preshaped core provides a measure of dimensional stabilty and integrity to the composite during fabrication.
The third component of the impact absorbers of this invention is an adhesive for affixing the foam core to the wall. This adhesive is most conveniently an activated adhesive such as a light activated adhesive, UV activated adhesive or heat activated adhesive so as to permit the parts to be fitted together and then bonded. A typical heat-activated adhesive is the Royal Adhesive DC-11324 material sold by Uniroyal. This adhesive is a two part poly(urethane)/isocyanate adhesive which has the added advantage of being water-based. When applied to the foam and/or wall it dries to a non-tacky surface which permits easy assembly. This material heat-activates at 300°-325° F. to form a tough adherent bond. Other useful adhesives can include epoxy adhesives, contact cement type poly(urethane) adhesives such as the Uniroyal "Silaprenes", the 3M "Scothgrip" adhesives and the isoprene contact cements. In general, one can employ as adhesive any material which will bond the foam to the outer wall with a strength which will not be exceeded by the forces of impact applied to the impact absorber or by the forces applied by the pressure applied to the impact absorber.
In the fabrication methods in which a liquid solution of prepolymer is applied to the core to create the outer layer or in which the core is foamed in place, it is often the case that the required intimate bond between the core and the outer wall is formed directly without the need for added adhesive.
The outer wall portions of the impact absorber are joined together such as by the use of adhesive or by heat sealing or the like to give a fluid impermeable wall to which the inner core is bonded. After the fusing together of the wall components, the impact absorber can be trimmed and, if desired, further shaped to conform to the environment of use.
The core of the present impact absorbers contain a fluid. Gases and in particular air are very suitable fluids. Liquids and gells could be used as well, if desired.
Turning to FIGS. 3 and 4, the advantages of the impact absorber of this invention are graphically illustrated. In each of these figures a shoe 30 is shown together with foot 31 impacting downward into a heel pad shown as 32 (in FIG. 3--not according to the invention) and as 10 (in FIG. 4--in accord with this invention). In the case of heel pad 32, the downward pressure of the heel causes the center of the pad 34 to be severely depressed while permitting the edges 35 and 36 to balloon up. This can be uncomfortable and unstable. With pad 10 the center 33 depresses somewhat but there is minimal ballooning.
Turning now to FIG. 5, a variation of the core 11 is shown. This core (core 50) is fabricated from a plurality of foams of differing properties, for example density. As shown, the core includes a series of plugs 51A, 51B, etc of firm density foam inserted into the body of core 11. This can result in a light weight core having the firmness of the plugs. This is merely a representative configuration and one could as well have one entire section of the core with one density foam and another section with another density. One could also vary the core based on other properties, such as the ability of a region of the foam to take a set or the like. The various core sections are adhered to the outer wall of the impact absorber as is shown in FIGS. 1 and 2. One could form a core of this type by placing preshaped pieces of one foam in the cavity and then foaming in place the other material, if desired.
The plastic wall of the impact absorber can have structural properties and contribute to the rigidity and shock absorbing properties of the device. FIGS. 6, 7 and 8 illustrate an embodiment 60 of the impact absorber which includes a depression or "column" 61 in its structure so as to provide additional wall surface and structure in that region of the absorber. In this embodiment as shown in FIG. 8, the valve 16 is illustrated being laminated into the composite as the top 12 is joined to the bottom 14.
FIG. 9 illustrates other variations which may be employed without departing from the spirit of this invention. FIG. 9 shows impact absorber 80. The foam core of absorber 80 is fabricated from several different foams including foam section 81, section 82, section 83 and section 84. These sections are all adhered to the wall 12/14. Valve 16 is again provided to permit the pressure of the core to be altered and controlled. The various core sections can be adhered to one another, if desired. If they are adhered to one another, it must be borne in mind that the glue layers or the like between the various sections can serve as barriers for the transport of fluid between the various sections. If such fluid communication is desired, gaps must be left in the glue layers or glues which are fluid-permeable must be used.
Absorber 80 includes several other features which can be incorporated into the present absorbers. An exterior pad 85 is provided. This can provide additional shock absorbancy. A top layer 86 is also present. This can be a cosmetic over layer or can be provided as a replaceable hygienic layer.
In the absorbers shown in FIGS. 1, 6 and 9, the means for adjusting the pressure (valve 16) has been in communication with the foam core itself and has relied upon the open-cell foam structure of the core to distribute the applied pressure throughout the core and thus provide a uniform level of support throughout the absorber. While this structure is very suitable, one can also employ closed-cell foams, if desired. FIGS. 10 and 11, and FIGS. 12 and 13 respectively illustrate two representative configurations for a closed-cell foam core. In the configuration shown in FIGS. 10 and 11, the core 87 contains an aperture 88 into which the pressure adjusting valve 16 can fit. This aperture 88 communicates with a network of channels 89 spaced throughout the core so as to transmit and distribute the pressure applied to aperture 88. In this embodiment, the network of channels is contained by and enclosed by the closed-cell foam core. This means that the core itself can contribute to the containment of the pressure applied to the channels. This offers the advantage that localized stress on the outer wall is avoided or minimized and possible failures due to rupture at localized stress points are minimized.
The configuration shown in FIGS. 12 and 13 is substantially the same as that shown in FIGS. 10 and 11 with the exception that aperture 97 communicates with a network of passages 98 which are not fully contained within the core. This configuration does not offer the localized stress relief of the configuration of FIGS. 10 and 11 but would be less expensive and simpler to produce.
Turning to FIG. 14 an additional embodiment of the impact absorber is shown as foot pad 90 housed within the sole portion of shoe 95. Foot pad 90 includes the foam core 11 and adherent outer wall 12/14 described herein. Pad 90 is equipped with a built in pump to alter the pressure within its core. This pump includes a one way check valve 16 which admits air into pump cavity 91. Pump cavity 91 is compressed and released to give a region of low pressure so that air can enter through valve 16. When the cavity 91 is depressed again, this forces the newly admitted air through passage 92 into the core 11, thus increasing its pressure. This process is repeated until the proper pressure is attained. Shoe 95 also includes a collar 93. This can be formed with the same structure as pad 90 with an internal core adhered to the walls. Such a collar would be very effective at absorbing the shock which would occur as the wearer's foot comes up in the shoe and impacts it or would be effective as a protection to the wearer's ankle and achilles tendon region.
FIG. 15 illustrates that the present invention finds application in many areas beyond athletic equipment. It illustrates an automotive dashboard structure 101 having an impact pad 100 on its face as well as phantom steering wheel 102. Impact pad 101 includes core 11, wall 12/14 and valve 16. Such a pad can provide efficient dashboard impact protection for the occupants of the automobile in the event of a crash.
FIGS. 16 and 17 illustrate in two views a ventilated footpad 110 for use in shoes. Pad 110 has a complex shape which requires numerous compound curves. In its application as a shoe footpad, pad 110 will be subjected to a wide variation in impacts depending upon the weight of the runner using it and the runner's lightness of footstrike. It is of substantial advantage to adjust the pressure within the pad with valve 16 to accommodate these variations.
FIG. 18 illustrates another embodiment of the present invention, an underpad 180 for use in conjunction with contact sports shoulder pads. Underpad 180 has a structure which includes numerous compound curves and a plurality of "Swiss-cheese" holes through its structure. The compound curve-forming ability and the plurality of holes permit the pad to conform to and bend over the wearer's shoulder with comfort and breathability. It is a special advantage that the present invention makes these complex curves possible and provides superior shock and impact absorption in such settings.
The effectiveness of the present invention can be demonstrated by comparative tests. A series of impact tests were run on a standard state-of-the-art basketball shoe. The same tests were then performed on the same model shoe which had been modified by replacing a portion of its sole structure (the heel pad region) with an impact absorber of this invention. The impact absorber was fabricated from 35 mil flexible poly(urethane). The core was about 1/2 inch thick open-cell poly(urethane) foam of 5 lbs per cubic foot density. The foam core slightly prestressed the outer wall by being somewhat oversized and was adhered to the walls using a heat activated waterbased urethane adhesive. Tests were run with the core sealed at atmospheric pressure and with the core pressurized to 5 and 10 psig. FIGS. 19 and 20 present the results of these tests. In each figure line A is the results observed with the prior art shoe. It can be seen that for a given application of energy to the shoe, i.e. a given impact, the shoe transmits a certain peak force and a certain acceleration, (in G's) to the wearer. Lines B show the results achieved when the atmospheric bladder is used. They show that the force and acceleration transmitted to the wearer is significantly reduced. Importantly, this reduction occurs over the entire range of applied energies. Thus the effectiveness of the present absorbers is substantially universal and will be observed with hard impacts such as may result with heavy athletes and also with lighter impacts such as may result with lighter weight athletes, etc.
Lines C show that even better shock absorbancy is achieved when a positive pressure is applied to the bladders. Similar results were obtained with the 5 and 10 pound pressures which suggest that in practical terms these pressures may be quite adequate. On the basis of these tests, it is believed that pressures in the range of 0 to about 20 psig are preferred.
The present invention has been described herein in detail with respect to a number of preferred embodiments and configurations. It will be appreciated, however, that modifications and changes to various aspects of these embodiments may be made while still coming with in the spirit and scope of this invention which is as defined by the following claims.
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An improved composite for absorbing and dispersing impacting forces is disclosed. The composite includes a flexible plastic enclosure defining an internal cavity. The flexible enclosure is generally impermeable to air and capable of having its internal pressure changed. The composite further includes a foam core filling the cavity and retained within the cavity and adhered on substantially all of its external surface to the internal surface of the cavity. The cavity can be pressurized for higher impact absorbance. Methods for fabricating the composites are disclosed, as well.
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RELATED APPLICATIONS
This application is a divisional application of a U.S. patent application Ser. No. 12/815,144 filed Jun. 14, 2010 now U.S. Pat. No. 8,092,487, which is a divisional application of U.S. patent application Ser. No. 10/772,782, filed Feb. 5, 2004 now U.S. Pat. No. 7,758,606, which patent application is a continuation of U.S. patent application Ser. No. 09/896,258, filed Jun. 29, 2001 now U.S. Pat. No. 6,692,513 which '258 cation claimed the benefit of prior U.S. Provisional Patent Application Ser. No. 60/215,542, filed Jun. 30, 2000 by Richard B. Streeter et al. for INTRAVASCULAR FILTER WITH DEBRIS ENTRAPMENT MECHANISM, which patent application is hereby incorporated herein by reference, and of prior U.S. Provisional Patent Application Ser. No. 60/231,101, filed Sep. 8, 2000 by Richard B. Streeter et al, for INTRAVASCULAR FILTER WITH DEBRIS ENTRAPMENT MECHANISM, which patent application is hereby incorporated herein by reference.
FIELD OF THE INVENTION
This invention relates to intravascular filtering apparatus and methods in general, and more particularly to apparatus and methods for filtering and irreversibly entrapping embolic debris from the vascular system during an intravascular or intracardiac procedure.
BACKGROUND OF THE INVENTION
Intracardiac and intravascular procedures, whether performed percutaneously or in an open, surgical, fashion, may liberate particulate debris. Such debris, once free in the vascular system, may cause complications including vascular occlusion, end-organ ischemia, stroke, and heart attack. Ideally, this debris is filtered from the vascular system before it can travel to distal organ beds.
Using known filter mechanisms deployed in the arterial system, debris is captured during systole. There is a danger, however, that such debris may escape the filter mechanism during diastole or during filter removal. Apparatus and methods to reduce debris escape during diastole or during filter removal may be desirable to reduce embolic complications
SUMMARY OF THE INVENTION
An object of the invention is to provide a filtering mechanism that irreversibly entraps debris therein.
Another object of the invention is to provide a filtering mechanism that permanently captures debris from the intravascular system of a patient.
A further object of the invention is to provide a filtering mechanism with greater ability to collect debris in the intravascular system of a patient to decrease the number of complications attributable to such debris.
Another further object of this invention is to provide a filter holding mechanism suitable to be secured to a retractor used to create access to the heart and surrounding structures during heart surgery procedures.
A still further object is to provide a method for using a filtering mechanism in the intravascular system of a patient to permanently capture debris therefrom.
Another still further object of the present invention is to provide a method for introducing a filtering device in the aorta downstream of the aortic valve to restrict the passage of emboli while allowing blood to flow through the aorta during cardiovascular procedures, and to entrap debris collected in the filter so as to prevent its escape during cardiac diastole or during manipulation, repositioning or removal of the device from the aorta.
With the above and other objects in view, as will hereinafter appear, there is provided apparatus for debris removal from the vascular system of a patient, said apparatus comprising: a filtering device having a proximal side and a distal side said filter being sized to allow blood flow therethrough and to restrict debris therethrough and said filter having a first given perimeter, wherein blood flow in a first direction passes from the proximal side to the distal side of the filtering device; an entrapment mechanism having a proximal side and a distal side, the entrapment mechanism forming a selective opening to allow debris and blood flow passage in the first direction from the proximal side to the distal side therethrough, the selective opening having a restriction mechanism to debris passage in a second direction opposite to said first direction the selective opening having a second given perimeter, the first given perimeter and the second given perimeter being deployed within the vascular system so as to form a chamber between the distal side of the entrapment mechanism and the proximal side of the filtering device, wherein the entrapment mechanism allows blood flow and debris to pass therethrough in the first direction, the filtering device allows blood flow to pass therethrough in the first direction, the restriction mechanism prevents debris from passing back through said selective opening in a second direction opposite to the first direction and the chamber contains the debris received through the entrapment mechanism so as to prevent the escape of the debris therein by said filtering device in the first direction and said restriction mechanism in said second direction.
In accordance with another further feature of the invention there is provided a method for filtering and entrapping debris from the vascular system of a patient, the method comprising: providing apparatus for filtering and entrapping debris from the vascular system of a patient, the apparatus comprising: a filter device being sized to allow blood flow therethrough and to restrict passage of debris therethrough, and the filter device having a first given perimeter, a proximal side and a distal side; and wherein the filtering device captures debris carried in a first direction of blood flow from the proximal side to the distal side thereof on the proximal side of the filter device; an entrapment mechanism having a proximal side and a distal side, the entrapment mechanist including a selective opening to allow passage of blood and debris therethrough, the selective opening being configured to allow passage of blood and debris carried therein therethrough in the first direction of blood flow from the proximal side to the distal side of the entrapment mechanism, the selective opening having a restriction mechanism to prevent debris passage from the distal side to the proximal side of the entrapment mechanism in a second direction opposite to the first direction, the selective opening forming a second given perimeter, and the first given perimeter and the second given perimeter being deployed within the vascular system so as to form a chamber between the distal side of the entrapment mechanism and the proximal side of the filtering device; wherein the entrapment mechanism allows blood and debris carried therein therethrough in the first direction of blood flow, the filtering device allows blood therethrough in the first direction of blood flow, and the restriction mechanism prevents debris back through the selective opening in the second direction of blood flow opposite to the first direction of blood flow such that the chamber entraps the filtered debris received therein for debris removal from the vascular system of the patient; inserting said apparatus into the vascular system of the patient; allowing blood and debris carried therein to flow through the entrapment mechanism, and into the chamber; and removing the apparatus from the vascular system of the patient.
The above and other features of the invention, including various novel details of construction and combinations of parts and method steps will now be more particularly described with reference to the accompanying drawings and pointed out in the claims. It will be understood that the particular devices and method steps embodying the invention are shown by way of illustration only and not as limitations of the invention. The principles and features of this invention may be employed in various and numerous embodiments without departing from the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other objects and features of the present invention will be more fully disclosed or rendered obvious by the following detailed description of the preferred embodiments of the invention, which are to be considered together with the accompanying drawings wherein like numbers refer to like parts, and further wherein:
FIG. 1A is a perspective view of a deployable entrapment filtering device for debris removal showing the filtering device in its fully deployed shape as released from its cannula into the blood stream of a patient;
FIG. 1B is an exploded perspective view of the deployable entrapment filtering device of FIG. 1A showing the components thereof;
FIG. 1C is a schematic cross-sectional illustration depicting the deployable entrapment filtering device of FIGS. 1A and 1B during cardiac systole;
FIG. 1D is a schematic cross-sectional illustration depicting the deployable entrapment filtering device of FIGS. 1A and 1B during cardiac diastole;
FIG. 2A is an exploded perspective view of a deployable entrapment filtering device for debris removal showing the components thereof including a set of filter mesh entrapment leaflets;
FIG. 2B is a schematic cross-sectional illustration depicting the deployable entrapment filtering device of FIG. 2A during cardiac systole;
FIGS. 3A-3D are a series of schematic illustrations depicting a method of using the deployable entrapment filtering device of FIGS. 2A and 2B ;
FIG. 4A is an exploded perspective view of a deployable entrapment filtering device for debris removal showing the components thereof including a set of non-porous valve leaflets;
FIG. 4B is a schematic cross-sectional illustration depicting the deployable entrapment filtering device of FIG. 4A during cardiac systole;
FIGS. 5A-5D are a series of schematic illustrations depicting a method of using the deployable entrapment filtering device of FIGS. 4A and 4B ; and
FIGS. 6A-6D are schematic illustrations depicting an orthogonally deployable valve/filter apparatus.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A filtration and entrapment apparatus 5 is shown in FIGS. 1A-5D for debris removal from the vascular system of a patient. Filtration and entrapment apparatus 5 generally includes a filter device 10 and an entrapment mechanism 15 . Filtration and entrapment apparatus 5 can be used to filter emboli during a variety of intravascular or intracardiac procedures, including, but not limited to, the following procedures: vascular diagnostic procedures, angioplasty, stenting, angioplasty and stenting, endovascular stent-graft and surgical procedures for aneurysm repairs, coronary artery bypass procedures, cardiac valve replacement and repair procedures, and carotid endardarectomy procedures.
Now looking at FIGS. 1A-1D , a preferred embodiment of the present invention is shown with filtration and entrapment apparatus 5 as described herein below.
FIG. 1A depicts the profile of filtration and entrapment apparatus 5 in its fully deployed shape, with filter device 10 and entrapment mechanism 15 released from cannula 20 into the blood stream (not shown). Prior to deployment, filter device 10 and entrapment mechanism 15 are collapsed within cannula 20 , e.g., by moving the proximal end 25 A proximally along center post 50 .
FIG. 1B depicts the primary components of filtration and entrapment apparatus 5 comprising filter device 10 and entrapment mechanism 15 in attachment to deployable frame 25 . In the present embodiment of the invention, filter device 10 comprises a filter mesh bag 30 , and entrapment mechanism 15 comprises a piece of coarse mesh 35 and a set of entrapment flaps 40 .
FIG. 1C depicts filtration and entrapment apparatus 5 deployed within an aorta 45 during cardiac systole. Blood and debris flow through opened deployable frame 25 , across course mesh 35 , between and through entrapment flaps 40 and into the end of the filter mesh bag 30 . Entrapment flaps 40 ensure unidirectional flow of blood and debris into filter mesh bag 30 .
FIG. 10 depicts filtration and entrapment apparatus 5 within the aorta 45 responding to any retrograde flow of blood and/or back pressure within the aorta 45 during cardiac diastole. The back flow of blood and/or back pressure causes filter mesh bag 30 to partially deform and entrapment flaps 40 to close against coarse mesh 35 . Coarse mesh 35 is of a structure adequate to permit the free flow of blood and debris through it and into filter mesh bag 30 , and serves as a supporting structure against which entrapment flaps 40 can close and remain in a closed position to prevent the escape of embolic debris.
Still looking at FIGS. 1A-1D , it should also be appreciated that the entrapment flaps 40 may be attached to structures other than deployable frame 25 , e.g., the entrapment flaps 40 may be attached to a center post 50 , or to coarse mesh 35 , etc. Furthermore, if desired, entrapment flaps 40 may be biased closed or biased open. In addition, entrapment mechanism 15 may consist of one or more flaps 55 , and have a configuration including, but not limited to, a single disk diaphragm (not shown), a semi-lunar configuration (not shown), a gill slit configuration (not shown), a multi-leaflet flap configuration (not shown), etc.
It should also be appreciated that, while in the foregoing description the apparatus shown in FIGS. 1A-1D has been described in the context of functioning as a filter, it may also function as a one-way check valve. To the extent that the apparatus shown in FIGS. 1A-1D is intended to function primarily as a one-way check valve, filter mesh bag 30 (see FIG. 1B ) may be retained or it may be omitted.
Looking next at FIGS. 2A and 2B , there is shown an alternative form of the present invention as a bidirectional flow filtration and entrapment apparatus 105 . Bidirectional flow filtration and entrapment apparatus 105 of FIGS. 2A and 2B generally comprises a filter device 110 and an entrapment mechanism 115 delivered by a cannula 120 to the interior of a vascular structure 122 (see FIGS. 3A-3D ); a deployable filter frame 125 ; a filter bag 130 attached to the perimeter of deployable filter frame 125 ; a compliant, soft outer cuff 135 (preferably formed out of a biologically inert material such as Teflon, Dacron, Silastic, etc.) for sealing filtration and entrapment apparatus 105 against the inner wall of vascular structure 122 when deployable filter frame 125 is expanded; entrapment leaflets 140 , preferably in the form of a fine filter mesh; a center post 150 (preferably formed out of steel or the equivalent) passing across the interior of the deployable filter frame 125 ; a hinge line 155 on entrapment leaflets 140 , connected to center post 150 , for permitting the entrapment leaflets 140 to open and close; co-aptation strands 160 extending across the interior of deployable filter frame 125 and providing a seat against which entrapment leaflets 140 may close during diastole; and a perimeter seal 165 (preferably formed out of expanded Teflon or the like). Perimeter seal 165 acts like a step to help support entrapment leaflets 140 during diastole.
In addition, it should also be appreciated that soft outer cuff 135 may comprise a radially expandable mechanism (e.g., a balloon, a decompressed sponge, a spring loaded leaflet, etc.) for sealing filtration and entrapment apparatus 105 against the inner wall of vascular structure 122 .
As noted above, entrapment leaflets 140 are preferably formed out of a fine filter mesh. This filter mesh is sized so that it will pass blood therethrough but not debris. Furthermore, this filter mesh is sized so that it will provide a modest resistance to blood flow, such that the entrapment leaflets will open during systole and close during diastole. By way of example but not limitation, the filter mesh may have a pore size of between about 40 microns and about 300 microns.
FIGS. 3A-3D illustrate operation of bidirectional flow filtration and entrapment apparatus 105 shown in FIGS. 2A and 2B . More particularly, cannula 120 of deployable filtration and entrapment apparatus 105 is first inserted through a small incision 170 in the wall of the vascular structure 122 (see FIG. 3A ). Then deployable filter frame 125 is deployed (see FIG. 3B ). Thereafter, during systole (see FIG. 3C ), blood flows through deployable filter from 125 , forcing entrapment leaflets 140 open, and proceeds through filter bag 130 . Any debris contained in the blood is captured by filter bag 130 and thereby prevented from moving downstream past bidirectional flow filtration and entrapment apparatus 105 . During diastole (see FIG. 3D ), when the blood flow momentarily reverses direction, entrapment leaflets 140 (shown in FIGS. 2A and 2B ) close, seating against co-aptation strands 160 (shown in FIGS. 2A and 2B ) extending across the interior of deployable filter frame 140 (shown in FIGS. 2A and 2B ). The blood passes through the fine mesh of entrapment leaflets 140 (shown in FIGS. 2A and 2B ), being filtered as it passes, thus permitting coronary profusion to take place during the diastolic phase. The fine mesh of entrapment leaflets 140 (shown in FIGS. 2A and 2B ) prevents debris from passing back through bidirectional flow filtration and entrapment apparatus 105 .
It should also be appreciated that with bidirectional flow filtration and entrapment apparatus 105 of FIGS. 2A , 2 B and 3 A- 3 D, entrapment leaflets 140 may be attached to structures other than center post 150 , e.g., they may be attached to co-aptation strands 160 , or to deployable filter frame 125 , etc. Furthermore, if desired, entrapment leaflets 140 may be biased closed, or biased open. In addition, entrapment mechanism 15 may consist of one or more flaps (not shown), and have a configuration including, but not limited to, a single disk diaphragm (not shown), a semi-lunar configuration (not shown), a gill slit configuration (not shown), a multi-leaflet flap configuration (not shown), etc.
Looking next at FIGS. 4A and 4B , there is shown a deployable valve/filter apparatus 205 . Deployable valve/filter apparatus 205 of FIGS. 4A and 4B generally comprises a filter device 210 and a valve entrapment mechanism 215 delivered by a cannula 220 to the interior of the vascular structure 222 ; a deployable valve/filter frame 225 ; a filter bag 230 attached to the perimeter of deployable valve/filter frame 225 ; a compliant, soft outer cuff 235 (preferably formed out of a biologically inert material such as Teflon, Dacron, Silastic, etc.) for sealing the filter device 210 against the inner wall of vascular structure 222 when deployable valve/filter frame 225 is expanded; valve leaflets 240 , preferably in the form of a blood-impervious material; a center post 250 (preferably formed out of steel or the equivalent) passing across the interior of deployable valve/filter frame 225 ; a hinge line 255 on valve leaflets 240 , connected to center post 250 , for permitting valve leaflets 240 to open and close; co-aptation strands 260 extending across the interior of deployable valve/filter frame 225 and providing a seat against which valve leaflets 240 may close during diastole; and a perimeter seal 265 (preferably formed out of expanded Teflon or the like). Perimeter seal 265 acts like a step to help support valve leaflets 240 during diastole.
In addition, it should also be appreciated that soft outer cuff 235 may comprise a radially expandable mechanism (e.g., a balloon, a decompressed sponge, a spring loaded leaflet, etc.) for sealing deployable valve/filter apparatus 205 against the inner wall of vascular structure 222 .
FIGS. 5A-5D illustrate operation of deployable valve/filter apparatus 205 of FIGS. 4A and 4B . More particularly, valve/filter apparatus 205 is first inserted through a small incision 270 in the wall of the vascular structure 222 (see FIG. 5A ). Then deployable valve/filter frame 225 is deployed (see FIG. 5B ). Thereafter, during systole (see FIG. 5C ), blood flows through deployable valve/filter frame 225 , forcing valve leaflets 240 open, and proceeds through filter bag 230 . Any debris contained in the blood is captured by filter bag 230 and thereby prevented from moving downstream past valve/filter apparatus 205 . During diastole (see FIG. 5D ), when the blood flow momentarily reverses direction, valve leaflets 240 (shown in FIGS. 4A and 4B ) close, seating against co-aptation strands 260 (shown in FIGS. 4A and 4B ) across the interior of deployable valve/filter frame 225 (shown in FIGS. 4A and 4B ). The closed leaflets 240 (shown in FIGS. 4A and 4B ) prevent blood from passing back through the valve/filter frame 225 (shown in FIGS. 4A and 4B ).
It should also be appreciated that with valve/filter apparatus 205 shown in FIGS. 4A , 4 B and 5 A- 5 D, valve leaflets 240 may be attached to structures other than center post 250 , e.g., they may be attached to co-aptation strands 260 , or to deployable valve filter frame 225 , etc. Furthermore, if desired, valve leaflets 240 may be biased closed, or biased open. In addition, valve entrapment mechanism 215 may consist of one or more flaps (not shown), and have a configuration including, but not limited to, a single disk diaphragm (not shown), a semi-lunar configuration (not shown), a gill slit configuration (not shown), a multi-leaflet flap configuration (not shown), etc.
Looking next at FIGS. 6A-6B , there is shown an orthogonally deployable valve/filter apparatus 305 . Orthogonally deployable valve/filter apparatus 305 of FIGS. 6A-6D generally comprises a filter device 310 and a valve entrapment mechanism 315 deployed at an angle substantially orthogonal to an axis 318 of a cannula 320 , such as a catheter introduced to the vascular system at a location which may be remote from the point of operation, in the interior of a vascular structure 322 ; a deployable valve/filter frame 325 ; a filter bag 330 attached to the perimeter of deployable valve/filter frame 325 ; a compliant, soft outer cuff 335 (preferably formed out of a biologically inert material such as Teflon, Dacron, Silastic, etc.) for sealing the filter device 310 against the inner wall of vascular structure 322 when deployable valve/filter frame 325 is expanded; valve leaflets 340 , preferably in the form of a blood-impervious material, having a first portion 350 in attachment to deployable valve/filter frame 325 , and a second portion 355 separable from deployable valve/filter frame 325 , so as to allow valve leaflets 340 to open and close; and a mesh material 360 extending across the interior of deployable valve/filter frame 325 and providing a seat against which valve leaflets 340 may close during diastole. In addition, it should be appreciated that mesh material 360 may comprise coaptation strands such as coaptation strands 160 as first shown in FIG. 2A .
In addition, it should also be appreciated that soft outer cuff 335 may comprise a radially expandable mechanism (e.g., a balloon, a decompressed sponge, a spring loaded leaflet, etc.) for sealing orthogonally deployable valve/filter apparatus 305 against the inner wall of vascular structure 322 .
In addition, it should also be appreciated that valve entrapment mechanism 315 may be mounted for blood flow in either direction within vascular structure 322 .
FIGS. 6A-6D illustrate operation of deployable valve/filter apparatus 305 . More particularly, deployable valve/filter apparatus 305 is first inserted through the interior of vascular structure 322 to a desired location (see FIG. 6C ). Then deployable valve/filter frame 325 is deployed (see FIG. 6D ). Thereafter, during systole (see FIG. 6A ), blood flows through deployable valve/filter frame 325 , forcing valve leaflets 340 open, and proceeds through filter bag 330 . Any debris contained in the blood is captured by filter bag 330 and thereby prevented from moving downstream past deployable valve/filter apparatus 305 . During diastole (see FIG. 6B ), when the blood flow momentarily reverses direction, valve leaflets 340 close, seating against mesh material 360 across the interior of deployable filter frame 340 . The closed leaflets 340 prevent blood from passing back through the valve/filter frame 325 .
It should also be appreciated that with valve/filter apparatus 305 shown in FIGS. 6A-6D , valve leaflets 340 may be attached to structures other than deployable valve/filter frame 325 , e.g., they may be attached to mesh material 260 , or to cannula 320 , etc. Furthermore, if desired, valve leaflets 340 may be biased closed, or biased open. In addition, valve entrapment mechanism 315 may consist of one or more flaps (not shown), and have a configuration including, but not limited to, a single disk diaphragm (not shown), a semi-lunar configuration (not shown), a gill slit configuration (not shown), a multi-leaflet flap configuration (not shown) etc.
The filter design as described herein to prevent the escape of captured debris during diastole or filter removal may also be applied to all intravascular filters. Such a filter design may comprise a one-way valve and a filtering mesh in series. Liberated debris may pass through the one-way valve and come to rest in the filtering mesh. The one-way valve ensures permanent entrapment of debris. Potential applications of such an apparatus extend to all percutaneous and surgical procedures on the heart and vascular system, including open heart surgery, balloon dilatation of cardiac valves and arteries, deployment of stents in arteries, diagnostic catheterizations, and other cardiac and vascular procedures. Advantages of such a system include more complete collection of liberated debris, with a resulting decrease in the complications attributable to such debris.
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Apparatus for filtering and entrapping debris in the vascular system of a patient, the apparatus including a filter to allow blood to flow therethrough and to restrict passage of debris, wherein the filter captures debris carried in a first direction of blood flow. The apparatus further includes an entrapment mechanism which allows passage of debris and blood therethrough, in the first direction of blood flow and prevents debris passage in a second direction. The entrapment mechanism and filter allow blood and debris therethrough in the first direction of blood flow. The entrapment mechanism prevents debris flow in the second direction of blood flow. A method for filtering and entrapping debris in the vascular system includes inserting the apparatus into the vascular system, allowing blood and debris carried therein to flow through the entrapment mechanism, and removing the apparatus and accumulated debris from the vascular system.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention is generally related to optical component manufacturing and more particularly to protective coatings used in manufacturing optical components.
2. Technical Background
Variable optical attenuators (VOAs), 1×2 switches, and 2×2 switches are non-limiting examples of photonic devices which use a multiclad coupler. In these applications, the coupler requires a protective coating at the taper region to protect the coupler from breakage during the normal handling associated with assembly of the devices as well as during the functioning of the device. In the devices listed above, the coupler is flexed to attenuate the light signal propagating in the device. Any properties of the coating that degrade the optical signal are undesirable. Thus, the application of the coating must not negatively impact the attenuation response of the coupler after it is incorporated into the device.
FIG. 1 depicts an exemplary variable optical attenuator (VOA) 20 which uses a multiclad coupler 22 and a servomotor 26 . Coupler 22 includes an input fiber 28 and two output fibers 30 and 32 . First output fiber 30 is the output of VOA 20 and second output fiber 32 acts as a “dead-end” lead. An optical signal passes from input fiber 28 to either first output 30 or second output 32 through taper region 24 which couples the light signal from fiber 30 to fiber 32 . Flexing coupler 22 at taper region 24 by different amounts via servomotor 26 causes more or less of the light signal to be transmitted to the dead-end fiber 32 . The amount of flexing controls the attenuation of the signal. Thus, tapered region 24 functions as a commutator.
FIG. 2 depicts an optical step response 10 that was generated by an optical switch having a coupler without a coating in the tapered region. As depicted in FIG. 1, the tapered region is moved between a first unflexed position to a second flexed position, at the time of switching, T sw . The first position corresponds to a signal transmission state 12 wherein the insertion loss is approximately zero. The second state corresponds to a signal attenuation state 14 wherein the insertion loss is approximately 19.3 dB. Note that the plot of the insertion loss as depicted in FIG. 1 a is a square-wave. The insertion loss in both the first state and the second state is substantially constant. This is a desired response. Unfortunately, the coupler represented by FIG. 2 does not have a coating. It is unprotected and susceptible to breakage.
In one approach that has been taken, couplers have been coated with a cationic ultraviolet (UV) curable epoxy system. FIG. 3 depicts the insertion loss response 10 of the switch of FIG. 2 having a coupler that is coated with the cationic UV epoxy. Again, the tapered region is moved between a first unflexed position to a second flexed position, at the time of switching, T sw . IL swc is the peak insertion loss of the coated coupler at the time of switching (T sw ). IL swc overshoots the insertion loss IL swu of the uncoated coupler in the attenuation state. IL swu is used a reference insertion loss value. Peak insertion loss IL swc is followed by hysteresis 12 , which is the decay of the peak insertion loss IL swc to IL swu . IL Δsw =¦IL swc −IL swu ¦ and represents the absolute value of the difference between the peak insertion loss of the coated coupler at the time of switching and the insertion loss of the uncoated coupler in the second state. As shown in FIG. 3, IL Δsw =23 dB−19.3 dB=3.7 dB. This formula is used to accommodate a coating material that generates a peak insertion loss IL swc that undershoots IL swu .
It is useful to measure hysteresis 12 in terms of its decay time T D . The decay time T D is a measure of the time it takes for peak insertion loss IL swc to decay to IL swu . As depicted in FIG. 3, the cationic ultraviolet (UV) curable epoxy system produces transients that have a decay time T D lasting approximately 14 seconds. As depicted, the decay of the transient hysteresis continues for several minutes. In more rigorous terms, T D is defined as T D =T 1 −T sw , wherein T sw is the time at which the coupler is switched from the first state to the second state, and T 1 is the time at which peak insertion loss IL swc decays to IL D . IL D =(0.27)IL Δsw =(0.27)¦IL swc −IL swu ¦, which represents an exponential decay over time.
When the device is commutated from the second position to an unflexed first position at time T usw , a second hysteresis 16 is generated. The analysis discussed above with respect to hysteresis 12 can be used to analyze hysteresis 16 . As depicted, its decay time will also last several minutes. Both hysteresis 12 and hysteresis 16 are undesirable and illustrate the unwanted transients produced by the coating immediately after switch commutation. Another drawback to the cationic ultraviolet (UV) curable coating is that it is colorless. It is difficult to determine that the coating has been applied.
What is needed is a protective coating that does not generate the unwanted optical transients and hysteresis produced by earlier approaches. An optical device is needed that settles into a quiescent state immediately after commutation. Furthermore, the protective coating should include a tinted material. Since clarity is important, the tinted material should allow internal areas in the coupler to be viewed through the coating.
SUMMARY OF THE INVENTION
The present invention overcomes the aforementioned disadvantages as well as others. In accordance with the teachings of the present invention, the coating protects optical devices without generating unwanted optical side effects during flexing. The coating adheres readily to the glass of the waveguide component. The coating has a tint so that it can be readily ascertained that the coating has been applied, but also has sufficient clarity so that the internal areas in the component may be viewed. In one embodiment a UV coating cures to a tack free state in air so that a nitrogen blanket is not required during the cure. A solvent based coating such as a lacquer can also be used. The coating also does not degrade when exposed to relatively severe environmental conditions.
One aspect of the present invention is an optical device for directing a light signal. The optical device includes a commutation region movable between a first position corresponding to a signal transmission state, and a second position corresponding to a signal attenuation state. A protective coating is disposed on the commutation region that does not substantially introduce insertion loss transients when the commutation region is moved between the first position and the second position.
In another aspect, the present invention includes a method of directing a light signal in an optical device having a first output, and a commutation region movable between a first position corresponding to a signal transmission state, and a second position corresponding to a signal attenuation state. The method includes the steps of applying a protective coating onto the commutation region. Directing a light signal into the optical device. Moving the commutation region from the first position to the second position to thereby attenuate the light signal in the first output, whereby the protective coating does not substantially produce insertion loss transients in the optical device.
In yet another aspect, the present invention includes a method of fabricating an optical device, the optical device having a commutation region movable between a first position corresponding to a signal transmission state, and a second position corresponding to a signal attenuation state. The method including the steps of providing a coating material. Applying the coating material to the commutation region, wherein the coating material does not substantially produce insertion loss transients when the commutation region is moved between the first position and the second position.
Additional features and advantages of the invention will be set forth in the detailed description which follows, and in part will be readily apparent to those skilled in the art from that description or recognized by practicing the invention as described herein, including the detailed description which follows, the claims, as well as the appended drawings.
It is to be understood that both the foregoing general description and the following detailed description are merely exemplary of the invention, and are intended to provide an overview or framework for understanding the nature and character of the invention as it is claimed. The accompanying drawings are included to provide a further understanding of the invention, and are incorporated in and constitute a part of this specification. The drawings illustrate various embodiments of the invention, and together with the description serve to explain the principles and operation of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a variable optical attenuator having a tapered region, in accordance with the present invention;
FIGS. 2 is a plot of insertion loss with respect to time, illustrating the optical response of an optical device without a coating;
FIGS. 3 is a plot of insertion loss with respect to time, illustrating the optical response of an optical device having a cationic ultraviolet (UV) curable epoxy coating;
FIG. 4 is a detail view of a multiclad coupler having a coating in accordance with the present invention;
FIG. 5 a flowchart depicting the steps associated with applying the coating of the present invention to an exemplary optical component; and
FIGS. 6 is a plot of insertion loss with respect to time, illustrating the optical response of an optical device having a coating in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Reference will now be made in detail to the present preferred embodiments of the invention, an example of which is illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts. An exemplary embodiment of the optical device of the present invention is shown in FIG. 1, and is designated generally throughout by reference numeral 20 .
In accordance with the invention, the present invention for a protective coating for optical components includes a commutation region that is flexed between a first position and a second position. The first position corresponds to a signal transmission state having negligible insertion loss. The second position corresponds to a signal attenuation state. One of ordinary skill in the art will recognize that the device can be flexed over a range of positions depending on the required degree of attenuation. A protective coating is disposed on the commutation region that does not substantially alter an insertion loss characteristic of the optical device when the commutation region is moved between the first position and the second position. In other words, any transients or hysteresis generated by the coating during commutation have a duration of less than one second.
As embodied herein and depicted in FIG. 1, a perspective view of a variable optical attenuator 20 is shown. In accordance with the present invention, coupler 22 has a protective coating disposed on tapered region 24 . The protective coating of the present invention protects coupler 22 from breakage due to handling during device assembly, and during flexure when the device is commutated. As discussed above, the protective coating does not generate the unwanted optical transients and hysteresis of earlier approaches. One of ordinary skill in the art will recognize that the protective coating compositions of the present invention is not limited to the VOA depicted in FIG. 1, but rather includes all types of photonic components that may undergo flexing. For example, a 2×2 switch commutated by a flexing motion can use the protective coating compositions of the present invention.
FIG. 4 is a detail view of the type of multiclad coupler 22 that is used in the optical device depicted in FIG. 1 . As embodied herein and depicted in FIG. 4, coupler 22 has a flexible acrylate coating 40 that is disposed on tapered region 24 . Flexible acrylate coating 40 has a thickness 42 . In this embodiment, coating thickness 42 is approximately 25 microns and coupler thickness 44 is approximately 65 millimeters.
EXAMPLE
The invention will be further clarified by the following example which is intended to be exemplary of the invention. The protective coating of the present invention is a low viscosity, low modulus, flexible acrylate coating that is cured in air to a tack free state. The coating is based on an acrylate oligomer and monomers that are available from such suppliers as Sartomer Corporation. The oligomer is CN 966 180 which is an aliphatic urethane acrylate oligomer blended in an 80:20 ratio with propoxylated neopentyl glycol diacrylate monomer in order to reduce the viscosity of the oligomer. This oligomer is a highly flexible material which provides the low modulus desired in the switch application while the flexibility enhances the adhesion of the coating to the coupler. The coating composition of the present invention as depicted in FIG. 4 is shown in Table 1:
TABLE 1
Material
Level (phr)
Exemplary Supplier
CN 966 I80
30
Sartomer Corporation
SR-501
30
Sartomer Corporation
SR-9003
40
Sartomer Corporation
Irgacure 1850
3
Ciba Corporation
Irganox 1035
2
Ciba Corporation
Resiflow LG-99
2
Estron Chemical
A-174 Silane
4
OSi Corporation
Triphenylphosphine
5
Aldrich Chemical
PCB-1
3
Corning ICA Lab
(Note: “phr” indicates parts per hundred resin).
SR-9003 is propoxylated neopentyl glycol diacrylate. This difunctional monomer serves as a reactive diluent. SR-501 is propoxylated trimethylolpropane triacrylate and provides a fast cure response. These monomers' properties include water resistance, abrasion resistance and good adhesion.
The remainder of the formulation includes various additives with different functions. Irgacure 1850 from Ciba is a photoinitiator. It is a 50:50 blend of bis (2,6-dimethoxybenzoyl)-2,4,4-trimethyl pentyl phosphine oxide and 1-hydroxy-cyclohexyl-phenyl-ketone. Its function is to absorb the UV light and initiate the polymerization reaction by generating free radicals. Irganox 1035 is also supplied by Ciba and is an antioxidant used to protect the coating against thermal yellowing and degradation. Resiflow LG-99 is an acrylate functional flow and wetting agent from Estron Chemical. It provides good wetting to the glass as well as aids in the leveling of the coating after application which helps to ensure a smooth even layer.
The A-174 is a methacrylate functional silane coupling agent from OSi Corporation. It provides increased adhesion to the glass and is particularly useful for maintaining adhesion after high humidity exposure. Triphenylphosphine, from Aldrich, has been added to overcome the oxygen inhibition at the surface of the coating when cured in air. This additive allows the coating to be cured to a tack free state in air without having to resort to the use of a nitrogen blanket to provide an inert atmosphere, thus making the use of this coating in a production environment easier.
The PCB-1 is a Corning developed pigment dispersion. The function of the dispersion is to provide enough color so that the coating is visible after application. The use of a very small particle size transparent (<0.5 micron) pigment helps to ensure that the coating retains the clarity needed for viewing the air lines (Note: some pigments have particle sizes this small but are opaque pigments, for example, TiO 2 ). The composition for this dispersion is provided in Table 2:
TABLE 2
Material
Level (phr)
Exemplary Supplier
Hostaperm Blue B2G
20
Clariant
SR-9003
80
Sartomer Corporation
Disperbyk 164 (60% solids)
15
BYK Chemie
The pigment is a copper pthalocyanine blue pigment (CI 15:3) from Clariant. Disperbyk 164 is a proprietary polymeric dispersing agent supplied by BYK Chemie at a 60% solids loading in butyl acetate. The function of the dispersing agent is to provide steric stabilization of the pigment particles once they are dispersed into the monomer. Finally, the monomer used in the dispersion is the SR-9003. It was chosen for its relatively low surface tension which results in good pigment wetting. One of ordinary skill in the art will recognize that the present invention is not limited to the above described pigment dispersion, but can also include the use of any commercially supplied pigment dispersion or dye that achieves the tint requirement. For example, a dispersion source from US Colors and Coatings can also be used.
The modulus of elasticity of coating 40 is approximately 3.1×10 8 Pa (modulus at 25° C.), and the viscosity range of coating 40 is 200 to 600 centipoises (cps). One of ordinary skill in the art will recognize that alternate embodiments of the present invention include modulus of elasticity values of 4.0×10 8 Pa (modulus at 25° C.) and higher. Furthermore, one of ordinary skill in the art will recognize that the present invention is not limited to these values, but rather such values vary depending on application and other physical properties such as creep, and stress relaxation.
Coating 40 performed well under environmental testing and did not exhibit degradations such as delamination from the glass, flaking, adhesion problems, or peeling. Overall, coating 40 of the present invention is a low viscosity, low modulus, flexible acrylate coating that cures rapidly to a tack free state in air.
As embodied herein and depicted in FIG. 5, a process for applying coating 40 to coupler 22 is shown. The coating application process starts at step 50 wherein a brush is used to apply coating to the taper region of a coupler. The coating is cured at step 52 . In the preferred embodiment, the coating is cured for approximately 90 seconds with a UV light source, such as with a Lessco Superspot UV light. The coating is placed under a Bondwand for preferably approximately 30 minutes at step 54 . Finally, the coating is exposed to 125° C. for 4 hours during thermal postcure of the funnel adhesive at step 56 . One of ordinary skill in the art will recognize that the present invention is not limited only the above-described parameters but includes operating the process with parameters sufficient to achieve the intended effect. For example, in alternate embodiments, the protective coating of the present invention are a solvent based coatings or lacquers.
As discussed above, FIG. 2 depicts the optical step response 10 of an optical device 20 that uses a coupler without a coating in the tapered region. As embodied herein and depicted in FIG. 6, a plot of insertion loss with respect to time, illustrating the response 82 of an optical device having coating 40 in accordance with the present invention is disclosed. FIG. 6 illustrates the advantages of the present invention, and in particular the substantial reduction of the hysteresis effect by the coating of the present invention.
Using the terminology developed above, FIG. 6 shows a peak insertion loss IL swc of the coated coupler at time T sw of approximately 17.03 dB. As shown, IL swc overshoots the insertion loss IL swu of the uncoated coupler (16.93 dB) by 0.1 dB. Thus, IL Δsw =¦IL swc −IL swu ¦=0.1 dB. In terms of decay time T D , the optical device employing coating 40 of the present invention exhibited a decay time T D of approximately 0.9 seconds.
One of ordinary skill in the art will understand that there are numerous applications and implementations for the present invention. For example, the coating formulation of the present invention includes any type of UV curable formulation cured by either a free radical or cationic polymerization mechanism. For example, the coating formulation of the present invention includes such materials that cure cationically as epoxies and vinyl ethers. Other coating formulations include free radical cationic hybrids so that the advantages inherent in both chemistries can be realized. Also, the present invention includes using UV cure/thermal hybrids. The UV cure portion provides for a quicker process cure while the thermal portion cures during the 4 hour 125° C. thermal postbake (i.e., during step 56 of FIG. 5 ). One of ordinary skill in the art will also recognize that lacquer or solvent based coatings including thermoset or thermoplastic polymer formulations are within the scope of the present invention.
It will be apparent to those skilled in the art that various modifications and variations can be made to the present invention without departing from the spirit and scope of the invention. Thus, it is intended that the present invention cover the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents.
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A coating and a method for protecting a flexible region of an optical device that generates different output optical signals based upon whether the region is flexed. The coating is applied to at least a portion of the region. The coating has a relaxation time that does not substantially affect the different output optical signals transmitted through the region while the region is being flexed and then unflexed.
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This is a continuation of application Ser. No. 08/614,029 filed 12 Mar. 1996, now U.S. Pat. No. 5,675 599 which is a continuation of application Ser. No. 08/124,124 filed 20 Sep. 1993, now abandoned.
BACKGROUND OF THE INVENTION
The present invention relates to an optical transmission device which is used for a short range optical data link or an optical communication system for subscribers and more particularly to an optical transmission device which requires no automatic optical power control.
PRIOR RELATED ART
When an automatic optical power control method, that is, "a control method for monitoring optical power of a laser diode, feeding back a bias current and electric modulation current, and obtaining fixed optical power from the laser diode without depending on changes in the electric threshold current value which are caused by temperature changes" is used, the circuit configuration becomes complicated.
Therefore, a great deal of attention has been recently given to driving a laser diode by zero-bias or fixed-bias.
One article "Sub-system optical interconnections using Long Wave-length Laser Diode and Single-mode Fiber Arrays" (1992 Technical Report of the Institute of Electronics, Information and Communication Engineers (Optical Communication System), OCS92-30, p 31), describes driving of a laser diode and unformatted optical signal transmission by fixed level decision receiving system.
On the other hand, the article, "APC Free Zero-Bias Modulation of an Alignment-free Optical Coupled 4-Channel Optical Module" (1992 Spring National Convention Record, The Institute of Electronics, Information and Communication Engineers, paper B-1008 (1992)), describes a fixed-bias driving experiment with a laser diode. In this second article, a bias electric current I b is set so that it becomes equal to an electric threshold current value Ith of the laser diode at a high temperature in the operating temperature area range (I b =I th (at a high temperature)). When a non-return-to-zero coding (NRZ) signal having a mark ratio which is almost 1/2 is received, "0" or "1" is identified generally on the average received optical power level, so as to prevent the optical power of the laser diode at a high temperature from lowering. Because the electric threshold current value increases as the temperature rises.
Problems that the Invention is to Solve
However, in the state that the fixed-bias electric current is set so that it becomes equal to the electric threshold current value of the laser diode at a high temperature in an assumed operating temperature area range as in the second article, the fixed-bias electric current becomes larger than the electric threshold current value of the laser diode at a low temperature in the operating temperature area range (I b >I th (at a low temperature)). Therefore, the optical power level (extinction level) increases when an electric input signal to the laser diode is off and it disturbs unformatted data optical transmission by fixed level decision receiving system described in the first article.
Namely, it is required to set the fixed decision level of the receiver side to a high value, so that the minimum optical power from the laser diode which is necessary to identify "1" on the receiver side increases.
As shown in a measurement example of turn-on delay time of the laser diode in FIG. 4a, when zero-bias driving is carried out for the laser diode, the turn-on delay time increases compared with that when a bias electric current is applied to this laser diode.
The present invention minimizes the turn-on delay time of a laser diode and allows unformatted optical signal transmission by fixed level decision receiving system.
Means of Solving the Problems
This accomplished by driving a laser diode in the state that a fixed-bias electric current which is not more than the electric threshold current value of the laser diode is applied by using a driving circuit of laser diode having a means of applying a fixed-bias electric current which is not more than the electric threshold current value.
By applying a fixed-bias electric current which is not more than the electric threshold current value of a laser diode to the laser diode, the turn-on delay time of the laser diode can be minimized.
Since the extinction level can be lowered, the fixed level decision receiving system can be used and the optical receiver circuit can be simplified.
Furthermore, the optical receiver circuit using the above constitution can be simplified compared with that when the automatic optical power control is applied.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows an embodiment of the driving circuit of laser diode of the present invention.
FIG. 2 is a drawing showing a bias electric current of the driving circuit of laser diode and the dependency of electric threshold current value of the laser diode on temperature.
FIG. 3 is a drawing showing an optical transmission device using the driving circuit of laser diode.
FIGS. 4a and 4b are drawings showing characteristics of the laser diode.
FIG. 5 shows an array example of the circuit of the embodiment shown in FIG. 1.
DETAILED DESCRIPTION
FIG. 1 shows an embodiment of the driving circuit of laser diode of the present invention.
An electric input signal 1 is supplied to a laser diode 3 via a current switch 2. A fixed-bias electric current I b which is not more than the electric threshold current value I th of the laser diode is applied to the laser diode 3 by a bias circuit 4. To produce the circuit, the Si bipolar IC process is used. FIG. 2 shows a bias electric current of the driving circuit of laser diode and the dependency of electric threshold current value of the laser diode on temperature which will be described later.
The bias electric current of a driving circuit of laser diode 5 ranges from 1.64 mA to 2.75 mA within the operating temperature area range from 20° C. to 80° C. under the condition that the supply voltage variation of the driving circuit is 10% and the resistance variation due to the production process variation is 20%.
On the other hand, the electric threshold current value of the laser diode 3 ranges from 2.92 mA to 10.33 mA within the operating temperature area range from 20° C. to 80° C. under the condition that the electric threshold current value at 25° C. when the characteristic temperature is 55° C., varies within a range from 3.2 mA to 3.8 mA.
When the laser diode 3 is mounted in the neighborhood of the driving circuit of laser diode 5 so as to make the temperatures of the two almost equal, the electric threshold current value of the laser diode 3 varies as shown in FIG. 2 within the entire temperature range from 20° C. to 80° C. and the bias electric current of the driving circuit of laser diode can be set less than the electric threshold current value of the laser diode actually on the side of the driving circuit of laser diode 5 regardless of characteristics of the laser diode 3 such as changes in the electric threshold current value due to changes in the temperature.
In the embodiment shown in FIGS. 1 and 2, since the bias electric current of the driving circuit of laser diode 5 is not more than the electric threshold current value of the laser diode, the extinction level is almost that of spontaneous emission light such as about -30 dBm. Furthermore, FIG. 3 shows an optical transmission device using the driving circuit of laser diode and the fixed level decision optical receiver described in the 1992 Technical Report referred to above.
Therefore, for example, by combining an optical transmission device having this constitution and the fixed level decision optical receiver described in that Technical Report, unformatted optical signal transmission can be carried out.
When a bias electric current of about 2.0 mA which is smaller than the electric threshold current value 2.8 mA of the laser diode is applied as shown in the example in FIG. 4(a), for example, at 25° C., the turn-on delay time can be reduced to about 1/7 of that in the case of zero-bias driving.
FIGS. 4(a) and 4(b) show characteristic examples of the laser diode. FIG. 4(a) shows the relationship between turn-on delay time T d and ln((I d -I b )/(I d -I th ) when the driving current of laser diode I d is fixed at 20 mA and the bias electric current I b is changed at 25° C. The electric threshold current value Ith of this laser diode at 25° C. is 2.8 mA.
The increasing rate for turn-on delay time decreases from around the point where Ib becomes larger than 1.0 mA. It is found that the point is in the neighborhood of the current value corresponding to a threshold voltage Vth of I b -V plot when the static characteristic graph (dependency of forward voltage and resistance on bias electric current) shown in FIG. 4(b) is compared with FIG. 4(a).
The semiconductor laser is a semiconductor device having a pn junction. Therefore, when a forward bias of approximately the built-in potential of the laser diode is given beforehand, the resistance of the laser diode decreases and an electric current can be easily supplied to the laser diode.
Therefore, when the bias electric current is preset above the current value corresponding to threshold voltage V th of I b -V plot, variations of the turn-on delay time due to temperature changes of the laser diode can be minimized.
The manifestation of this embodiment can be realized, for example, by the following methods.
(i) An electric signal of all "0" is supplied to the driving circuit of laser diode and the emission light spectrum from the laser diode is observed. Namely, when the electric signal of all "0" is inputted, only a bias electric current smaller than the "electric threshold current value" is supplied to the laser diode, so that the laser diode generates no laser beam and the output optical spectrum is seen broad.
Therefore, by observing the emission light spectrum by an optical spectrum analyzer, it is found that the bias electric current of driving circuit of laser diode is smaller than the electric threshold current of the laser diode.
(ii) The coherence length of the emission light from the laser diode is changed greatly before and after the laser diode starts laser oscillation. Therefore, by observing the coherence length, it is found that the the bias electric current of driving current of driving circuit of laser diode is smaller than the electric threshold current of the laser diode.
In the embodiment shown in FIG. 1, the Si bipolar IC process is used to produce a driving circuit of laser diode. However, other bipolar, MOS, or FET systems may be used. The laser diode may be produced on a n-substrate, too.
In the above embodiment, an example that a bias electric current which is smaller than the electric threshold current value and larger than the current value corresponding to threshold voltage V th is applied to the laser diode is shown. However, there are no restrictions on it. A bias electric current which is smaller than the current value corresponding to V th may be applied depending on the system demands.
The driving circuit of the laser diode of the embodiment shown in FIG. 1 may be modified to a monolithic array circuit as shown in FIG. 5 as indicated in the 1992 Technical Report described in the background section of this specification. The circuit is a monolithic circuit consisting of a plurality of channels.
As mentioned above, by constructing a multi-channel optical transmitter having a laser diode array and a driving circuit array of laser diode array having a means of applying a fixed-bias electric current which is not more than each electric threshold current value of the laser diode array, a multi-channel optical transmitter having a small electric crosstalk can be constructed.
By combining this multi-channel optical transmitter with the fixed level decision optical receiver described in the prior art, a high-speed, unformatted data parallel optical signal transmission device which has a small crosstalk can be constructed.
Furthermore, a characteristic which is unrelated to the characteristics of the laser diode, for example, an intended temperature characteristic may be given to the fixed bias electric current of the driving circuit of laser diode.
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An optical transmission device which is used for a short range optical data link or an optical communication system for subscribers and more particularly requires no automatic optical power control minimizes the turn-on delay time of a laser diode and allows unformatted optical signal transmission by fixed level decision receiving system. By applying a fixed-bias electric current which is not more than the electric threshold current value of the laser diode to the laser diode, the turn-on delay time of the laser diode can be minimized, and the extinction level can be lowered by it, and the fixed level decision receiving system can be used, and the optical receiver circuit can be simplified more.
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The present application is a divisional of application Ser. No. 566,760, filed Aug. 14, 1990, now U.S. Pat. No. 5,153,299.
FIELD OF THE INVENTION
The present invention relates to a production method of novel condensates of aromatic aminosulfonic acids with bisphenols, in particular, novel 4-aminobenzenesulfonic acid-2, 2-bis(4-hydroxyphenyl)propane-formaldehyde type condensate and the condensate itself. The invention is also concerned with a dispersant for disperse dye, which gives a dye dispersion excellent in high-temperature distensibility, less in contaminability and excellent in leveling property, an additive for carbonaceous fine powder-water slurry, which gives a water slurry high in viscosity-reducibility, less in fluidity change over time and excellent in transportability through pipe line, and a water-reducing agent for cement compositions such as cement paste, mortar and concrete, which has high water-reducibility, less decrease in fluidity over time and improved executability and workability, all of them being based on said condensates.
BACKGROUND OF THE INVENTION
Recently, as a water-reducing agent which improves the consistency of cement compositions and which decreases the change in fluidity such as slump loss with the lapse of time, a condensation product with high-molecular weight used aromatic aminosulfonic acids and phenols has been developed (Japanese Unexamined Patent Publication No. Hei 1-113419).
In this reaction, however, unreacted aromatic aminosulfonic acid showing no water-reducing property (dispersibility) ends up to remain in large amounts. This is considered to be due to the fact that phenols tend to make homopolymer. In addition, because of this property of phenols, the stability under acidic condition etc. cannot be said to be good.
In the invention, a condensate is provided, which has aromatic aminosulfonic acid as a component, in which unreacted aromatic aminosulfonic acid being an ineffective component is decreased to the utmost and yet which has more excellent performance and is useful in wider scope of fields over conventional aromatic aminosulfinic acid type condensate by imparting polar group, heat-resistant structure and stericity to the hydrophobic skeleton.
Next, the disperse dye has been mainly used so far for dyeing polyester fibers etc. This is made up to be dispersed stably into water by using dispersing agent, since the dye itself of disperse dye is insoluble or hard soluble into water.
As dispersing agents in such case, lignin sulfonic acid, naphthalenesulfonic acid-formaldehyde condensate, etc. have been used.
Lignin sulfonic acid is excellent in dispersibility at high temperature and exhibits good dispersibility even in a high-temperature region such as the case of dyeing polyester fibers. On the other hand, however, it tends to contaminate the cloths.
Moreover, with naphthalenesulfonic acid-formaldehyde condensate, the contaminability is low in an ordinary temperature region and it is excellent in this respect. But, it has a problem on the high-temperature dispersibility, thus the dispersibility decreases to the utmost in a high-temperature region.
Besides these lignin sulfonic acid and naphthalenesulfonic acid-formaldehyde condensate, a condensation product comprising cresol, 2-hydroxynaphthalene, sulfite and formaldehyde (Japanese Unexamined Patent Publication No. Sho 54-30983) etc. have been developed, but they are insufficient in any of high-temperature dispersibility, contaminability and leveling property.
As a result of diligent investigations on the dye dispersion which exhibits excellent dispersibility even in a high-temperature region, less contaminability and excellent leveling property, the inventors have reached the invention.
Next, accompanying with the worsening circumstances of oil supply, the coal, which is abundant in resources, lies in wide deposit areas and distributes over all parts of the world, has been reconsidered as an energy source in substitution for oil.
Moreover, the petroleum coke being a distillation residue of oil, which found little utilization hitherto as an energy source, has also become to attract attention as an important energy source.
However, the carbonaceous fine powder of coal, petroleum coke, etc. is solid material as opposed to oil making it impossible to transport by pump. For this reason, a method of pulverizing coal and petroleum coke, dispersing them into water and converting to water slurry has been put into practice.
In this case, however, the increase in the concentration of coal and petroleum coke brings about markedly increased viscosity to lose the fluidity and, inversely, the decrease in the concentration of coal and petroleum coke brings about decreased transport efficiency and also expenditure for the dehydration process, leading to impracticability.
Moreover, there is a problem in storage because of the change in produced slurry with the lapse of time, that is, early coagulation and sedimentation of carbonaceous fine powder.
As a method for raising the concentration of carbonaceous fine powder in this carbonaceous fine powder-water slurry and yet producing fluidized carbonaceous fine powder-water slurry, the addition of dispersing agent has been proposed.
For example, as a dispersing agent for coal-water slurry, naphthalenesulfonic acid-formaldehyde condensate (Japanese Unexamined Patent Publication No. Sho 62-16893) can be mentioned. As dispersing agent for petroleum coke-water slurry, polyether compound (Japanese Unexamined Patent Publication No. Sho 59-91195) etc. can be mentioned.
All of these however can hardly be said to be sufficient in viscosity-reducing property and storage stability.
Hence, a dispersing agent having high viscosity-reducing effect at lower addition level and high storage stability of slurry is still demanded.
As a result of diligent studies in detail on aromatic aminosulfonic acid type polymers, the inventors have succeeded in the development of a dispersing agent having high viscosity-reducing effect at lower addition level and yet high storage stability of carbonaceous fine powder-water slurry.
Finally, various water-reducing agents are used recently in the mortar constructions, concrete constructions, etc. aiming at the improvement in different physical properties such as improved workability, enhanced strength and durability and decreased cracking property, but high-performance AE water-reducing agent is still demanded.
So far, as the water-reducing agents for cement, salt of sulfonated melamine resin, polycarboxylate, salt of naphthalenesulfonic acid-formaldehyde high-degree condensate, lignin sulfonate, etc. have been utilized. However, with salt of sulfonated melamine resin, the water-reducing effect is low and high level of addition is required and, with polycarboxylate, the water-reducing effect is high, but increased level of addition causes a remarkable retardation of setting resulting in the deficiency of hardening as the case may be. With salt of naphthalenesulfonic acid-formaldehyde high-degree condensate, the water-reducing effect is high, the retardation of setting is low and the air-entraining property is also low, but the decrease in fluidity of mortar and concrete over time is significant. With lignin sulfonate, the water-reducing effect is high, but the air incorporation is high affecting inversely on the physical properties of mortar and concrete. These and others have been problematic points.
In recent, a concrete-admixing agent containing aromatic aminosulfonic acid-phenol-formaldehyde condensate has been developed (Japanese Unexamined Patent Publication No. Hei 1-113419). It is said that this admixing agent improves the consistency of cement composition and decreases the change in fluidity such as the slump loss with the lapse of time. With this, however, further improvements in high amount of residual monomer on condensation etc. are desired as described earlier.
As a result of diligent studies aiming at the decreased residual monomer (aromatic aminosulfonic acid) in aromatic aminosulfonic acid type admixing agent and the further improvement in fluidity of cement compositions without injuring the preventive effect on decrease in fluidity over time by imparting polar group and stericity to the hydrophobic skeleton, the inventors reached the invention.
SUMMARY OF THE INVENTION
The first of the invention is to provide a production method of novel condensates obtainable by condensing compounds represented by a general formula (I) ##STR1## wherein X indicates any of ##STR2## or --O--(R 1 , R 2 and R 3 indicate each independently hydrogen or alkyl group and R 4 indicates aklyl group)], or their salts and aromatic aminosulfonic acids represented by a general formula (II) ##STR3## [wherein Y indicates hydrogen or alkyl group], or their salts with formaldehyde in the presence of alkali catalyst.
When the compound represented by said general formula (I) is 2, 2-bis(4-hydroxyphenyl)propane represented by a formula (I)" ##STR4## or its salts and the compound represented by the general formula (II) is 4-aminobenzenesulfonic acid represented by a formula (II)' ##STR5## or its salts, the novel condensate obtainable is presumed to be 4-aminobenzenesulfonic acid-2, 2-bis(4-hydroxyphenyl) propaneformaldehyde type condensate represented by a following general formula (III). ##STR6## [wherein n is an integer of 1 to 20].
The dispersant for disperse dye being the second of the invention is the condensation products of compounds (I) or their salts and aromatic aminosulfonic acids (II) or their salts with formaldehyde in the presence of alkali catalyst.
Moreover, the additive for carbonaceous fine powder-water slurry and the water-reducing agent for cement being the third and the fourth of the invention, respectively, have condensates obtainable by condensing 4-aminobenzenesulfonic acid (II)' or its salts and bisphenol compounds represented by a following general formula (I)' ##STR7## wherein X indicates ##STR8## or --O--], their salts with formaldehyde as major components.
Besides, another type of water reducing agent for cement has 80 to 20 parts by weight of said condensates of 4-aminobenzenesulfonic acid (II)' or its salts and bisphenol compounds (I)'or their salts with formaldehyde and 20 to 80 parts by weight of lignin sulfonate treated the sulfite pulp spent liquor through ultrafiltration until the reducible sugars become to not more than 5% or lignin sulfonate containing not less than 0.20 mol of carboxyl group and not less than 0.10 mol of sulfonic group per phenylpropane unit as major components.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a gel permeation chromatogram of the condensate of Example 1,
FIG. 2 and FIG. 3 show infrared spectra thereof, and
FIG. 4 shows a nuclear magnetic resonance spectrum thereof.
DETAILED DESCRIPTION OF THE INVENTION
In the invention, as the compounds represented by the general formula (I), ##STR9## can be used preferably. It is also possible to vary the properties by combining these.
In the invention, the condensation reaction is performed at rates of 20 to 150 parts by weight of bisphenols represented by the general formula (I) or their salts and 20 to 65 parts by weight of formaldehyde to 100 parts by weight of aromatic aminosulfonic acids represented by the general formula (II) or their salts. Preferably, total molar ratio of one or not less than two kinds of compounds of general formula (I) or their salts, molar ratio of compounds of general formula (11) or their salts and molar ratio of formaldehyde are made to be 0.3-1.0:1.0:1.5-3.0. In the case of additive for carbonaceous fine powder-water slurry, however, the molar ratios of bisphenols, 4-aminobenzenesulfonic acid and formaldehyde are maintained at 0.3-0.8:1.0:1.0-3.0, respectively.
Moreover, the alkali catalysts to be used are metal oxides such as sodium hydroxide, calcium hydroxide and potassium hydroxide, hydroxide of ammonium bases, etc. It is preferable to use 0.5 to 2.0 mol equivalent of them to 1 mol of aromatic aminosulfonic acids represented by the general formula (II). In the case of water-reducing agent for cement, the addition rate of alkali is preferable to be 0.95 to 1.05 mol to 1 mol of 4-aminobenzenesulfonic acid when bisphenol compounds/4-aminobenzenesulfonic acid=1/1.
If out of these ranges of molar ratio and molar equivalent, the amount of unreacted aromatic aminosulfonic acid tends to increase. Such condensation reaction can be performed in suitable solvent not causing the condensation, but, preferably, it is performed through solid-liquid reaction by mixing bisphenols represented by the general formula (I), aromatic aminosulfonic acids represented by the general formula (II) and alkali with water. In this case, though the bisphenols represented by the general formula (I) are hard to dissolve into water (except the case of strong alkaline condition), they dissolve with the progress of reaction.
Moreover, salts of aromatic aminosulfonic acids may be dissolved into water and bisphenols are added to this to react. In this case, pH value of aqueous solution of aromatic aminosulfonates is preferable to be adjusted to 7 to 12 with alkali catalyst. If out of this range, the amount of unreacted aromatic aminosulfonic acid tends to increase.
The reaction temperature is 60° to 110° C. and the reaction time is preferably 4 to 20 hours, though not limited particularly. Moreover, if reacting again by adjusting to strong alkaline condition (pH value of 10 to 13) after the reaction for several hours, the progress of condensation would become rapid.
Furthermore, it is desirable to add formaldehyde dropwise over 1 to 3 hours and the reaction concentration is made usually to be 20 to 50 wt. %.
The condensates of the invention comprising bisphenols and aromatic aminosulfonic acids make it possible to extremely reduce the residual rate of unreacted aromatic aminosulfonic acid compared with the condensates comprising phenols and aromatic aminosulfonic acids. This is considered to be due to the difference in forming tendency of homopolymer between bisphenols and phenols. Since bisphenols show larger steric hindrance so that the freedom of reaction points is restricted significantly over phenols, they are hard to form homopolymer by themselves. Consequently, they would react almost completely with aromatic aminosulfonic acids.
In this way, it has become possible to convert almost all of aromatic aminosulfonic acids used to effective components.
Moreover, since the condensates themselves are hard to cause the re-condensation, the stability of condensates is good even under acidic condition.
Furthermore, it is possible to introduce useful polar group, hydrophilic group or heat-resistant structure into the hydrophobic skeleton. It is also possible to impart the stericity to the hydrophobic skeleton so as to make difficult to be adsorbed onto dispersed medium.
From these points, the condensates of bisphenols with aromatic aminosulfonic acids can exert their usefulness in wider scope of fields.
The dye dispersion containing the dispersants obtainable by the method of the invention has following effects.
1) It exhibits excellent dispersibility even in a high-temperature region during dyeing and causes no obstructions such as tarring and mottling.
2) It has less contamination onto polyester fibers and cotton and exhibits excellent effect even on light-color dyeing.
3) The composition of the invention is of low foaming property leading to no dyeing troubles when using for dyeing operation and uniform dyeing.
Besides, the dispersants obtainable by the method of the invention can be used together with naphthalenesulfonic acidformalhyde condensate, lignin sulfonic acid, condensation product comprising cresol, sodium salt of Schaffer's acid, sodium hydroxide and formaldehyde, and other publicly known surfactants as well as independent use thereof.
Here, with respect to the additive for carbonaceous fine powder-water slurry, some important facts should be added.
For producing the condensed compounds being the major components of additive, it is required to perform the condensation at molar ratios described above. If out of these ratios, the viscosity-reducibility, fluidity and characteristic of change over time would be decreased.
The weight-average molecular weight of condensates being the major components of additive is desirable to be 3,000 to 50,000 and, if deviating from this range, the viscosity-reducibility and storage stability would be lowered.
The particle size of carbonaceous fine powders such as cool and petroleum coke is not prescribed particularly, but it is desirable to have 200 mesh pass of not less than 50%, preferably 70 to 80%.
Moreover, in the invention, it is also possible to use the condensates together with publicly known additives such as carboxymethylcellulose, methylcellulose, polyacrylate and condensed polyphosphate. Naphthalenesulfonic acid-formaldehyde condensate and lignin sulfonate used as dispersants hitherto are similarly possible to be used together.
Also, with respect to the water-reducing agent for cement, followings should be noted.
For producing the condensates being major components of water-reducing agent, it is required to perform the condensation at specified rates described above. If out of these rates, the water-reducibility, fluidity and characteristic of change over time would be decreased. Since the effect of alkali is very significant in this condensation reaction, the addition rate of alkali is also required to be strictly retained as above. If out of the rate, the amount of residual monomer (unreacted 4-aminobenzenesulfonic acid) would become high abruptly.
The weight-average molecular weight of the condensed compounds lies in a range of 10,000 to 50,000 when determining by means of gel permeation chromatography (GPC), and, if deviating from this range, the effect for improving the fluidity would be lowered.
The lignin sulfonate treated through ultrafilzration, which is used as an another component of water-reducing agent, is one purified until the reducible sugars in sulfite pulp spent liquor become to not more than 5%. The fractionation membrane during ultrafiltration treatment is desirable to be 1,000 to 30,000, preferably 5,000 to 20,000.
Moreover, the lignin sulfonate containing not less than 0.20 mol of carboxyl group and not less than 0.10 mol of sulfonic group per phenylpropane unit can be produced by oxidizing sulfite pulp spent liquor under alkaline condition to reduce sulfonic group, as described in Japanese Patent Publication No. Sho 56-40106, or by sulfomethylating thiolignin in kraft pulp spent liquor to introduce sulfonic group.
With the condensates of bisphenol compounds and 4-aminobenzenesulfonic acid with formaldehyde alone, the fluidity over long term is not still enough and satisfied effect can be achieved for the first time by using said specified lignin sulfonate together. The rates of condensate to lignin sulfonate are 80-20:20-80 (parts by weight), and, if out of this range, the effect would be decreased remarkably.
The condensates to be used in the invention exhibit remarkable improvement effect on fluidity over the condensate of 4-aminobenzenesulfonic acid and phenol with formaldehyde (hereinafter abbreviated as A compound) described in Japanese Unexamined Patent Publication No. Hei 1-113419. This is based on following reason.
Namely, it is considered that, after the condensation reaction of A compound, about 10% of 4-aminobenzenesulfonic acid remain as residual monomer, and, in consequence of the tendency of phenol to form homopolymer, unreacted 4-aminobenzenesulfonic acid is easy to remain.
In this way, in the case of the condensation reaction of A compound using phenol, because of accompanying side-reaction and property of phenol itself, a complicated means of first process (reaction under weak alkaline condition) and second process (reaction under strong alkaline condition) is required.
Whereas, in the case of the condensates of 4-aminobenzenesulfonic acid and bisphenol compounds with formaldehyde being major components of the water-reducing agent of the invention, the residual monomer decreases to about one third compared with the case of A compound. This is considered to be due to the facts that the bisphenol compounds of the invention are hard to dissolve into water and alkali and that the formation of homopolymer being the side-reaction is hard to occur over phenol. Moreover, in the case of the invention using bisphenol compounds, there is also a feature that the complicated reaction means as the case of A compound using phenol is not required.
The water-reducing agent for cement of the invention is used in a rate of 0.01 to 2.0%, preferably 0.1 to 0.6% to cement. If the formulation level is too low, expected effects cannot be obtained and, if it is too high, the cement disperses excessively to cause separating phenomenon, leading to undesirable state.
As the cements applicable to the invention, normal portland cement, high early strength cement, ultrahigh early strength cement, blast furnace cement, moderate heat cement, fly ash cement, sulfate-resisting cement, etc. are used. Moreover, the water-reducing agent for cement of the invention can be used together with other additives for cement, for example, water-reducing agent, air-entraining agent, setting retarder, waterproofing agent, inflating agent, silica fume, stone powder, etc.
In following, the invention will be illustrated in detail based on examples.
EXAMPLE 1
Into a reactor equipped with stirring device, refluxing device, thermometer and dropping device of aqueous solution of formaldehyde, following materials were charged in fixed amounts.
______________________________________4-Aminobenzenesulfonic acid 173.20 g (1 mol)2, 2-Bis (4-hydroxyphenyl) propane 114.15 g (0.5 mol)Aqueous solution of NaOH 95% NaOH 42.11 g (1 mol) H.sub.2 O 768.74 g______________________________________
To this solid-liquid, 171.43 g of 35% aqueous solution of formaldehyde (formaldehyde 2 mol) were added over 1 hour at a temperature of 90° C.
Then, the mixture was refluxed for 9 hours at a temperature of 100° C. to obtain an aqueous solution of condensate.
The weight-average molecular weight (Mw) and the amount of residual monomer (4-aminobenzenesulfonic acid) of the condensate thus obtained were 31,568 and 2.5% (based on solids), respectively.
Besides, the weight-average molecular weight was determined by means of gel permeation chromatography and calculated making pullulan as a standard. The residual monomer was determined from area ratio with differential refractometer of gel permeation chromatography.
A gel permeation chromatogram, infrared spectra and nuclear magnetic resonance spectrum of the condensate obtained are shown in FIG. 1, FIG. 2 and FIG. 3, and FIG. 4, respectively.
In FIG. 4, there are a peak at 44 ppm originating from quaternary carbon of 2, 2-bis (4-hydroxyphenyl) propane and a peak at 33 ppm originating from methyl group of 2, 2-bix (4-hydroxyphenyl) propane, thus showing a condensate of 2, 2-bis (4-hydroxyphenyl) propane.
EXAMPLE 2 THROUGH 7
Varying the bisphenol compounds, condensates were obtained similarly to Example 1.
These results are shown in Table 1.
TABLE 1__________________________________________________________________________ Condensate after reaction Residual 4-amino- Reaction conditions (g/mol) benzenesulfonic 4-Aminobenzene- Weight-average acid (%, based sulfonic acid Bisphenol compound 95% NaOH Water 35% HCHO molecular weight on__________________________________________________________________________ solids)Example 2 173.20/1 4,4'Dihydroxy- 42.11/1 736.00 171.43/2 31.290 3.8 diphenylmethane 100.12/0.5Example 3 173.20/1 4,4'-Dihydroxy- 42.11/1 719.62 171.43/2 26,361 2.7 biphenyl 93.10/0.5Example 4 173.20/1 4,4'-Dihydroxy- 42.11/1 794.41 171.43/2 38,210 1.8 diphenylsulfone 125.15/0.5Example 5 173.20/1 4,4'-Dihydroxy- 42.11/1 738.06 171.43/2 26,981 3.1 diphenyl ether 101.00/0.5Example 6*.sup.) 173.20/1 4,4-Bis(4-hydroxy- 42.11/1 836.45 171.43/2 28,238 4.1 phenyl)-valeric acid 143.17/0.5Example 7*.sup.) 173.20/1 2,2-Bis(4-hydroxy- 42.11/1 782.27 171.43/2 32.450 3.1 phenyl)-propane 91.32/0.4 4,4-Bis(4-hydroxy- phenyl)-valeric acid 28.63/0.1__________________________________________________________________________ *.sup.) Temperatures on adding formaldehyde are 93° C. in Example and 92° C. in Example 7, respectively.
EXAMPLE 8
The aqueous solutions of the condensates of Example 1 through 6 were powdered with spray dryer and the contaminability of powdered samples to cloth was tested.
Moreover, the contaminability tests with naphthalenesulfonic acid-formaldehyde low-degree condensate (hereinafter abbreviated as NSF) and partically desulfonated lignin sulfonic acid (hereinafter abbreviated as LIG) were performed concurrently using them as comparative samples.
the testing method of contaminability is as follows:
Into water, 600 mg (bone dry basis) of dispersant were dissolved. After adjusted the PH value to 5.0 with acetic acid, total volume was made to be 250 ml. This was charged into a dyeing tester together with 8 g of test cloth. After dyeing for 1 hour at 105° C., the test cloth was dried to measure the brightness.
Results obtained are shown in Table 2.
TABLE 2______________________________________ Brightness of cloth (%) Mixed-spun of Cotton tetron and cotton______________________________________Example 1 81.0 84.0Example 2 79.0 81.6Example 3 81.1 81.5Example 4 84.0 85.3Example 5 81.6 82.3Example 6 82.0 82.4NSF 81.7 83.0LIG 59.0 62.0______________________________________
EXAMPLE 9
The high-temperature dispersibility of powdered condensates of Example 1 through 6 prepared from aqueous solutions with spray drier and NSF and LIG as comparative samples was compared.
The testing method is as follows:
Dye, dispersant and water were mixed in fixed amounts. After milled to fine particles, they were filtered and dried with spray dryer (inlet temperature: 100°-150° C., outlet temperature: 50°-55° C.).
Thereafter, the speck test and the speck test after heat treatment (80° C., 15 hours) were carried out.
Results are shown in Table 3.
TABLE 3______________________________________ Speck test______________________________________Example 1 ◯Example 2 ΔExample 3 ◯Example 4 ⊚Example 5 ◯Example 6 ◯NSF XLIG ⊚______________________________________
EXAMPLE 10
Into a reactor, following materials were charged in fixed amounts.
______________________________________(I) 4-Aminobenzenesulfonic acid 173.20 g (1 mol)(II) 2, 2-Bis (4-hydroxyphenyl) propane 114.15 g (0.5 mol)(III)95% NaOH 42.11 g (1 mol)Water 768.74 g______________________________________
Next, to this solid-liquid suspension, 171.43 g (2 mol) of (IV) 35% aqueous solution of formaldehyde were added dropwise under reflux, and the reaction mixture produced was stirred for 10 hours to obtain a transparent aqueous solution of condensate.
The weight-average molecular weight (Mw) and the amount of unreacted 4-aminobenzenesulfonic acid of the condensate thus obtained were 24,950 and 2.8% (based on solids), respectivly.
EXAMPLE 11 THROUGH 15
Varying the bisphenol compounds, condensates were obtained similarly to Example 10.
Results are shown in Table 4.
TABLE 4__________________________________________________________________________ Condensate after reactionReaction conditions Residual 4-aminoben- I:II:III:IV Weight-average zenesulfonic acidType of bisphenol compound Molar ratio molecular weight (%, based on solids)__________________________________________________________________________Example 11 4,4'-Dihydroxydiphenyl- 1:0.5:1:2 29,865 3.6 methaneExample 12 4,4'-Dihydroxybiphenyl 1:0.5:1:2 24,156 2.4Example 13 4,4'-Dihydroxydiphenyl- 1:0.5:1:2 40,817 1.8 sulfoneExample 14 4,4'-Dihydroxydiphenyl 1:0.5:1:2 21,287 3.5 etherExample 15 4,4-Bis(4-Hydroxyphenyl)- 1:0.5:1:2 26,443 3.5 valeric acid__________________________________________________________________________ (I + II + III):Water = 0.3:0.7 (ratio by weight)
EXAMPLE 16 THROUGH 22
Molar ratios of (I) 4-aminobenzenesulfonic acid, (II) 2,2-bis-(4-hydroxyphenyl) propane, (III) NaOH and (IV) formaldehyde were varied as the reaction conditions to obtain the condensates similarly to Example 10.
Results are shown in Table 5.
TABLE 5______________________________________Reaction Condensate after reactionconditions Weight-average Residual 4-aminoben-I:II:III:IV molecular zenesulfonic acidMolar ratio weight (%, based on solids)______________________________________Example 10 1:0.5:1:2 24,950 2.8Example 16 1:0.5:0.98:2 29,387 1.9Example 17 1:0.5:1.03:2 13,890 5.0Example 18 1:0.4:1:1.8 20,050 --Example 19 1:0.44:1:1.88 20,230 3.4Example 20 1:0.6:1:2.2 26,420 --Example 21 1:0.62:1:2.24 27,938 2.1Example 22 1:0.75:1:2.5 44,281 1.5______________________________________ (I + II + III):Water = 0.3:0.7 (ratio by weight)
COMPARATIVE EXAMPLE 1 THROUGH 6
In a reactor, fixed amounts of following four materials were mixed and the pH value was adjusted to 8.1 with 0.1 N aqueous solution of NaOH.
______________________________________(I) 4-Aminobenzenesulfonic acid 173.20 g (1 mol)(II) Phenol 94.10 g (1 mol)(III) 95% NaOH 42.11 g (1 mol) Water 721.97 g______________________________________
Nest, to this aqueous solution, 171.43 g (2 mol) of (IV) 35% aqueous solution of formaldehyde were added under reflux and the mixture was stirred for 7.5 hours under reflux (first process).
The mixture was cooled to room temperature and, after adjusted the PH value to 11.0, it was refluxed for 3 hours (second process) to obtain the condensate.
The weight-average molecular weight (Mw) and the amount of residual 4-aminobenzenesulfonic acid were 23,375 and 11.8% (based on solids), respectively.
Table 6 shows the results when varied the molar ratios of materials above.
TABLE 6______________________________________ Condensate after reaction Reaction Weight- conditions average Residual 4-aminoben- I:II:III:IV molecular zenesulfonic acid Molar ratio weight (%, based on solids)______________________________________Comparative 1:1:1:2 23,375 11.8example 1Comparative 1:1:0.98:2 24,306 9.8example 2Comparative 1:1:1.03:2 33,143 15.0example 3Comparative 1:0.88:1:1.88 25,975 15.4example 4Comparative 1:1.24:1:2.24 27,294 10.6example 5Comparative 1:1.5:1:2.5 45,863 9.5example 6______________________________________ (I + II + III):Water = 0.3:0.7 (ratio by weight)
EXAMPLE 23
The carbonaceous fine powder-water slurry was prepared and the fluidity was measured as follows:
1. Preparation Method of Carbonaceous Fine Powder-Water Slurry
Into water dissolved beforehand a fixed amount of dispersant, carbonaceous fine powder pulverized to 200 mesh pass of 80% was thrown (total amount: 400g), which was enough wetted with a mixing rod (for pasting). Then, this was stirred for 40 minutes at 8000 rpm with TK homomixer made by Nihon Tokushu Kiko Kogyo Co. to prepare the carbonaceous fine powder-water slurry and the viscosity of slurry was measured at 20° C. by using model BL rotational viscometer. Examples and comparative examples carried out under these conditions are shown in Table 7 and Table 8. Lower viscosity indicates better fluidity.
2. Measuring Method of Fluidity of Carbonaceous Fine Powder-Water
Slurry
The carbonaceous fine powder-water slurry prepared under conditions of 1) was transferred to a cylinder (inner diameter: 35 mm, height: 250 mm) and a glass rod with diameter of 6 mm and weight of 30 g was intruded to measure the dropping state with the lapse of day. If the glass rod intrudes to bottom by its own weight, the stability of slurry is good, but, if it stops at a depth of less than one half on the way and becomes not to intrude below on pushing it by hand, the stability becomes poor.
The stability of slurry was measured under these conditions and examples and comparative examples thereby measured the lasting days are shown in Table 7 and Table 8. Longer lasting days indicate better stability.
TABLE 7______________________________________(Great Greta coal) Addition Viscosity Stability level (%) (cps) (day)______________________________________Example 10 0.1 1050 32Example 10 0.2 670 40Example 10 0.4 270 45Example 12 0.1 960 42Example 13 0.1 1020 35Example 18 0.1 1000 40Example 20 0.1 1100 31Comparative 0.1 1950 5example 7Comparative 0.2 1200 6example 7Comparative 0.4 700 7example 7Comparative 0.1 2500 15example 8Comparative 0.2 1800 18example 8Comparative 0.4 1150 20example 8______________________________________ Comparative example 7: Naphthalenesulfonic acidformaldehyde condensate Comparative example 8: Cocondensate of modified lignin sulfonic acid treated with hydrogen peroxide after airoxidation treatment under alkalin condition and naphthalenesulfonic acid with formaldehyde.
Comparative example 7: Naphthalenesulfonic acid-formaldehyde condensate
Comparative example 8: Co-condensate of modified lignin sulfonic acid treated with hydrogen peroxide after air-oxidation treatment under alkaline condition and naphthalenesulfonic acid with formaldehyde.
TABLE 8______________________________________(Petroleum coke, Paskagula) Addition Viscosity Stability level (%) (cps) (day)______________________________________Example 10 0.1 1400 35Example 10 0.2 980 38Example 10 0.4 600 45Example 12 0.2 1000 39Example 13 0.2 960 42Example 18 0.2 1000 40Example 20 0.2 1040 35Comparative 0.1 3800 4example 9Comparative 0.2 2200 5example 9Comparative 0.4 1600 8example 9______________________________________ Comparative example 9: Glycerine polyether adduct (PO/EO = 3/7), MW 30,00
EXAMPLE 24
The consistency of concrete added with the water-reducing agents of the invention was compared with that of concrete added with the reducing agents of comparative examples to compare the slump loss (change in fluidity over time) of concrete.
The formulation is as shown in Table 9.
For preparing concrete, cement, aggregates and water or water containing water-reducing agent were kneaded for 3 minutes in a 100 transportable tilting mixer and the slump was measured immediately and 30 and 60 minutes later. The slump and the amount of air were measured according to JIS.
The measurement results are as shown in Table 10. With inventive articles (examples), target slump can be obtained at lower addition level than that of conventional water-reducing agents (Comparative examples) showing that the inventive articles are excellent in the dispersibility over the conventional ones.
TABLE 9______________________________________Formulation W/C S/a Unit weight* (kg/m.sup.3) (%) (%) C W S G______________________________________Concrete added with 53.1 50 320 170 931 947water-reducing agent______________________________________ *C Cement: Normal portland cement, S.G. 3.16 W Water: Tap water S Fine aggregates: River sand produced at Kashima, S.G. 2.59, F.M. 2.62 G Coarse aggregated: Crushed stone produced at Yamaguchi, S.G. 2.71, F.M. 6.86
TABLE 10______________________________________ Addition* Amount Slump (cm) level of air Immedi- (%) (%) ately 30 min 60 min______________________________________Example 10 0.42 1.5 19.5 18.5 18.0Example 13 0.40 1.6 19.5 19.0 18.5Example 14 0.42 1.6 20.5 20.0 19.0Example 21 0.42 1.9 20.0 19.0 18.5Comparative 0.50 1.6 19.5 18.0 16.5example 1Comparative 0.52 1.7 20.0 18.0 17.0example 5Comparative 0.42 1.5 14.0 10.0 8.5example 5______________________________________ *% by weight based on cement
EXAMPLE 25 THROUGH 28
Specified lignin sulfonates were produced as follows:
1. The sulfite pulp spent liquor was oxidized with air under alkaline condition and allowed to precipitate with sulfuric acid. The precipitates were washed with water and neutralized with sodium hydroxide to obtain lignin sulfonate containing 0.3 mol of sulfonic group and 0.4 mol of carboxyl group per phenylpropane unit.
2. The sulfite pulp spent liquor was concentrated and purified through ultrafiltration membrane (trade name GOST (fractionatable molecular weight: 5,000) made by Bioengineering KK). The content of reducible sugars in lignin sulfonate thus obtained was 3.2% (based on solids).
The lignin sulfonates produced under 1) and 2) were mixed with the condensate produced in Example 10 at 50:50 (ratio based on solids) to obtain the inventive articles (Examples 25 and 26), respectively.
Similarly, the condensate produced in Example 13 was mixed with the lignin sulfonate produced under 1) at 60:40 (ratio based on solids) and with the lignin sulfonate produced under 2) at 40:60 (ratio based on solids) to obtain the inventive articles (Examples 27 and 28), respectively.
The materials used for concrete and the formulation are as follows:
Cement (C): Normal portland cement
Fine aggregates (S): Land sand produced at Kisarazu (S.G. 2.59, F.M. 2.40)
Coarse aggregates (G): Crushed stone produced at Yamaguchi (S.G. 2.70, F.M. 6.75)
Water (W): Tap water
TABLE 11______________________________________Formulation Target Target amountW/C S/a C W S G slump of air(%) (%) (kg/m.sup.3) (cm) (%)______________________________________50 48 320 160 869 981 20 4______________________________________
The water-reducing agents of Example 25 through 28 were added to the formulation in Table 11, respectively and kneaded for 3 minutes in a 100 mixer. The amount of air in each slump was measured immediately and 30, 60, 90 and 120 minutes later. Besides, the measurements of slump and amount of air of concrete were made according to JIS. Moreover, similar measurement was carried out for comparison using water-reducing agents comprising the condensates obtained in Example 10, 12, 13 and 15 to obtain Comparative example 10, 12, 13 and 15.
TABLE 12______________________________________Test results of concreteType of Amount ofwater- Slump (cm) air** (%)reducing Immedi- 30 60 90 120 Immedi-agent ately min min min min ately______________________________________Example 25 20.5 20.0 19.5 19.0 18.0 4.5Example 26 20.0 20.0 19.0 18.5 18.0 4.4Example 27 20.5 19.5 19.5 19.0 18.5 4.6Example 28 19.5 19.0 18.5 18.0 17.5 4.2Comparative 20.5 19.0 17.5 15.5 13.0 4.3example 10Comparative 19.5 18.0 17.0 14.5 12.0 4.3example 12Comparative 19.5 18.5 17.0 14.0 11.5 4.7example 13Comparative 20.0 18.0 17.5 16.0 12.5 4.6example 15______________________________________ *Addition level of waterreducing agent: 0.5% based on cement **Adjusted with surfactant
The measurement results are as in Table 12, which show better retainment in fluidity of the inventive articles over comparative ones.
As described above, the condensates of the invention are useful as industrial dispersants and epoxy resin hardeners.
When using them as water-reducing agents for cement compositions such as cement paste, mortar and concrete in accordance with the invention, the water-reducing property is particularly high, the expected fluidity can be achieved at lower addition level over conventional cement admixing agents and the decrease in fluidity over time is low to improve the executability and workability.
Moreover, when using as dye dispersants, they exhibit excellent dispersibility even in a high-temperature region, excellent leveling property and low contaminability.
Furthermore, they show high viscosity-reducing effect at lower addition level over conventional additives for carbonaceous fine powder-water slurry and stability. They have also excellent dispersibility for gypsum, calcium carbonate, etc.
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Novel condensates comprising bisphenols and aromatic aminosulfonic acids, in particular, novel 4-aminobenzenesulfonic acid-2,2-bis (hydroxyphenyl)propaneformaldehyde condensates, and methods for their production are disclosed. The novel condensates are useful as a dispersant for disperse dyes, an additive for carbonaceous fine powder-water slurries and as a water reducing agent for cement.
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CROSS-REFERENCED TO RELATED APPLICATIONS
[0001] Not applicable
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable
BACKGROUND OF THE INVENTION
[0003] I. Field of the Invention
[0004] This invention is directed generally to the field of agriculture machinery, and more particularly, it relates to implements associated with soil trench closing mechanisms adjusted with controllers. Associated implements include seed planting devices, fertilizer applicators, tillage closers, irrigation drip line equipment, and related products. Specifically, the invention relates to row treating units incorporating a combination of tools in the form of closing devices and soil packing devices, also known as closing wheels and soil firming/packing wheels. The units are designed to be attached to the rear of seed planting implements or other ground engaging equipment. The deployment of and/or down force exerted by the closing wheels and packing wheels are independently adjustable and use pneumatic operators for controlling up and down adjustments.
[0005] II. Related Art
[0006] In the spring or fall, prior to planting, farmers must prepare their fields for accepting seed. Many tillage implements have been designed and are used to condition the soil in preparation for planting. Traditional farming includes both primary and secondary tillage tasks to prepare the soil such as plowing, disking, field cultivating and harrowing. Disking is an example of a method of primary tillage and harrowing is an example of a method of secondary tillage.
[0007] Primary tillage is an optional first pass over the soil using a soil conditioning implement attached to the rear of a tractor which works deep into the soil. The soil is usually worked several inches deep to break up clods of soil, remove air pockets, and destroy weeds deep in the earth.
[0008] Secondary tillage involves another pass over the same soil, at a more shallow depth, using implements which are generally attached to the rear of the primary tillage unit or to the front of a planter such that the secondary tillage unit follows the primary tillage unit. The secondary tillage unit generally may work the soil to a depth of a few inches or more, but usually not to exceed the desired seed planting depth. More recently, secondary tillage may be the only soil conditioning that takes prior to planting.
[0009] A secondary tillage unit is usually a final conditioning tool to prepare the soil for planting. Thus, rotating blade coulter units may be used to chop up crop residues and loosen the soil; and row cleaners, which include a pair of converging multi-bladed trash wheels, used to move the crop residue out of the way to provide a cleared area for rows to be planted. Rolling baskets also may be used to break up soil clods and break up any crust on the top of the soil prior to planting.
[0010] After the soil has been prepared and crop residue moved out of the way, the planting/seeding operation takes place. Seeding devices are multi-row devices pulled by tractors and include opening disks that create an open seed trench that allows for seed to be dropped into soil at a metered rate and set depth. Thereafter, the trenches made by the opening disks must be closed with the proper amount of pressure and the soil firmed/packed. This is preferably done using, in combination, pairs of closing wheels followed by firming/packing wheels which are mounted on a row unit or tool bar. A combination of these implements is associated with each row unit on the seeding equipment.
[0011] Closing wheels are usually mounted in pairs that are angled to converge rearward of the seeding equipment. The closing wheels are designed to crush and crumble trench walls from both sides. They may take any of several forms including round rubber wheels, or wheels with radially distributed spikes. The sets of closing wheels are mounted on assemblies that include springs that apply downward force to pivot the closing wheel mounts and force the closing wheels to the ground. The downward force may be adjusted by adjusting the tension in the spring. A problem with prior closing wheel assemblies is that in some instances the force will cause the closing wheels to penetrate to a depth that interferes with the seeds planted at the bottom of the trench and cause problems with seed spacing and depth. This may even lead to some seeds being thrown from the seed trench or uneven emergence.
[0012] Mounting systems for firming/packing wheels are typically provided with a down force spring arrangement, but have no ability to lift the packing wheel or reduce pressure desired. The packing wheels are designed to follow the closing wheels to firm/pack the soil over the seeds. This must be accomplished with a proper amount of pressure to be successful. Thus, too little pressure results in voids or air pockets in the soil, and too much pressure will compact the soil too tightly making it difficult for the plants to sprout through the hard packed soil, and roots will be obstructed by the seed trench compaction all season and will not penetrate the ground as easily as desired. Too little compaction will allow soil to dry out too soon.
[0013] It would present a desirable advantage if the depth and amount of pressure exerted by the closing mechanisms could be more closely and conveniently controlled.
SUMMARY OF THE INVENTION
[0014] By means of the present invention there is provided a row implement treating unit that combines a soil trench closing assembly and a firming/packing wheel assembly for attachment to a multi-row implement. Certain embodiments may include the trench closing assembly without the firming/packing wheel. Embodiments of the unit generally include a soil trench closing assembly and is provided with a pair of height adjustable closing wheels and a closing wheel mounting arrangement that operates the closing wheels and a down-force device for applying a down force to the closing wheels to force them to penetrate the soil. Optionally, a single wheel system can be used. This is used in combination with an adjustable depth limiting or positive stop device to control or limit lowest height adjustment and thereby limit the degree of soil penetration to a desired setting or to raise the lower limit of the closing wheels to a height above the ground. Alternatively, the trench closing assembly may be an active actuator system that includes a device to raise the closing wheels.
[0015] In most preferred embodiments, the unit also includes a firming/packing wheel assembly which includes a packing wheel and a packing wheel mounting and actuating arrangement for deploying and lifting the packing wheel which has a pivotally-mounted framework preferably operated by a pneumatic control system which includes down-force and lift pneumatic devices. A down-force only embodiment is also shown.
[0016] In one arrangement, the pneumatic control system for the firming/packing wheel includes a single down-force airbag and a pair of smaller lift airbags. In an alternate embodiment, the system includes aligned, opposed down-force and lift airbags located between fixed plate members with a traveling intermediate plate member therebetween which operates the pivotally-mounted framework arrangement for the packing wheel mounting framework. The pneumatic control operating system for the packing wheel further includes mechanical down-force and lift stop devices to limit down-force and lift travel of the packer wheel.
[0017] The system may also include a debris deflector mounted ahead of the closing wheels and the unit may be provided with a follower angle adjustment arrangement for adjusting the follower angle between the row unit and any main unit to which it is attached.
[0018] Operation and adjustment of the pneumatic devices of the row units may be controlled from the cab of a prime mover, normally, a tractor, which is attached to pull an associated seeding device or other tow bar arrangement to which one or more of the row units is attached. In addition, sensors may be provided that provide information that can be used to automatically control aspects of the operation.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] In the drawings wherein like reference characters denote like parts:
[0020] FIG. 1 is a perspective view of one row treating unit embodiment that includes a combination of spiked closing wheels and a packing wheel in accordance with the invention;
[0021] FIG. 2 is a perspective view of the embodiment of FIG. 1 with smooth closing wheels;
[0022] FIGS. 3A and 3B are fragmentary perspective views of the embodiment of FIG. 1 further illustrating the operating systems;
[0023] FIGS. 3C and 3D are fragmentary views with parts removed for clarity that illustrate mechanical lift and down stops for the pivoting arm mount arrangement for raising and lowering the packing wheel of the embodiment of FIG. 1 ;
[0024] FIG. 4 is a side partial sectional view of through the embodiment of FIG. 1 showing the mechanism with the packing wheel fully deployed and the closing wheels raised;
[0025] FIG. 5 is a view similar to FIG. 4 with the packing wheel also raised;
[0026] FIG. 6 is a sectional view similar to FIG. 4 with both the closing wheels and the packing wheel deployed in a down position;
[0027] FIGS. 7A and 7B are top and side elevation views of an alternate embodiment of a row unit in accordance with the invention;
[0028] FIG. 8 is a perspective view showing the mechanism of the embodiment of FIGS. 7A and 7B with parts removed for clarity;
[0029] FIG. 9 is a view of the embodiment of FIGS. 7A and 7B shown with both the closing wheels and the packing wheel in a raised position;
[0030] FIG. 10A is a view of the alternate embodiment including smooth closing wheels and a cylinder closing wheel deployment mechanism shown in the deployed or down position;
[0031] FIG. 10B is a view similar to that of FIG. 10A with the deployment mechanism in the retracted or lifted position;
[0032] FIG. 10C is a view similar to FIGS. 10A and 10B except that an airbag is used to produce the down force on the closing wheel assembly;
[0033] FIGS. 11A and 11B illustrate the use of left and right adjustment bolts to adjust the angle of the row unit, including the packer wheel, left and right of dead center;
[0034] FIG. 12A is a fragmentary side view with parts removed for clarity of a closing wheel arrangement using a pneumatic down-force actuator and movable wedge travel limiting assembly;
[0035] FIG. 12B is a view similar to that of FIG. 12A provided with a dual aligned down-force and lift actuator arrangement
[0036] FIGS. 13A and 13B depict side views of an embodiment of a row treating unit employing a packing wheel only with a down-force actuator and adjustable mechanical stop shown in lowered and raised positions, respectively;
[0037] FIGS. 13C and 13D depict side views of an embodiment of a row treating unit in which the packing wheel of FIGS. 13A and 13B is combined with a closing wheel arrangement;
[0038] FIGS. 14A and 14B depict a typical 2-position plunger-operated five-port valve associated with the operation of pneumatic operators in accordance with the invention shown in alternate position;
[0039] FIGS. 15A , 15 B and 15 C show additional implements used prior to planting that may be pneumatically operated;
[0040] FIG. 16 is a schematic representation of a multi-row pneumatic system for operating a plurality of spaced row treating units that may be attached to a tow bar or multi-row seed planting implement;
[0041] FIG. 17 depicts a pneumatic system that can be used to operate the pneumatic actuators associated with a system employing a number of row units; and
[0042] FIG. 18 is a view of a possible cab control panel associated with controlling the operation of one or more row units.
DETAILED DESCRIPTION
[0043] The detailed description of the illustrative embodiments is intended to illustrate representative examples of the inventive concepts and is not intended to limit the scope of those concepts. The examples are to be read in connection with the accompanying drawings, which are to be considered part of the entire written description of this invention. In the description, relative terms such as “lower”, “upper”, “horizontal”, “vertical”, “above”, “below”, “up”, “down”, “top” and “bottom”, “left” and “right” as well as derivatives thereof (e.g., “horizontally”, “downwardly”, “upwardly”, etc.) should be construed to refer to the orientation as then described or as shown in the drawings under discussion. These relative terms are for convenience of description and do not require that the apparatus be constructed or operated in a particular orientation. Terms such as “connected”, “connecting”, “attached”, “attaching”, “join” and “joining” are used interchangeably and refer to one structure or surface being secured to another structure or surface or integrally fabricated in one piece, unless expressively described otherwise. As used herein, the term “trench closing mechanism” is meant to include any configuration of wheeled seed, fertilizer, tillage, etc., trench closing device and may be used interchangeably with trench closing wheels. The terms “firming wheel”, “firming/packing wheel” and “packing wheel” are also used interchangeably for such wheel devices used in conjunction with closing systems.
[0044] The term “airbag” as used herein is defined to mean any type of inflatable pneumatic operator, without limitation, including convoluted and non-convoluted devices with single and multiple air access ports, and ports at different locations.
[0045] FIG. 1 illustrates a row treating unit generally at 20 that includes a trench closing mechanism assembly 22 and a firming/packing wheel assembly 24 . An optional debris deflecting attachment 25 is mounted ahead of the trench closing wheels to deflect rocks and other field debris that otherwise might damage the closing wheels or cause them to skid because rock or debris becomes lodged between the closing wheels.
[0046] The trench closing wheel assembly includes a pair of converging spiked closing wheels 26 mounted on stub axles as at 28 which is carried by a heavy structural frame 30 which includes spaced heavy flanking shaped side plate members 32 and 34 , each of which is designed to pivot about a fulcrum pivot joint as at 36 as the closing wheel mounting assembly moves up and down.
[0047] As best seen in FIGS. 4 and 5 , side plate members 32 and 34 are connected to a shaft 40 that extends between the side plate members and carries one end of a tension spring 42 which is also connected to lever member 44 that is fixed to an independent fixed support structure arrangement 46 so that the tension spring 42 tends to pivot the trench closing assembly downward forcing the spikes 48 of the closing wheels 26 into the ground. The maximum depth of soil penetration of the closing wheels is limited by a stop system that includes an adjustable set screw 50 that is threaded through a top plate 52 of the trench closing wheel assembly and contacts a fixed gusset member 54 to thereby adjustably limit the downward travel of the wheel mounting assembly. As pictured in FIGS. 4 and 5 , the set screw 50 is almost fully extended toward the gusset member 54 and the closing wheels 26 are therefore in a raised position. In FIG. 6 , the set screw is backed off, thereby permitting the spiked wheels 26 to enter the soil, a controlled or limited amount.
[0048] It is important for the closing wheels to be mounted on a resilient system that enables them to raise up to prevent damage if obstacles are encountered. The spring biased mounting enables the closing wheels to rise out of the way when they encounter something hard in the soil such as a rock. The optional adjustable stop system enables the maximum depth of the closing wheels to be adjusted as necessary to accommodate seed trenches of varying depths. The maximum depth penetrated by the closing wheels needs to be shallower that the depth of the planted seeds to avoid interference with the seeds. The closing wheels are designed to crush and crumble the seed trench walls without disturbing the planted seeds. Several different kinds of wheels are used and FIG. 2 shows the use of smooth edge wheels rather than spiked wheels. An important aspect of the present system is the adjustability of the maximum depth of the closing wheels. The set screw position can be adjusted as often as desired. Also, other devices can be used to apply the down force to and limit penetration of the closing wheels.
[0049] The packing wheel assembly 20 has a pivoting framework that includes a pair of rather long spaced, generally arcuate, shaped support arm members 70 and 72 connected together by spaced cross members 74 and connected at their free ends to a yoke 76 which carries the packing wheel 78 on a shaft or axle 80 . The support arm members with bushings 82 are pivotally mounted on a bolt shaft 84 in structural shape 86 that extends through fixed support structure 46 . The packing wheel assembly is operated by a pneumatic system that includes airbags. This embodiment includes three airbags, a single down-force airbag 90 and a pair of smaller spaced lift airbags 92 and 94 . As best seen in FIGS. 3C and 3D , the down-force airbag 90 operates between a fixed plate 96 attached to the support structure and a bent flange member 98 that is pivotally fixed to the spaced support arms 70 and 72 at pivot points 100 and 102 , respectively. Reinforcing gusset members are shown at 104 and 106 . The lift airbags 92 and 94 operate between fixed plates 108 reinforced by gusset member 110 and a lift pedestal member 112 which, in turn, is carried on a lift pin 114 , which is journaled in support arm members 70 and 72 .
[0050] In operation, as best seen in FIGS. 3A-3D , when the packing wheel is raised, the down-force airbag is vented and the lift pedestal member is displaced forward as the lift airbags extend. A lift stop is reached when the lift pin 114 contacts the fixed plate member 96 ( FIG. 3C ). Conversely, when the packing wheel is deployed in the ground-engaging position, the down-force airbag inflates and the lift airbags are vented and deflate. A downward limit stop is provided when the lift pedestal member is displaced rearward by the lift pin 114 . As the support arm members are lowered, contacts a down stop plate 116 , which also determines the minimum length of the lift airbags ( FIG. 3D ). Of course, pressure can also be supplied to both lift and down-force airbags in any desired combination to provide any desirable controlled down force to the packing wheel to adjust to any soil condition.
[0051] An alternate embodiment of the row unit of the invention is shown in FIGS. 7A through 11B . The row unit, generally 200 , includes a seed trench closing wheel assembly 202 , packer wheel assembly 204 and debris deflector 206 .
[0052] The trench closing wheel assembly is similar to the previously described embodiment and includes a pair of converging spiked closing wheels 208 , smooth rimmed wheels and/or flat or concave disk members 210 ( FIGS. 10A-10C ) mounted on axles or shafts 212 which extend through heavy shaped side plate members 214 and 216 connected by heavy top plate member 218 . As with the previous embodiment, the side plates are attached to pivot about a fulcrum at 220 . As shown in FIG. 8 , a shaft 222 extends between the side plates and carries one end of a heavy tension spring 224 , the other end of which is connected to a fixed lever 226 . As with the previous embodiment, the tension spring 224 provides the down force to pivot the closing wheel assembly downward. Depth adjustment is accomplished using a set screw 228 threaded through to plate 218 and contacting fixed stop member 230 .
[0053] The packing wheel assembly employs a modified operating system, but is otherwise similar to the first described embodiment. It includes a supporting pivoting packing wheel framework including spaced, generally arcuate support arms 250 and 252 spanned by connecting cross members 254 . The arms 250 and 252 are connected at fixed ends to pivot on a pivot arm mounting shaft 256 at 258 and 260 , respectively. The packing wheel framework connects at its free end to a yoke 262 which carries packing wheel 264 on an axle 266 , which may be a bolt member provided with bushings as at 267 and 268 attached to wheels 264 .
[0054] The alternative packing wheel assembly is operated by a fixed dual aligned linear airbag system that includes a down-force airbag 270 and a lift force airbag 272 separated by a central traveling intermediate plate 274 that reciprocates linearly between the airbags. The system airbags are further flanked by a fixed down-force plate 276 and a fixed lift-force plate 278 . The traveling plate 274 is connected or otherwise integral with a double-acting flange 280 which has a pair of arms 282 and 284 that extend along generally parallel to the aligned airbags and connect to the pivot arms using an upper mounting shaft or stub shafts 286 at 288 and 290 .
[0055] As best viewed in FIG. 8 , a heavy set screw 292 is threaded through the lower portion of the fixed lift force plate 278 to contact a lower extension of the traveling intermediate plate 274 , when the down-force bag extends and the lift bag deflates, to limit the rearward travel of the traveling intermediate plate 274 and thereby provide an adjustable stop for downward travel of the packing wheel support arms. Travel in the forward direction is limited by contact between the traveling intermediate plate and a fixed member 294 to thereby provide a positive stop limiting the upward travel of the packing wheel lift arms. As with the previous embodiment, pressure can be supplied to both airbags at the same time to control the net downward force exerted by the packing wheel to accommodate any soil type or condition encountered.
[0056] FIGS. 10A-10C illustrate an embodiment similar to that of FIGS. 7A-9 that utilizes alternate types of actuators in the deployment of the closing wheel arrangement. In FIG. 10A , there is shown a double-acting pneumatic cylinder 300 pivotally attached at 302 between a member 304 fixed to lift-force plate 278 and at 306 pivotally attached to a member 308 fixed to the closing wheel assembly 202 . The actuator is shown with the rod 310 extended which forces the closing wheels into the down or deployed position. A stop arrangement similar to that of other embodiments can be used to limit vertical travel of the closing wheels 210 . Down-force and lift pneumatic connectors are shown at 312 and 314 . It will be appreciated that a hydraulic cylinder arrangement could also be used to deploy the closing wheels.
[0057] FIG. 10B is a view similar to FIG. 10A showing the closing wheels in the raised or fully retracted position. The packer wheel is shown in a deployed or down position in both FIGS. 10A and 10B .
[0058] In FIG. 10C , there is shown a further actuator device for deploying the closing mechanisms in the form of an airbag 320 connected between a fixed member 322 connected between lift-force plate 278 and member 308 . The lower plate 324 is fixed to a member 326 pivotally mounted at 328 to the closing mechanism 202 . Airbag 320 is shown partially extended in FIG. 10C .
[0059] The FIGS. 11A and 11B illustrate a follower angle adjustment system for adjusting the relative angle between the row unit and the main unit to which it is attached. The row unit is shown with the packing wheel assembly removed. The unit is shown hitched pivotally at 400 to a main unit 420 . A heavy mounting flange member 402 is provided as part of the fixed mounting assembly of the row unit. Heavy oppositely disposed adjustment bolts 404 and 406 are threaded through the flange 402 behind the pivot joint at 408 and 410 . The flange member 402 extends over a shaped member 412 to which the row treating unit is hitched. By adjusting the adjustment bolts in and out, the angle between the row unit and the attachment flange can be slightly varied to move the row treating unit to the left or to the right of dead center, if desired, as shown in the figures.
[0060] FIGS. 12A and 12B depict another embodiment of a row unit having a closing wheel arrangement shown generally at 500 that includes a pivotally mounted closing wheel assembly 502 and a mounting assembly 504 . The closing wheel assembly includes a pair of closing wheels, one of which is shown at 506 , carried by a structure pivotally connected at 508 to a fixed mounting structure 510 . The closing wheel assembly includes main structural shapes as at 512 and a travel limiting arrangement that includes a bolt member 514 carried by a flange member 516 . The bolt 514 is threaded through members 518 and 520 . The bolt 514 addresses and adjusts a movable wedge member 522 which, in turn, limits the gap between a top stop plate 524 and a bottom stop plate 526 to determine the vertical travel limit of the wheel 506 .
[0061] The closing wheel assembly 502 is operated by a down-force only pneumatic arrangement in FIG. 12A . That arrangement uses a down-force airbag 540 mounted between a fixed vertical stop member 542 and is fixed to the pivoting wheel assembly by a pivotal mount at 544 . The member 542 is fixed to and carried by a fixed mounting member 546 .
[0062] In FIG. 12B , the closing wheel assembly 502 is operated by an aligned dual airbag system that includes down-force airbag 550 and lift airbag 552 which operate against a fixed intermediate member 554 to raise and lower a shaped flange arrangement that includes a flange member 556 that is vertically adjustable and attached at 558 to the closing wheel assembly and to the airbag system at 560 .
[0063] FIGS. 13A and 13B depict another embodiment of a row unit having a packing wheel arrangement that is not combined with a closing wheel system. The row unit shown generally at 600 and includes a pair of spaced curved support arms, one of which is shown at 602 , which carry a yoke 604 into which is journaled a packing wheel 606 . The arms 602 are mounted to rotate on a pivot joint 608 that is mounted in a fixed attachment structure 610 . The packing wheel is operated by a down-force pneumatic operator which operates between a moveable plate member 614 and a fixed plate member 616 to operate a bent flange member 618 that is connected to the arms 602 at a further pivot joint 620 . The travel distance allowed the system for the deployment of the packing wheel 606 is controlled and limited by an adjustable bolt or rod member 622 .
[0064] In FIG. 13A , the pneumatic operator is inflated and the packing wheel is in the fully down or deployed position with member 614 fully extended along member 622 . Conversely in FIG. 13B , the pneumatic operator 612 is collapsed or deflated and the member 614 is fully retracted along the member 622 to upward stops 624 and the packing wheel is in the fully raised position.
[0065] FIGS. 13C and 13D are views of the embodiment of FIGS. 13A and 13B with the addition of a closing wheel assembly 630 in combination with the packing wheel arrangement. A debris deflector is shown at 632 .
[0066] In FIG. 17 , there is shown a pneumatic system with parts of the enclosure removed to expose certain internal parts. The system, shown generally at 700 , includes an accumulator tank, shown partially at 702 , which may be sized according to the desired capacity of the system for performing the necessary functions. The accumulator tank is provided with mounting legs (not shown) and is designed to be mounted on a multi-row seeding implement, or the like, in a well-known manner. A control box housing the control devices for the system is shown at 704 with parts removed to expose the interior which houses an air compressor 706 , which may be electric or hydraulic. An ignition solenoid is shown at 708 and a pressure switch at 710 , which operates to cycle the compressor in a well-known manner, alternatively, the compressor assembly can be controlled from an ISOBUS capable terminal.
[0067] The compressor output line is shown at 712 and a check valve is shown at 714 that prevents back flow from the tank 702 . A safety pressure relief or pop-off valve is shown at 716 that prevents over pressurization of the system. Control knobs for manually adjusted pressure regulators are shown at 718 and associated output pressure gauges are shown at 720 . These are used to regulate output or operating pressure to the elements of the system and their settings may be changed, if necessary, during operation of the implements, but are preferably preset.
[0068] Blocks of electronic pressure regulators as at 722 can be used to regulate up and down pressure applied to pneumatic operators for various devices controlled by the system which may include trash whips (row clearing devices), coulters, rolling baskets, or the like, employed prior to seeding in addition to post-seeding implements. The electronic pressure regulators may be controlled by commands from a control panel, such as shown in FIG. 18 . A typical 5-way valve is shown at 724 and more fully described in conjunction with FIGS. 14A and 14B .
[0069] FIG. 18 depicts one possible control or switch panel 740 designed to interface between an operator in the cab of a tractor or other prime mover and the pneumatic system. The control is used to send commands to all of the valves and regulators. Thus, buttons P 1 -P 5 represent an array of preset pressures for various regulators. These can be used to fix preferred conditions. The panel also includes a display screen 742 , up and down screen scroll buttons 744 and 746 . A menu button 748 allows the operator to view all menu screens, fault codes, adjustment of dump valve times, maintenance information, etc. An enter button 750 is associated with the menu screens and may also be used to turn on the pneumatic system.
[0070] Controls 752 , 754 and 756 are encoders that enable the operator to change the commanded pressure of each of several regulators.
[0071] The four buttons on the bottom of the switch panel with the word “UP” above them and numerals one through four below them are the buttons that can be used to actuate dump valves and five port valves 724 ( FIG. 17 ). These buttons are used to switch the different attachments from the down position (with the button turned off) to the “UP” position (with the button turned on).
[0072] It will be appreciated that sensors mounted on the row units can transmit data to the cab control system that can also be used to adjust various pressures and/or depth of soil penetration for corresponding implements. Such devices are known.
[0073] FIGS. 14A and 14B are schematic representations of a two-position, five-port air valve assembly (as at 724 in FIG. 17 ) in two alternative positions. The assembly, generally at 770 , includes ports 772 , 774 , 776 , 778 and 780 and cylinder 782 , housing axially adjustable cylinder valve or plunger 784 . The valve body or block is depicted at 786 . Ports 772 and 776 are connected to receive air from a high pressure air source. Thus, port 772 is connected to receive compressed air via a manual regulator to provide lift force. Port 776 is connected to receive air via a controlled source to control down force. Ports 778 and 780 connect respectively to a lift force airbag or other pneumatic operator and a down force operator. Finally, port 774 is a vent port for venting air from either the up force operator or the down force operator.
[0074] In FIG. 14A , the port receiving high pressure air 772 is connected through the valve block with a lift force operator through outlet port 778 with the central valve plunger 784 shifted down (in the drawing) in cylinder 782 in a first position. With the central cylinder in this position, the corresponding down force operator is connected to the vent port 774 via port 780 so that down force operator is enabled to collapse while the lift force operator inflates. This raises the corresponding implement.
[0075] FIG. 14B shows the valve 770 in an alternate position with the central cylinder moved upward (in the drawing). With the plunger in this position, port 776 is connected through the central cylinder to port 780 and port 778 is connected to the central cylinder to vent port 774 and port 772 is deadheaded. With the valve in this position, the source of high pressure air is connected through ports 776 and 780 to the down force operator and the lift force operator is connected to vent through ports 778 and 774 . This will enable the down force operator to inflate and the lift force operator to collapse in accordance with moving the corresponding implement to a lowered or deployed position.
[0076] FIGS. 15A-15C depict additional pneumatically operated implements that can be used with the pneumatic system of the invention. They include a row clearing or trash whip device 800 , in FIG. 15A , with a pair of pneumatic operators, one of which is shown at 802 . A rolling basket device, generally 820 in FIG. 15B with pneumatic operators as at 822 and a combination trash whip and coulter device depicted generally at 840 in FIG. 15C with trash whip blades 842 and coulter wheel 844 . Pneumatic operators are depicted at 846 and 848 .
[0077] FIG. 16 is a schematic representation of a multi-row pneumatic system layout that can be controlled by the system of FIGS. 17 and 18 . The schematic includes a plurality of central section row units 860 and these are flanked by a plurality of wing section units at 862 and 864 . A down-force pressure air line is shown at 866 that supplies down pressure to the center units through a manifold 868 and supplies pressurized down-force air to wing section units 862 and 864 through manifolds 870 and 872 , respectively. A common lift pressure system is shown using air line 876 which supplies manifolds 878 , 880 and 882 . A controlled source is depicted at 884 .
[0078] This invention has been described herein in considerable detail in order to comply with the patent statutes and to provide those skilled in the art with the information needed to apply the novel principles and to construct and use such specialized components as are required. However, it is to be understood that the invention can be carried out by specifically different equipment and devices, and that various modifications, both as to the equipment and operating procedures, can be accomplished without departing from the scope of the invention itself.
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This disclosure is directed to the field of agricultural machinery and relates to implements generally used in combination with a multi-row soil trench closing mechanism. Specifically, the disclosure relates to row treating units adapted to be attached to and following a multi-row planter and incorporating a combination of tools that includes a seed trench closing wheel assembly and a firming/packing wheel assembly. The deployment of and down force exerted by the packing wheel is independently adjustable and controlled using pneumatic air bag operators and the soil penetration of the trench closing wheels is limited.
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RELATED CASES
This application is a Continuation-In-Part of our prior patent application Ser. No. 08/217,666, filed Mar. 25, 1994, and now abandoned.
FIELD OF INVENTION
This invention relates to oil drainage and disposal devices and devices particularly to apparatus for draining used oil from automotive vehicles and the like and for disposing of the used oil in an environmentally safe manner.
PRIOR ART
As is well known, automotive vehicles use oil for lubricating and cooling their engines and, periodically, this oil must be drained out and replaced. Conventionally, the oil is drained into a suitable pan and the used oil must be disposed of. For many years, such used oil was simply dumped on the ground or down a sewer. However, in recent years, it has been learned that petroleum products, such as lubricating oil, are highly carcinogenic and is a serious source of environmental contamination. Consequently, the dumping of used oil, as was done in the past, is now widely condemned and many communities have passed laws making such dumping a criminal offense. Thus, having drained the oil from a vehicle into a drain pan, a person is now required to pour the used oil from the drain pan into suitable containers and to transport the used oil to an approved disposal area. Unfortunately, it is often difficult to find suitable containers and the act of pouring the oil from the drain pan into such containers is a delicate task, which often results in spillage of at least some of the oil, with resultant contamination of the surrounding area.
At the same time, it was formerly standard practice to sell lubricating oil in cans having metal lids which could be perforated by a conventional punch-type opener to allow the oil to be poured through a funnel into the oil fill spout of a vehicle. This was also a difficult and delicate chore which often resulted in spillage. However, in recent years, it has become customary to sell lubricating oil in plastic containers having lids which can simply be unscrewed to allow the neck of the plastic container to be inserted into the oil fill spout of the vehicle. This is generally easier and cleaner than the funnel method. However, the plastic containers always contain residual traces of the oil which presents disposal problems, as noted above. Moreover, the plastic containers present an additional disposal problem since the plastics do not decompose and, hence, remain intact indefinitely in landfills and the like.
Numerous prior art devices have been proposed to overcome these problems. However, many of the prior art devices have provided only partial solutions. Thus, prior art devices have been proposed to facilitate draining oil into suitable containers for delivering the used oil to an appropriate disposal facility, but have done nothing about solving the problem of disposal of the plastic oil containers. Other prior art devices have been complicated to use and expensive to purchase. Yet other prior art devices have proposed dual-chambered containers, having one empty chamber into which the used oil from the vehicle may be drained and having a second chamber filled with clean oil for refilling the vehicle. However, these devices are of value only if the oil companies sell the oil in such containers. Otherwise, the oil must still be transferred into these containers from the original containers, which increases the likelihood of spillage and does not resolve the problem of disposing of the original oil containers. A search in the United States Patent Office has revealed the following:
______________________________________PATENT NO. INVENTOR ISSUED______________________________________4,524,866 P. J. Pollacco Jun. 25, 19854,533,042 W. E. Pollacco Aug. 6, 19854,296,838 M. L. Cohen Oct. 27, 19814,640,431 R. W. Harrison Feb. 3, 1987______________________________________
Each of these references is subject to the disadvantages discussed above. Thus, none of the prior art oil draining and disposal devices have been entirely satisfactory.
BRIEF SUMMARY AND OBJECTS OF INVENTION
These disadvantages of the prior art are overcome with the present invention and an improved oil drainage and disposal device is proposed which is inexpensive to purchase and is simple to use, yet which eliminates the problems involved in draining the oil from a drain pan into suitable containers for delivery to a disposal facility and which permits repeated reuse of the original oil containers.
These advantages of the present invention are preferably attained by providing an improved oil drainage and disposal device comprising a generally box-like container having a large opening formed eccentrically in one surface of said container to permit a plurality of oil containers to be inserted into the interior of said container for storage and to allow oil being drained from a vehicle to enter said container through said opening, at least one cam-actuated opening formed in a second surface of said container perpendicular to said one surface for releasably retaining the necks of oil containers, and closure means mounted in each of said cam-actuated openings and resiliently urged into a position to seal said openings.
Accordingly it is an object of the present invention to provide an improved oil drainage device.
Another object of the present invention is to provide an improved oil disposal device.
An additional object of the present invention is to provide an improved oil drainage and disposal device.
A further object of the present invention is to provide an improved oil drainage and disposal device which is economical to purchase and easy to use.
Another object of the present invention is to provide an improved oil drainage and disposal device which eliminates the problems involved in draining the oil from a drain pan into suitable containers for delivery to a disposal facility.
An additional object of the present invention is to provide an improved oil drainage and disposal device which permits repeated reuse of the original oil containers.
A specific object of the present invention is to provide an improved oil drainage and disposal device comprising a generally box-like container having a large opening formed eccentrically in one surface of said container to permit a plurality of oil containers to be inserted into the interior of said container for storage and to allow oil being drained from a vehicle to enter said container through said opening, at least one cam-actuated openings formed in a second surface of said container perpendicular to said one surface for releasably retaining the necks of oil containers and closure means mounted in each of said cam-actuated openings and resiliently urged into a position to seal said openings.
These and other objects and features of the present invention will be apparent from the following detailed description, taken with reference to the figures of the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a side view of an oil drainage and disposal device embodying the present invention;
FIG. 2 is a bottom view of the oil drainage and disposal device of FIG. 1;
FIG. 3 is an end view of the oil drainage and disposal device of FIG. 1;
FIG. 4 is an enlarged end view of the oil drainage and disposal device of FIG. 1, with the closure means shown in section;
FIG. 5 is an enlarged side view of the closure means of the oil drainage and disposal device of FIG. 1;
FIG. 6 is a bottom view of the closure means of the oil drainage and disposal device of FIG. 1;
FIG. 7 is a vertical section through the wiper of the closure means of FIG. 1; and
FIG. 8 is an isometric sectional view of the wiper of FIG. 7.
DETAILED DESCRIPTION OF THE INVENTION
In that form of the present invention chosen for purposes of illustration in the drawings, FIGS. 1, 2 and 3 show an oil drainage and disposal device, indicated generally at 10, comprising a generally box-like container 12 having a front wall 14, a solid rear wall 16, a bottom 18 and a top 20. The front wall 14 is formed with a large opening 22 located eccentrically of the front wall 14, which is preferably dimensioned to allow a plurality of oil containers 24 to be inserted through the opening 22 into the interior of the container 12 for storage. The bottom 18 has an inclined portion 26 communicating with the rear wall 16 and at least one funnel area 30 about which is mounted an internally cam-actuated closure member 32, which serves to releasably retain the externally threaded neck 34 of a respective one of the oil containers 24, as best seen in FIGS. 4-6. Each of the internally cam-actuated closure members 32 is dimensioned to mate with the external threads on the necks 34 of the oil containers 24 and a wiper means 36 is resiliently mounted in each of the openings 32 and is normally urged, by suitable means such as springs 38, into sealing relation with an annular flange 40 encircling the tubular neck 42 of the closure member 32, as best seen in FIGS. 4, 5 and 6. The closure means 36 is a hollow member encircling the tubular neck portion 42 which projects downwardly from the bottom 18 of the container 12. As best seen in FIGS. 7 and 8, the wiper 36 is formed with a channel 44 extending vertically through the wiper 36 and the wiper 36 has a flanged lower end 46 formed to sealingly mate with the necks 34 of the containers 24. The upper portion 48 of the wiper means 36 is formed to sealingly mate with the exterior surface of the tubular neck portion 42 to prevent leakage from the tubular neck portion 42 when no oil container 24 is engaged with the closure means 32 and spring 38 urges the wiper means 36 to its full downward position. A ball member 50 is slideably mounted within the channel 44 of the wiper 32 and is retained in a chamber 52 formed by a tubular member 54. The ball 50 is formed of material, such as air-entrained ceramic, having a specific gravity less than that of oil, which allows the ball 50 to float upward, when oil enters the chamber 52, to sealingly engage the tubular member 54 to prevent oil from flowing through the tubular member 54. As best seen in FIGS. 4, 5 and 6, the closure member 32 is a generally cylindrical member having an opening 56 formed in the lower end 58 of the closure member 32 below the annular flange 40 and a recess 60 is formed below the annular flange 40 to receive a spring 62. The spring 62 is generally U-shaped, having its end portions 64 crossed and formed to provide handles 64, while the main side portions 66 of the spring 62 are spaced apart and are relatively flat, extending generally parallel to each other, as best seen in FIG. 6, which serve to clamp about the neck portions 34 of the oil containers 24 to releasably retain the neck portions 34 of the oil containers 24 is engagement with the closure member 32. When the neck portion 34 of an oil container 24 is inserted between the side portions 66 of the spring, 62, the neck portion 34 forces the sides 66 of the spring 62 apart and the side portions 66 of the spring 62 bear against the threads of the neck 34 to releasably retain the neck portion 34 and, thereby, to retain the oil container 24 in engagement with the closure member 32. Also, because the sides portions 66 of the spring 62 are relatively flat and parallel, the side portions 66 can accommodate neck portion 34 of substantially any dimension. Finally, a handle 68 may be provided on the oil drainage and disposal device 10 to facilitate carrying and handling of the device 10.
In use, a plurality of oil containers 24 may be inserted through opening 22 for storage within the container 12 of the oil drainage and disposal device 10. When needed, the oil containers 24 may be removed and the container 12 may be placed beneath a vehicle, lying on its rear surface 16 with the bottom 18 lying vertically and the front surface 14 facing upward and with opening 22 positioned to receive the oil as it is drained from the vehicle to allow the used oil to be retained within the container 12. When all of the used oil has been drained from the vehicle, the oil containers 24 may be emptied into the oil fill spout of the vehicle. As each of the oil containers 24 is emptied, the xteriorly threaded] neck 34 of the oil container 24 may be inserted into an appropriate one of the interiorly cam-actuated closure members 32. As this occurs, the neck 34 of the oil container 24 will engage the lower flanged end 46 of the wiper means 36 and will force the wiper means 36 inwardly of the closure means 32 against the urging of spring 38. Because the neck 34 of the oil container 24 mates with the flanged end 46 of the wiper 36, no oil will spill out of the closure member 32 as the oil containers 24 are captured and releasably retained by the spring 62. When all of the empty oil containers 24 have been captured, the user grasps the oil drainage device 10 by the handle 68 and lifts it to the position seen in FIGS. 1-3, with the front wall 14 and rear wall 16 extending vertically and with the container 12 being supported by the plurality of empty oil containers 24. When this is done, the surface of the oil within the container 12 will lie parallel to the lower surface 18 of the container 12 below the lower edge of the opening 22. As noted above, the closure means 32 are hollow tubular members and are provided with tubular neck portions 42. Consequently, the oil within the container 12 can flow through the neck portions 42 and the wiper means 36 into the open necks 34 of the oil containers 24. As each of the oil containers 24 becomes full, the oil will fill chamber 52 within the wiper member 36 and will cause the ball 50 to float upward to block the tubular member 54 and, hence to prevent further flow of oil through the neck portion 42 and wiper member 36 into the container 24. The remaining oil will flow through the interior of the container 12 to the other neck portions 42 and into the oil containers 24 attached thereto. When all of the oil containers are filled with the drained oil, they may be removed from the respective closure members 32 by squeezing the handles 64 of the spring 62 together to cause the side portions 66 of the spring 62 to spread apart and, hence, to release the neck 34 of the container 24. As this is done, the neck 34 of the oil container 24 will move outwardly through the closure member 32, which allows springs 38 to drive the wiper means 36 downwardly toward the annular flange 40 encircling each of the closure members 32. Before the neck 34 of the oil container 24 is fully removed, the upper portion 48 of the corresponding one of the wiper means 36 will sealingly engage the neck portion 42 of the container 12 to prevent discharge of oil from the associated one of the closure members 32. Once the refilled oil containers 24 have been removed from the closure members 32, they may be used to transport the used oil to an appropriate disposal facility or, preferably, may be delivered to a suitable refinery where the oil can be reprocessed and the oil containers 24 may be refilled with clean, reconditioned oil. In this way, the oil presents no disposal or contamination problem and the oil containers 24 may be reused indefinitely and, hence, they also present no disposal problem.
Obviously, numerous variations and modifications can be made without departing from the spirit of the present invention. Therefore, it should be clearly understood that the form of the present invention described above and shown in the figures of the accompanying drawing is illustrative only and is not intended to limit the scope of the present invention.
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An improved oil drainage and disposal device comprising a generally box-like container having a large opening formed eccentrically in one surface of the container to permit a plurality of oil containers to be inserted into the interior of the container for storage and to allow oil being drained from a vehicle to enter the container through the opening, a plurality of annular openings formed in a second surface of the container perpendicular to the one surface for releasably retaining the necks of oil containers, closures mounted in each of the annular openings and resiliently urged into a position to seal the openings, and funnels formed in the second surface about each of the openings.
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BACKGROUND OF THE INVENTION
[0001] The present invention is directed to a toothbrush, either manual or powered, which includes a handle and a head. Cleaning elements are mounted to the head such as tufts of bristles. When toothpaste is applied to the cleaning elements the user inserts the head into the mouth and brushes the teeth in a known manner.
[0002] The head of a conventional toothbrush usually has a flat or slightly altered surface to which cleaning elements are attached. Usually the cleaning elements are strands of plastic material(s) formed into tufts, bundles or other groupings. The strands are attached to the head either before or after forming the toothbrush.
[0003] The toothbrush of the present invention facilitates more motion of cleaning elements in the toothbrush head thereby promoting healthy stimulation of gums and cleaner teeth. It is well known that the ideal brushing technique from a dental hygiene perspective is an up and down stroke along the vertical surface of teeth which massages the gums while cleaning the teeth. However, due to a number of factors, including ergonomic difficulties, haste, lack of education or the like, few consumers use the recommended brushing technique. Rather, the typical consumer brushes across their teeth in a horizontal motion rather than a vertical movement. Various approaches have been taken by others to translate horizontal brush movement into partial vertical movement of the bristles or cleaning elements.
[0004] Translation of horizontal to vertical movement of cleaning elements is accomplished in U.S. Pat. No. 4,783,869 through use of a helix groove in a movable shaft within a toothbrush handle. The groove receives a pin which rides in the groove. This mechanism causes the toothbrush head to partially rotate or oscillate as the handle moves left-to-right or vice versa in the user's mouth. That rotation or oscillation causes the cleaning elements to move in a vertical plane perpendicular to movement of the toothbrush handle.
[0005] U.S. Pat. No. 5,481,775 discloses an arcuate shaped base for a toothbrush. head aligned with the longitudinal axis of the head. A movable arcuate block containing cleaning elements is flexibly mounted on the toothbrush head. The block is free to slide on the head in a manner whereby the cleaning elements may travel in a vertical direction generally transverse to the typical side-to-side motion of the toothbrush.
[0006] U.S. Pat. No. 5,528,786 discloses pivotal mounting of cleaning elements that allows those elements to move up and down in concert with a side-to-side stroke along the teeth.
[0007] A general disclosure of flexible mounting for cleaning elements on a toothbrush head is contained in U.S. Pat. No. 5,839,149. In this patent the cleaning elements are mounted on a flexible membrane supported between a horseshoe shaped handle extension.
[0008] U.S. Pat. No. 6,141,817 discloses cleaning elements mounted on a flexible membrane that splay outward when the toothbrush is pressed against the user's teeth.
[0009] U.S. Pat. No. 6,338,176 B1 issued Jan. 15, 2002 to Smith, et al. discloses round sections of cleaning bristles mounted on individual pads that rotate within a toothbrush body. This converts backward and forward motion of the toothbrush into circular motion of the cleaning elements (column 1, lines 11-13). The bristles associated with each pad are of varying height to accommodate irregularities, gaps, pockets and contours in natural tooth formation (column 1, lines 40-45). The rotating cleaning elements can be supplemented with fixed cleaning elements adjacent thereto (FIG. 11; column 5, lines 43-49).
SUMMARY OF THE INVENTION
[0010] This invention provides transverse movement of cleaning elements relative to the longitudinal axis of a toothbrush head without the cumbersome hinges, mechanisms and helical channels described in the aforementioned prior art toothbrushes. Those prior art toothbrushes using mechanical means to introduce such movement have a common fault of creating interstices and voids in the toothbrush head that can harbor bacteria and germs. The mechanical parts also add to the manufacturing cost of such toothbrushes.
[0011] This invention improves the movement of cleaning elements relative to a toothbrush head. That movement is induced by adding appropriately configured fingers to groups of cleaning elements, which fingers are attached by ribs to a flexible head. The ribs are relatively thin, typically rectangular, webs that connect the fingers to a flexible portion of the toothbrush head. As pressure is applied by the user to the toothbrush handle, the flexible portion of the toothbrush head underlying the finger moves. Because the ribs are physically attached to the flexible portion of the head, the movement of the head is translated to the fingers in a manner which causes the fingers to move laterally to the longitudinal axis of the head. This movement of the fingers wipes across teeth thereby providing extra cleaning of the teeth. The movement of the fingers closest to the gumline acts to massage the user's gums.
[0012] The “fingers” used in this invention may take a variety of shapes and materials. The entire finger can be made of elastomeric material. Alternatively, only a portion of the finger is made of elastomeric material with the tip facing away from the head comprised of bristles extending from the elastomeric material. Preferably the elastomeric material should extend far enough up the finger height to facilitate attachment of enough rib material to promote movement of the finger in the manner described herein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a side elevational overview of a toothbrush broken along its length having a flexible head with fingers mounted thereon, showing the ribs interconnecting the finger and flexible head.
[0014] FIG. 2 is a fragmental front plan view showing an arrangement of fingers connected by ribs to a flexible head.
[0015] FIG. 3 is a fragmental plan view of single finger connected by ribs to an unflexed toothbrush head.
[0016] FIGS. 4 and 5 are fragmental plan views of a single finger connected by ribs to a flexible head in flexed positions caused by movement of the flexible head.
[0017] FIG. 6-8 are fragmental plan views of multiple fingers interconnected to each other and to a flexible toothbrush head by ribs forming a web between the fingers.
[0018] FIG. 9 is a fragmental cross-sectional view in elevation of the fingers mounted in a flexible toothbrush head.
[0019] FIGS. 10-12 are fragmental elevational views of the fingers used with the toothbrush of the invention.
[0020] FIG. 13 is a side elevational view of a power toothbrush using a flexible head and gum stimulation fingers.
[0021] FIGS. 14 and 15 are cross sectional views of the fingers with ribs interconnecting the fingers to a flexible portion of the toothbrush head.
DETAILED DESCRIPTION OF INVENTION
[0022] FIGS. 1 and 2 illustrate a toothbrush 10 with a handle 12 and head 14 . Mounted on or in head 14 are fingers 16 , preferably having a tapered shape. As shown in FIG. 2 fingers 16 are preferably arranged about the periphery of head 14 . That location materially assists the gum massaging effect of the finger movement contemplated by this invention. More particularly, when the longitudinal axis of toothbrush 10 is perpendicular to the axis of teeth being brushed, as is typical with most users, the fingers 16 are closest to the gumline.
[0023] The fingers 16 are preferably flexible and soft to the touch. Accordingly they may be formed of a soft elastomeric material. The general shape of fingers 16 is illustrated in FIGS. 10-12 . As so illustrated they are tapered and comprise all elastomeric material ( FIG. 10 ) or a set of bristles 18 partially surrounded by elastomeric material 20 ( FIGS. 11 and 12 ). The elastomeric material should extend along the length of finger 16 a sufficient distance to facilitate attachment of ribs as described in more detail below.
[0024] To facilitate the therapeutic movement of fingers 16 it is important that head 14 of toothbrush 10 be flexible and that. fingers 16 be flexibly mounted in head 14 . FIG. 9 illustrates one form of flexible mounting of fingers in head 14 . In this embodiment the head 14 has a box-like shape in cross section. At least the upper face 22 of head 14 , and preferably the entirety of head 14 , is made of a flexible material so that the axes of fingers 16 can move relative to the plane of toothbrush 10 . The fingers 16 project from apertures 26 in the flexible upper face 22 of head 14 . Any rib and finger 16 arrangement shown in FIGS. 6-8 can be molded into the toothbrush head 14 . This flexible mounting in a flexible portion 22 of head 14 assists in obtaining the desired lateral movement of fingers relative to the axes of toothbrush 10 . The role of ribs in obtaining that movement is explained below.
[0025] Another means of imparting movement to the fingers 16 is illustrated in FIGS. 14 and 15 . As illustrated, fingers 16 are physically linked to a flexible face 22 A of head 14 by angled rib 24 . Rib 24 can be integrally molded into head 14 and finger 16 during the manufacture of toothbrush 10 . It can also be formed of a more rigid (than elastomeric) material such as polypropylene in order to enhance lateral movement of fingers 16 . Flexible face 22 A of head 14 in this embodiment can be molded around frame members 26 forming the outer periphery of head 14 . These frame members 26 of head 14 may be attached to handle 12 of toothbrush 10 in a known manner.
[0026] The role of ribs 24 and flexible head 14 in imparting lateral movement to fingers 16 is illustrated in FIGS. 2-5 . FIG. 2 illustrates the location of fingers 16 and ribs along outer edges of flexible face 22 of head 14 . Other groups of bristles or cleaning elements 17 are arranged inboard of fingers 16 as illustrated in FIG. 2 . Fingers 16 on the outer edge of head 14 are closest to the gum line when the user holds the toothbrush in a normal position, i.e., with the longitudinal axis perpendicular to the axis of the user's teeth. Ribs 24 extend from the side of finger 16 to the face 22 or 22 A of flexible head 14 . These ribs can have a triangular, trapezoidal or like shape that interconnect the finger 16 to the face of flexible head 14 . This interconnection assures lateral movement of finger 16 as the face 22 or 22 A deflects outward or inward along the longitudinal axis when in use as described below.
[0027] The lateral movement of finger 16 is illustrated in the sequence shown in FIGS. 3-5 . In FIG. 3 there is no deflection of face 22 or 22 A of flexible head 14 . FIG. 4 represents a deflection of face 22 that stretches that face as shown by the arrows 23 at the edge of this fragmental view. When so stretched the ends 28 of rib 24 anchored to face 22 move away from each other. That movement exerts a lateral force on finger 16 causing it to move laterally toward the outside periphery of head 14 as indicated by the arrow 25 in FIG. 4 . Conversely, when deflection of face 22 or 22 A of head 14 causes that face to compress, the ribs 24 push finger 16 laterally in the opposite direction as indicated by the arrow 25 in FIG. 5 . Thus, as various forces are transmitted to flexible face 22 or 22 A of head 14 during use, that head moves in compression or expansion. That movement causes fingers 16 to move in a lateral direction thereby promoting tooth cleaning and gum stimulation.
[0028] Another embodiment of the invention illustrated in FIGS. 14 and 15 shows ribs 24 oriented approximately 90 degrees to the longitudinal axis of toothbrush 10 versus approximately 45 degrees shown in FIGS. 2-5 . In the former embodiment, movement of the flexible face 22 A in an upward direction ( FIG. 15 ) causes lateral inward movement of fingers 16 as illustrated by the arrows 27 in this Figure. Conversely, downward movement of flexible face 22 A would cause lateral movement of fingers 16 away from each other toward the outside of head 14 (not illustrated).
[0029] Other arrangements of ribs 24 and their attachment to fingers 16 are illustrated in FIGS. 6-8 . As illustrated, multiple fingers 16 are interconnected by a continuous rib 24 . FIG. 6 illustrates the interconnecting ribs 24 on one side of fingers 16 . Thus, upon deflection of flexible face 22 or 22 A of head 14 all fingers 16 move in the same direction as indicated by the arrows 29 in FIGS. 6 and 7 . If it were desirable to have the fingers 16 move in different directions the arrangement of ribs 24 shown in FIG. 8 can be utilized.
[0030] Any suitable form of cleaning elements may be used as the cleaning elements 17 in the broad practice of this invention. The term “cleaning elements” is intended to be used in a generic sense which could include conventional fiber bristles or massage elements or other forms of cleaning elements such as elastomeric fingers or walls arranged in a circular cross-sectional shape or any type of desired shape including straight portions or sinusoidal portions.
[0031] It is to be understood that the specific illustration of the cleaning elements is merely for exemplary purposes. The invention can be practiced with various combinations of the same or different cleaning element configurations (such as stapled or in-molded technology bristles, etc.) and/or with the same bristle or cleaning element materials (such as nylon bristles, spiral bristles, rubber bristles, etc.). Similarly, while FIG. 2 illustrates the cleaning elements to be generally perpendicular to head 14 , some or all of the cleaning elements may be angled at various angles with respect to the outer surface of head 14 . It is thereby possible to select the combination of cleaning element configurations, materials and orientations to achieve specific intended results to deliver additional oral health benefits, like enhanced cleaning, tooth polishing, tooth whitening and/or massaging of the gums.
[0032] FIG. 13 illustrates a powered toothbrush 10 A containing the fingers 16 of the invention mounted on a flexible head 14 of the toothbrush. Cleaning elements 17 are preferably mounted inboard of fingers 16 as illustrated in FIG. 2 . This embodiment includes a power driven movable disc or section 30 having cleaning elements. The movable section 30 could be oscillated rotationally such as by using the type of drive mechanism shown in U.S. Pat. No. 5,625,916, or could move in and out using the type of drive mechanism shown in U.S. Patent No. 35,941; all of the details of both patents are incorporated herein by reference thereto. Although FIG. 13 shows movable section 30 to be at the distal end of the head, the movable section(s) could be located at any desired location on the head.
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A toothbrush ( 10 ) is disclosed with soft fingers ( 16 ) mounted on the toothbrush head ( 14 ). During use of the tooth-brush the fingers move laterally relative to the axis of the tooth-brush thereby improving the tooth cleaning and gum massaging performance of the toothbrush. The lateral movement of the fingers is accomplished by relatively stiff ribs ( 24 ) which physically interconnect the fingers to flexible portions of the toothbrush head. The ribs translate flexure of the head into the lateral movement of the fingers.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention pertains to a die plate for use in extruding a viscous material. More particularly, a die plate is shown that permits rapid extrusion of material and that has an extended service life.
2. Background of the Invention
Existing die plates used in the extrusion of viscous materials are formed from flat metal plates with a multiplicity of holes drilled through the plates. The holes through the plates are of substantially equal diameter and of substantially uniform diameter throughout their lengths. The holes through existing extrusion die plates are also spaced parallel to each other and substantially equal distance from each other.
A common problem with existing extrusion die plates is that the area around the perimeter of a group of holes through the plate tends to rip or tear away from the solid portion of the plate under the pressure of the extruder. The extruder generally forces a viscous or pasty material through the holes in the extruder die plate to form a plurality of cylinders of the viscous material that may be broken up into small particles for the preparation of solid granules.
The thickness of the extruding die plate controls the length of the holes through the die plate, which constitutes one of the factors affecting the power consumed by the extruder. The thickness of the die plate also affects the strength of the die plate, and hence resistance to failure by tearing along the boundary between the perforated section of the die plate and the solid support portion of the die plate. A change in the thickness of the die plate, and therefore in the length of the holes through the die plate, presents problems because it affects not only the pressure required to extrude the viscous materials through the die plate but also the rheology or flow characteristics of the material extruding through the die plate. The feed rate at which the viscous material is extruded through the die plate can also be changed in order to affect the pressure exerted on the die plate. A problem with reducing the feed rate in order to lower the back pressure on the die is a resultant lower production rate and reduced economy. The characteristics of the material being extruded, such as viscosity, can also be changed in an attempt to reduce the stress on the die plate during extrusion. Changes to the material characteristics of the extrusion materials is generally either impossible or undesirable as a result of the required characteristics of the end product.
SUMMARY OF THE INVENTION
In view of the foregoing problems with conventional die plates, the die plate according to one aspect of the present invention was developed to permit rapid extrusion of a solid viscous material under pressure while maintaining an extended service life of the die plate as compared with conventional die plates.
A die plate according to an aspect of the present invention includes a solid support area and a perforated area that borders on the solid area. The perforated area includes a main portion having holes through the die plate that are spaced from each other by first distances, and a transitional area separating the main portion from the solid support area and having holes through the die plate that are spaced from each other by second distances greater than the first distances.
The solid supporting section of the die plate separates the perforated portion of the die plate into a plurality of smaller perforated extruding sections. Each of the smaller perforated extruding sections has a major portion of holes through the die plate that are spaced from each other by first distances and a transition portion of holes through the die plate that are spaced from each other by second distances greater than the first distances. The transition portions surround the major portions in each smaller perforated extruding section and separate the major portions from the solid supporting section.
The solid supporting section of the die plate is shaped in accordance with the structure of the extruder used to force viscous material through the die plate. A typical extruder screw used for forcing the viscous material through the die plate is a screw-type extruder such as the six inch extruder sold under the trademark “EXTRUD-O-MIX” made by Hosokawa Bepex Corporation of Minneapolis, Minn. The extruder includes a beveled blade that wipes viscous material over the face of the die plate and pushes the material through the holes in the die plate.
The solid support section on the die plate borders perforated areas of the die plate through which the viscous material is extruded. The spacing, and therefore the amount of die plate material between the holes through the die plate in the transitional areas adjacent the solid support section is greater than the amount of material between the holes in a major portion of each perforated area. The increase in the amount of material between holes through the die plate closer to the solid support sections improves the strength of the die plate at the perimeters the perforated areas, thus increasing the service life of the die plate.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a conventional die plate design with uniformly spaced holes.
FIG. 2 shows a die plate according to an embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In one embodiment of the present invention, as shown in FIG. 2, a die plate 10 approximately six inches in diameter and approximately 0.04 inch thick includes a solid support section 20 and perforated sections 30 . The solid support section 20 includes a center hub 22 , radially extending spokes 24 and an outer rim 26 . The areas of the die plate 10 defined between the center hub 22 , the radially extending spokes 24 and the outer rim 26 of the solid support section constitute the perforated areas 30 . Each of the perforated areas 30 includes a major portion 32 of holes through the die plate and a transition portion 34 of holes through the die plate. The transition portions 34 completely separate the major portions 32 from the solid support portions 20 .
In the embodiment shown in FIG. 2, the holes through die plate 10 in major portions 32 of perforated areas 30 are 0.7 mm (0.027 inch) in diameter. The holes are shown to be substantially equal distance from each other within each of the major portions 32 . The holes within the major portions 32 are spaced from each other approximately 1.0 mm (0.04 inch) center-to-center.
The holes through the die plate 10 in the transition portions 34 of perforated areas 30 are also 0.7 mm (0.027 inch) in diameter. The holes within the transition portions are spaced from each other approximately 1.5 mm (0.06 inch). The transition portions 34 include at least 3 rows of the 0.7 mm (0.027 inch) diameter holes spaced 1.5 mm (0.06 inch) from each other center-to-center extending around the outer periphery of each major portion 32 .
Although the embodiment shown in FIG. 2 has holes through the plate in both the major portions and the transition portions of the perforated sections that are substantially equal diameter round holes, a skilled artisan will recognize that the holes could have other shapes. The shape of the holes through the die plate determines the shape of the tubes of extruded material being forced through the die plate. Additionally, the spacing between the holes in the major portions and the transition portions could vary as long as the holes in the transition portions are spaced by greater distances than the holes in the major portions, such that the transition areas have an increased strength and resistance to tearing away from the adjacent solid sections.
In the following examples a conventional extruder die plate was compared to die plates made in accordance with aspects of the invention.
EXAMPLES
In the following examples, intimate mixtures of sodium 4-sulfophenyl-[(1-oxyalkanoyl)amino]hexanoatee (alkanoyl=C 8 -C 10 ), citric acid or sodium citrate dihydrate, linear alkanesulfonate (Ufaryl 85™), and sufficient water to moisten the mix were extruded, using a six inch extruder sold under the trademark “EXTRUD-O-MIX™” (manufactured by Hosokawa Bepex Corporation of Minneapolis, Minn.), to form small pellets.
Examples 1 and 2 use conventional die plates, and example 3 uses a die plate made in accordance with aspects of this invention.
Example 1
A mixture of 123.8 kg of sodium 4-sulfophnyl-[(oxyalkanoyl)amino]hexanoate, 18.9 kg of LAS, and 16.2 kg of citric acid was extruded, using a die plate 0.7 mm (0.027 inch) thick with 50% open area which consisted of 0.7 mm (0.027 inch) holes (FIG. 1 ). Power drawn by the extruder was measured as the extrusion rate was increased from 226 to 376 kg/hr. The power consumed by the extruder rate was increased gradually from 1.28 to 3.63 kw. When an attempt was made to increase the extrusion rate further, the die failed by ripping of the perforated portion of the die away from the solid portion. It was observed during the run that the water level in the feed mix was not critical.
Example 2
In this example, a slightly thicker die plate 1 mm (0.04 inch) thick was used. The die failed after only 5 min running time, at an extrusion rate of 393 kg/hr. The feed material was the same as in Example 1, except that sodium citrate dihydrate was substituted for citric acid. The power drawn by the extruder at the time the die failed was 4.4 kw. The die failure was the same way as in Example 1.
Example 3
In this example, a die plate as described in this specification and illustrated in FIG. 2 was used. The die plate was 1 mm (0.04 inch) thick and contained 50% open area in which the 0.7 mm (0.027 inch) diameter holes spaced 1.0 mm (0.040 inch) apart from center-to-center were surrounded by holes spaced 1.5 mm (0.06 inch) center-to-center apart. The feed material was the same as that of Example 1. The extruder operated without interruption and with no die failure, at extrusion rates of 210-250 kg/hr, and at extruder power consumption as high as 7.6 HP (5.7 kw).
It is apparent from comparison of Examples 1 and 2 with Example 3 that die plate “ripping” that occurs with the conventional plate which contains only 0.7 mm holes spaced equidistant is avoided when the die plate of this invention is used. In Example 1, the plate failed when the extruder power consumption (a measure of the back pressure on the die plate) was only a little over 3.6 kw. In Example 2, in which a thicker plate was used, failure occurred at power consumption of 4.4 kw. In Example 3, in which the plate thickness was the same as Example 2, but the improved die plate was used, failure did not occur at power consumption as high as 5.7 kw. The power consumption varied during the run because of changes in the temperature and viscosity of the feed.
It will be understood that various modifications and changes can be made in the configuration of the extended life die plate according to the present invention. The thickness of the die plate can be varied to affect the pressure drop through the die plate. A thicker die plate could be used with a less viscous material while keeping total pressure drop through the die plate the same. The shape of the holes through the die plate could be round, square, trapezoidal, polygon, oval, or any other desired configuration, with a resultant change in the shape of the strands of material extruded through the die plate. The spacing between the holes through the die plate can be varied as long as the holes in a transition area adjacent solid support sections of the die plate are spaced further apart than holes in a major portion of the perforated area separated from the solid support sections by the transition area. The solid support section of the die plate can be varied to conform to different extruder devices. While a center hub, radially extending spokes and outer rim configuration for the support section is shown, other configurations for the solid support section could include various grid patterns, or even just a simple square or circle without a center solid support area.
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A die plate is shown suitable for extruding a viscous material into a convenient form for the preparation of small pellets or particles. The die plate includes solid support portions and perforated portions. Each perforated portion of the die plate includes a major portion of holes through the die plate spaced from each other by a first distance and a transition portion separating the major portion from the solid support portions, with the transition portions having holes spaced from each other by a distance that is greater than the first distances.
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CROSS REFERENCE TO RELATED APPLICATIONS
The present application is a continuation of commonly owned U.S. patent application Ser. No. 08/752,688, filed Nov. 19, 1996, U.S. Pat. No. 5,806,265, entitled "TRUSS JOINING GUSSET," which claims the benefit of U.S. Provisional Application Ser. No. 60/010,584, filed Jan. 25, 1996.
BACKGROUND OF THE INVENTION
Structural trusses are used for the fabrication of buildings in the construction industry. The primary application of structural trusses is to define a desired roof line and to support the roof by the building walls and interior structure. Trusses are typically fashioned from a series of joined vertical, horizontal, and angled members. Historically, trusses have been fabricated from wooden members joined by flat metal plates having a plurality of spiked projections therefrom for driving the plates into the wooden members and retaining the members in a joined relationship.
In recent years, metal trusses have gained favor in the construction industry. Metal trusses are typically comprised of metal U-channels and square tubular members with the members being joined by mechanical fasteners.
When added to a building structure, metal trusses are primarily in a parallel spaced apart relationship. However, for hipped roofs or roofs of multiple roof lines and the like, secondary trusses are required for attachment to the primary trusses to give the desired roof lines. The secondary trusses are joined to the primary trusses by abutting the secondary truss to the primary truss and manually holding the truss in place while angled clips are fastened to the trusses to join the various horizontal or vertical truss members. In practice, mechanical fasteners are installed through each flange of the angled clips thereby resulting in load transference between trusses via fasteners which are installed essentially at right angles to each other. This method of joining trusses results in the undesired inducement of bending movements in the flanges of the angled clips, misalignment of secondary trusses with respect to the primary trusses, and lateral movement and play between trusses as roof loads are applied.
SUMMARY OF THE INVENTION
In the present invention, a gusset is provided for joining trusses wherein the gusset has a body portion for attachment to a first truss and a finger for engaging a flange of a second truss to support the end of the first truss on the second truss until the first truss is permanently fastened to the second truss. This eliminates the need to independently support the first truss in relative position to the second truss while permanently fastening the first truss to the second truss.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a plurality of trusses arranged to support a roof wherein secondary trusses are joined to primary trusses according to the present invention.
FIG. 2 is a plan view of a metal truss joining gusset for joining metal trusses at substantially right angles.
FIG. 3 is a sectional perspective view of a truss joint showing a metal truss joining gusset attaching a secondary metal truss to a primary metal truss.
FIG. 4 is an alternate embodiment of the gusset for joining a secondary truss to a primary truss at an angle other than 90°.
FIG. 5 is a plan view of the gusset joining a secondary truss to a primary truss at an angle other than 90°.
FIG. 6 is an alternate embodiment of the gusset joining a secondary truss to a primary truss and to a second truss adjacent and parallel to the primary truss.
FIG. 7 is a plan view of the gusset joining a secondary truss to a primary truss and to a second truss adjacent and parallel to the primary truss.
FIG. 8 is a perspective view of the embodiment of the gusset joining a secondary truss to a primary truss and to a second truss adjacent and parallel to the primary truss.
FIG. 9 is a perspective view of an upper portion of trusses joined according to the present invention wherein the upper truss portions are joined with splice plates.
DESCRIPTION OF PREFERRED EMBODIMENT
For purposes of description herein, the terms "upper," "lower," "right," "left," "rear," "front," "vertical," "horizontal," and derivatives thereof shall relate to the invention as oriented in FIGS. 2 and 3. However, it is to be understood that the invention may assume various alternative orientations and step sequences, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification are simply exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise. Within this description, members of a truss referred to as chords are those horizontal or near horizontal members forming the bottom of the truss and those angled upper members defining a roof line. The truss members extending between chords and maintaining the chords in a spaced apart relationship are referred to as webs.
Turning to the drawings, FIG. 1 shows a network of trusses shown generally at 1. Primary trusses 2 are generally supported at the ends of the truss by the exterior supporting walls, and, depending upon the internal configuration of a building, the trusses may also be supported at an intermediate point depending upon the internal configuration of the building. Often times, the roof lines of buildings incorporate either multiple roof lines or hipped roofs thereby requiring trusses other than primary trusses to facilitate the alternate roof lines. In creating the multiple roof lines such as the hipped roof shown in FIG. 1, a secondary truss 4 is attached to a primary truss 2 and is oriented at an angle with respect to primary truss 2 to form the desired roof line. Additionally, secondary truss 4 may also act as t primary truss to secondary trusses 6 to complete the truss network for a particular roof. Secondary trusses 6 are mated and attached to truss 4 with gussets 10 positioned at a lower end portion of secondary truss 6 at the point where secondary truss 6 abuts against primary truss 4. Depending on the configuration of the desired roof lines, the secondary trusses may be mated with the primary truss 4 at either right angles or at an angle other than 90° to form the desired roof line.
Referring to FIG. 2, the preferred embodiment of the present invention discloses a gusset 10 comprising a flat metal plate 11 having a finger 12, a depending portion 13, a forward end 17 and an upper portion 19. Depending portion 13 and upper portion 19 generally forming a body of the gusset. Finger 12 and depending portion 13 combine to define slot 14 therebetween. The width of slot 14 is slightly greater than the thickness of upstanding flanges 23 of bottom chord 22 of truss 20 to which gusset 10 is to be mated, and the depth of slot 14 is substantially equal to the length of upstanding flange 23 (FIG. 3). Bottom chord 22 is in the general shape of a U-channel. Gusset 10 has a first hole series 15 in upper portion 19 located substantially in vertical alignment with finger 12. A second hole series 16 is also located in upper portion 19 forward of and in substantially horizontal alignment with hole series 15 and is substantially horizontally equi-distant from slot 14 as is holes series 15. The number of holes in series 15 and series 16 is dependent on the force loads to be transferred between trusses and is therefore application dependent; however, the number of holes in series 15 is typically equal to the number of holes in series 16.
In FIG. 3, two gussets 10 are shown in use joining secondary truss 30 to primary truss 20. Secondary truss 30 is typically comprised of bottom chord 32 in the shape of a U-channel having upstanding flanges 33 and terminating at butt end 34. Co-located at butt end 34 is web 31 typically formed in a square tubular cross-section. Web 31 rests within the U-shaped channel of bottom chord 32. Gussets 10 flank the outer sides of web 31 and also flank the inner sides 36 of upstanding flanges 33 on bottom chord 32 of secondary truss 30. Gusset 10 is attached to secondary truss 30 with fasteners 37 through second hole series 16; fasteners 37 engage both truss web 31 and gusset 10. Similarly, holes are formed through both bottom chord 32 and gusset 10 with fasteners 35 installed therethrough affixing portion 13 of gusset 10 to upstanding flange 33 of bottom chord 30. The number of fasteners 35 again depending on the force loads exerted on trusses 20 and 30. Gusset 10 is formed in a manner such that an angular web 38 extending from the approximate intersection of bottom chord 32 and web 31 can also be attached to gusset 10.
At such time as secondary truss 30 is desired to be joined to primary truss 20, secondary truss 30 is manually positioned relative to primary truss 20 so that butt end 34 of secondary truss 30 is abutted against primary truss 20 and each of gusset plates 10 flank vertical member 21 of primary truss 20. Secondary truss 30 is vertically lowered so that slots 14 in gussets 10 engage the upstanding flange 23 in bottom chord 22 most proximate to secondary truss 30. When flange 23 is fully engaged within slots 14, fingers 12 of gussets 10 extend into the U-section of bottom chord 22, thereby retaining secondary truss 30 in proper registration with primary truss 20 and alleviating the need to manually support secondary truss 30 while attaching secondary truss 30 to primary truss 20. Holes are formed in web 21 in registration with holes 15 and fasteners 24 are thereby installed in holes 15 for permanent attachment of secondary truss 30 to primary truss 20.
An alternate embodiment 40 of truss joining gusset 10 is shown in FIGS. 4 and 5 whereby gusset 40 is formed in a manner similar to gusset 10 such that plate 41 is bent along bend line 47. Finger 42, and holes series 45 are no longer co-planar with depending portion 43 and holes series 46. Mark line 48 is stamped on at least one side of gusset 40 slightly forward of slot 44 and parallel thereto. In the preferred embodiment, mark line 48 is approximately 3/16 inch forward of slot 44. In use, gusset 40 is mounted to secondary truss 30 in a manner similar to gusset 10 with butt end 34 horizontally aligned with mark line 48 on gusset 40. The purpose of gusset 40 is to mount secondary truss 30 to primary truss 20 at an angle other than 90° and corresponding to angle 49 formed in gusset 40 at bend line 47. Gusset 50 is formed in the same manner as gusset 40; however, the bend line for gusset 50 and the hole series for mounting gusset 50 to web 31 are located farther forward on gusset 50 to accommodate for the geometry of mounting secondary truss 30 to truss 20 at the other than 90° angle. After installation of gussets 40 and 50 on secondary truss 30, slot 44 in gusset 40 and a corresponding slot in gusset 50 and hole series 45 in gusset 40 and the corresponding holes series in gusset 50 are all in alignment to permit engagement of the slots in gussets 40 and 50 with the flange 23 on primary truss 20 and to permit gussets 40 and 50 to flank web 21. Gussets 40 and 50 are then fastened to web 21 in the same manner as gusset 10.
A third embodiment 60 of truss joining gusset 10 is shown in FIG. 6 whereby gusset 70 is formed in a manner similar to gusset 10 with the addition of tabbed portion 68 extending rearward from plate 61. Gusset 60 also has hole series 65 and 66 as does gusset 10 and has a third hole series 67 in tabbed portion 68. Hole series 67 is in substantially horizontal alignment with hole series 65 and 66 and horizontally spaced from hole series 65 to engage a second truss 70 adjacent to primary truss 20.
Referring to FIGS. 6-8, gusset 60 is shown in use in joining secondary truss 30 to primary truss 20 and second primary truss 70 at substantially right angles thereto. In use, gussets 60 flank web 31 in secondary truss 30 and are fastened thereto by fasteners 37. Depending portion 63 of gusset 60 flank interior surface 36 of vertical flanges 33 and are fastened thereto by mechanical fasteners 35. Secondary truss 30 is then abutted to primary truss 20 and vertically lowered until vertical flange 23 engages slot 64 in gusset 60. Gussets 60 flank the exterior portions of webs 21 and 71 in trusses 20 and 70 respectively. Holes are then formed in webs 21 and 71 corresponding to and in registration with hole series 65 and hole series 67 in gussets 60. Gussets 60 are then affixed to webs 21 and 71 with fasteners 24 and 74 respectively.
As illustrated in FIG. 8, in addition to the gusset, such as gusset 10, affixing the lower portion of a secondary truss 30 to a primary truss 20 as shown in FIG. 3, a splice plate can be attached to the sides of webs 31 and 21 and affixed in place with fasteners to maintain secondary truss 30 in a desired vertical relationship with respect to primary truss 20.
In the foregoing description, it will be readily appreciated by those skilled in the art that modifications may be made to the invention without departing from the concept disclosed herein. Such modifications are to be considered as included in the following claims, unless these claims expressly state otherwise.
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A gusset for joining first and second abutting support trusses wherein the gusset comprises a plate having a body portion and a finger portion. The body portion is adapted to be abutted against and fastened to a side of the first support truss at one end thereof and the finger portion is adapted to extend beyond the end of the first truss when the body portion is fastened to the first support truss. The finger portion is further adapted to hangingly engage at least one element of the second support truss for supporting the one end of the first truss thereon without fastening the first truss to the second truss.
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CROSS-REFERENCE TO RELATED APPLICATION
This is a continuation application of U.S. application Ser. No. 10/885,072, filed Jul. 7, 2004, now U.S. Pat. No. 6,996,054, which is a continuation application of U.S. application Ser. No. 10/437,912, filed May 15, 2003, now U.S. Pat. No. 6,845,081, which is a continuation of U.S. application Ser. No. 10/067,817, filed Feb. 8, 2002, now U.S. Pat. No. 6,580,685, which is a continuation of U.S. application Ser. No. 09/809,048, filed Mar. 16, 2001, now U.S. Pat. No. 6,392,985, which is with U.S. application Ser. No. 09/808,993, filed Mar. 16, 2001, now U.S. Pat. No. 6,370,106, which are continuations of U.S. application Ser. No. 09/514,284, filed Feb. 28, 2000, now U.S. Pat. No. 6,262,968, which is a continuation of U.S. application Ser. No. 09/181,677, filed Oct. 29, 1998, now U.S. Pat. No. 6,064,644, which is a continuation of U.S. application Ser. No. 08/958,867, filed Oct. 27, 1997, now U.S. Pat. No. 5,898,663, which is a continuation application of U.S. application Ser. No. 08/733,924, filed Oct. 18, 1996, now U.S. Pat. No. 5,982,738, which is a continuation-in-part application of U.S. application Ser. No. 08/600,730, filed Feb. 13, 1996, now U.S. Pat. No. 5,805,565, the subject matter of which are incorporated by reference herein.
This continuation application is also related to U.S. application Ser. Nos. 11/178,444, 11/178,433, 11/178,424, 11/178,434, 11/178,782, 11/178,435, 11/178,543, 11/178,445, 11/178,403, 11/178,420, 11/178,419, 11/178,404, 11/178,446, 11/178,448, and 11/178,401, filed Jul. 12, 2005, which are continuations of U.S. application Ser. No. 10/885,072, filed Jul. 7, 2004, now U.S. Pat. No. 6,996,054, and this continuation application is also related to U.S. application Ser. Nos. 11/176,367, and 11/176,338, filed Jul. 8, 2005, which are continuations of U.S. application Ser. No. 10/938,614, filed Sep. 13, 2004, which is a continuation of U.S. application Ser. No. 10/463,581, filed Jun. 18, 2003, now U.S. Pat. No. 6,661,489, which is a continuation application of U.S. application Ser. No. 10/437,912, filed May 15, 2003, now U.S. Pat. No. 6,845,081, which is a continuation of U.S. application Ser. No. 10/067,817, filed Feb. 8, 2002, now U.S. Pat. No. 6,580,685, which is a continuation of U.S. application Ser. No. 09/809,048, filed Mar. 16, 2001, now U.S. Pat. No. 6,392,985.
BACKGROUND OF THE INVENTION
The present invention relates to an optical recording medium and more particularly to a high-density optical recording medium having a track width smaller than an optical spot diameter.
An example of a medium for performing high-density (narrow track) recording is disclosed in, for example, JP-A-6-176404. According to this example, in an optical recording medium having grooves and lands which are formed on a substrate and information recording areas which are formed in association with both the groove and the land, prepits are disposed on a virtual extension line of the boundary between a groove and a land. In particular, the prepits are located on only one side of any specific position of the center line of each groove.
With this construction, recording information is formed on both the groove and the land, the prepits have charge of address data representative of the recording areas and one prepit is used in common to a pair of adjacent groove and land to provide address data therefor. When the technique as above is applied to, for example, a phase change recording medium or a magneto-optical recording medium, interference of information (crosstalk) between adjacent lands or grooves due to the optical interference effect within an optical spot can be prevented, thereby permitting narrowing of track.
On the other hand, in the prepit area free from the optical interference effect, the address data can be common to the paired groove and land and the effective track pitch can be increased to reduce crosstalk.
In the example of JP-A-6-176404, however, the disposition of the prepit area is offset on one side of the center line of the groove or land, so that when an optical spot is caused to track a groove or a land, a tracking error (tracking offset) increases, making it difficult to perform high-density recording in which the track pitch is narrowed.
SUMMARY OF THE INVENTION
The present invention achieves elimination of the above problems and it is a first object of the present invention to provide an optical recording medium which can suppress the tracking offset to a value or level which is sufficiently low for the practical use and permit efficient disposition of address data even when recording is effected on both the groove and the land.
A second object of the present invention is to provide a high-density optical recording medium which can ensure simple mastering and easy replica preparation and can permit decoding even when a readout error takes place.
To accomplish the above first object, the following expedients are employed.
(1) Grooves and lands are formed on a substrate of a recording medium, information recording areas are formed in association with both the groove and the land, and prepits are disposed on a virtual extension line of the boundary between a groove and a land.
The disposition of prepits satisfies the following requirements (a) to (c) at the same time.
(a) Prepits are located on both sides of a virtual extension of the center line of a groove; (b) Prepits are located on both sides of a virtual extension of the center line of a land; (c) Prepits are not located on the both sides of any specific position of the center line of a groove; and (d) Prepits are not located on the both sides of any specific position of a land.
With this construction, the arrangement of prepits is not offset on either one side of a virtual extension of the center line of the groove or the land to ensure that tracking offset hardly occurs and the prepits do not exist on both sides of any specific position of the center line of the groove or the land to prevent interference of prepit information between adjacent tracks from taking place within a reproduced spot so as to permit high-density narrow track recording.
(2) When prepits are disposed in the circumferential direction such that those on one side of a groove are not discriminative from those on the other side or those on one side of a land are not discriminative from those on the other side, at least consecutive two dispositions of prepits associated with the groove or the land are made to be different from each other to provide the same disposition of prepits periodically every two dispositions.
As the other option,
(3) A groove associated with at least one pair of pits disposed on both sides of the center line of the groove in a prepit area and an adjacent groove not associated with pits disposed on both sides of the center line of this groove within the prepit area are disposed alternately in the radial direction.
Through this, by merely reproducing the pits, prepits associated with the groove can be discriminated from those associated with the land to improve reliability of information recording reproduction.
(4) Either one of synchronous information and address data is represented by prepits disposed on either one of the both sides of a groove.
As the other option,
(5) Only one of synchronous information and address data is represented by prepits arranged on one side of a groove and both the synchronous information and the address data are represented by prepits arranged on the other of the both side of the groove.
Through this, address data can be reproduced under accurate synchronization. In addition, since the phase margin between prepits on the both sides can be extended, fabrication of a recording medium can be facilitated.
(6) The groove and the prepit have the same depth which is 70 nm or less. More preferably, the depth is 40 nm or more and 60 nm or less.
With this construction, an advantage of suitable crosstalk cancellation can be obtained between the groove and the land and besides an excellent tracking servo signal can be obtained. Formation and fabrication of the recording medium can be facilitated. With the groove depth exceeding 70 nm, the formation of the groove is difficult to achieve. When the groove depth is about 50 nm, the tracking servo is maximized and with the groove depth being about 50±10 nm, substantially the same effect can be attained.
(7) The groove and the land have substantially the same width which is between 0.3 μm and 0.75 μm.
With this construction, excellent tracking is compatible with high-density recording. If the groove and land have a width of not greater than 0.3 μm, then two of the groove and land will be confined within one optical spot and an excellent tracking signal cannot be obtained. On the other hand, if the groove and land have a width exceeding 0.75 μm, then effective high-density recording cannot be permitted.
(8) Of prepits, the smallest one has a diameter which is smaller than a width of each of the groove and the land. More preferably, the diameter is in the range from 0.25 μm to 0.55 μm.
Through this, an excellent prepit signal can be obtained without crosstalk. With the diameter being not greater than 0.25 μm, the prepit signal decreases in the extreme and with the diameter exceeding 0.55 μm, crosstalk is generated.
In the present invention, prepits are arranged on the both sides of a virtual extension line of the center line of a groove or a land in the optical spot scanning direction. Consequently, offset is decreased to make the tracking offset hardly occur and the prepits do not exist on the both sides of any specific position of the center line of the groove or the land to ensure that interference of prepit information between adjacent tracks within a reproduced spot can be prevented, and high-density narrow track recording can be permitted.
Further, even in the presence of tracking offset, the amount of tracking offset can be detected accurately by comparing amplitudes of signals representative of prepits on the both sides. Accordingly, by feedback-controlling the information indicative of a comparison result to a scanning unit, the tracking offset can be suppressed.
At a portion between a groove and a prepit area, between a land and a prepit area or between prepit areas, a gap takes place when a prepit train on a virtual extension line of the boundary between a groove and a land shifts to a prepit train on an adjacent virtual extension line. The aforementioned JP-A-6-176404, however, does not take the gap into consideration. Accordingly, in the absence of the gap or with the gap being very short, mastering of the substrate cannot be proceeded with by one-beam cutting and requires two-beam cutting. Further, during replica preparation, injection must be applied to a steep pattern, leading to a decrease in yield. In addition, during reproduction of signals, tolerance to distortion of the reproduced spot and the tracking offset is decreased and a readout error is liable to occur.
To accomplish the second object, the following expedients are employed.
(1) Grooves and lands are formed on a substrate and prepits are arranged on a virtual extension of the boundary between a groove and a land. In particular, the prepits are disposed on both sides of an extension of the center line of a groove or a land and therefore, the optical axis of a laser beam must be moved during cutting. An acoustic-optical deflector (AOD) is used to change the optical axis. But it takes a time for the AOD to cause the optical axis to reach a desired optical axis position after transmitting a signal for optical axis change and when a modulated laser beam is irradiated along the intact optical axis, pits are formed obliquely on the substrate. Accordingly, no pattern is formatted between the groove or the land and the succeeding prepits to provide a gap and an acoustic-optical modulator (AOM) is cut off corresponding to the gap to prevent laser irradiation and pit drawing. Thus, the substrate can be fabricated with a simple cutting machine. In addition, since a number of unevennesses are not formed on a narrow area on the substrate, the yield during preparation of replica can be increased.
(2) In the disposition in which prepits are arranged on a virtual extension of the boundary between a groove and a land, when the disposition of a prepit train on one side of a virtual extension of the boundary between the groove and the land is exchanged with the disposition of a prepit train on the other side or vice versa, the trailing edges of prepit trains on the respective one sides are aligned with each other in the radial direction of the substrate. The succeeding pit strains are spaced from those trailing edge positions in the circumferential direction or the recording/reproducing direction and the trailing edges of the succeeding pit trains are aligned with each other similarly. When the formed gap meets the recording rule, the substrate as a whole can be formatted conveniently and portions devoid of pits can be collected at a specified area on the substrate, thereby solving problems involved in cutting and replica preparation for reasons described previously.
(3) Radially adjacent pit trains each having only original information pits cannot be aligned with each other at the trailing edge in the radial direction. Accordingly, new pits are added to ensure the alignment of the trailing edges in the radial direction while observing the rule during recording.
(4) In the shift of the disposition of a pit train from one side to the other as described in the above (2), leading edges of pits in the disposition on the other side can be aligned in the radial direction to solve the problems involved in cutting and replica preparation for the same reasons set forth in the (2). In particular, from the standpoint of signal reproduction, a synchronous signal is allotted to pit information immediately after the shift of the pit train so that decision of a channel bit at the specified position may be thought much of, thereby ensuring that the tolerance to the leading edge position can be increased and a possibility that erroneous reading of important data of, for example, address at the position immediately before the shift of a pit train can be decreased.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an enlarged fragmentary plan view of a first embodiment of an optical recording medium according to the present invention.
FIG. 2 is a waveform diagram of reproduced signals from the medium of FIG. 1 .
FIG. 3 is a block diagram of an apparatus for recording and reproduction of the optical recording medium used in the present invention.
FIG. 4 is an enlarged fragmentary plan view of a second embodiment of the optical recording medium according to the present invention.
FIG. 5 is an enlarged fragmentary plan view of a third embodiment of the optical recording medium according to the present invention.
FIG. 6 is a similar view of a fourth embodiment of the optical recording medium according to the present invention.
FIG. 7 is a waveform diagram of reproduced signals from the optical recording medium of FIG. 6 .
FIG. 8 is an enlarged fragmentary plan view of a fifth embodiment of the optical recording medium according to the present invention.
FIG. 9 is a diagram showing an information structure in the fifth embodiment of the optical recording medium according to the present invention.
FIG. 10 is an enlarged fragmentary perspective view showing the relation between the prepit area and the groove in the fifth embodiment.
FIG. 11 is an enlarged fragmentary plan view showing details of positional displacement in the embodiments of the optical recording medium according to the present invention.
FIG. 12 is an enlarged fragmentary plan view of a sixth embodiment of the optical recording medium according to the present invention.
FIG. 13 is a diagram showing an example of a modulated code in the sixth embodiment of the optical recording medium according to the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Embodiment 1 (Optical Recording Medium)
Referring now to FIG. 1 , there is illustrated, in enlarged fragmentary plan view form, an optical recording medium of the present invention. Grooves 84 each having a width of 0.6 μm and a depth of 50 nm and lands 85 each having a width of 0.6 μm are arranged alternately in the radial direction of the medium and recorded marks 81 are formed on the two kinds of areas. In other words, each of the groove 84 and land 85 serves as a recording area. In a prepit area 83 , any groove is not formed but pits 82 are disposed on an extension of the boundary between a land and a groove. Each of the pits has a width of 0.35 μm and a depth of 50 nm. The prepit area is divided into a first prepit area 831 and a second prepit area 832 . In the first prepit region 831 , pits 82 are disposed on the upper side, as viewed in the drawing, of the center line of the land 85 and in the second prepit area 832 , pits 82 are disposed on the lower side, as viewed in the drawing, of the center line of the land 85 .
Accordingly, when an optical spot 21 scans, for example, the land 85 , pits on only either one of the sides are always reproduced and there is no fear that crosstalk will occur between adjacent tracks. Therefore, address data recorded in the form of the prepits can duly be reproduced without crosstalk.
Since the pits 82 do not adjoin to each other in the radial direction, they can be formed with ease. Also, pits 82 are uniformly disposed on both sides of a track (a land or a groove) and hence the influence on a tracking servo signal, which is caused by the pits 82 , can be canceled. Accordingly, the tracking offset can be suppressed to a sufficiently small level.
Further, when reproducing, for example, a land 85 , reproduction of address data at the second prepit area 832 is carried out continuously with reproduction of address data at the first prepit area 831 . Accordingly, when the two areas are united into one area in which information is arranged to provide address data for one track, an address (track number) of a land and that of a groove can be set independently of each other. In other words, by sequentially reproducing the address data pieces in the first and second prepit areas 831 and 832 , discrimination between the land and the groove can be ensured.
More particularly, for reproduction of the groove, address data represented by prepits arranged in the first prepit area is made to be identical to that represented by prepits arranged in the second prepit area but for reproduction of the land, address data represented by prepits in the first prepit area is made to be different from that represented by prepits in the second area. When addresses represented by prepits in the first and second prepit areas are different from each other, a correlation may be set up between the two addresses and the efficiency of error correction code can be increased by utilizing the correlation.
Preferably, synchronous information (VFO) 86 and address data 87 may both be arranged in each of the first and second prepit areas.
While in this example the prepit area is divided into two of the first and second prepit areas, the number of division which is plural may suffice. For example, when the number of division is four, pits in first and third prepit areas may be arranged on one side of a groove and pits in the second and fourth prepit areas may be arranged on the other side of the groove. By increasing the number of division of the prepit area, reliability against, for example, defects can be improved.
Here, a phase change recording material (GeSbTe) is used for the recording film. Accordingly, the recorded mark is formed in the form of an amorphous domain.
Referring now to FIG. 3 , there is illustrated an example of a configuration in which the optical recording medium of the present invention is applied to an optical recording/reproducing apparatus. In the apparatus, a semiconductor laser 311 having a wavelength of 680 nm and a collimating lens 312 are used as a light source 31 . A beam profile former such as a prism may also be provided as necessary. Power of the semiconductor laser is controlled by a light power controller 71 having the auto-light-power-control function. A light beam 22 emitted from the light source 31 is focused on a magneto-optical recording medium 8 by means of a focusing optics 32 . The focusing optics 32 has at least one lens 321 and in this example, it also has a beam splitter 324 . An objective lens 321 for focusing the light beam on the optical recording medium 8 is designed to have a numerical aperture of 0.6. Therefore, an optical spot 21 on the optical recording medium 8 has a diameter of 1.0 μm. The optical spot can be moved to a desired position on the optical recording medium 8 by means of a scanning unit 6 . The scanning unit 6 includes at least a motor 62 for rotating the disc-like magneto-optical recording medium 8 and an auto-position controller 61 having the function of auto-focus control and auto-tracking. The auto-position controller 61 utilizes a reflected beam 23 from the magneto-optical recording medium 8 to cause a photodetection unit 33 to detect an optical spot position which is used for feedback control.
The optical spot position can be detected by detecting power of a diffracted light ray from a groove. The photodetection unit 33 is constructed of a lens, a beam splitter and a plurality of photodetectors, and output signals of the plurality of photodetectors are calculated to produce a servo signal and a reproduced signal.
With the optical recording medium as shown in FIG. 1 used, signals as designated at 14 in FIG. 2 are produced as prepit signals. The signal is inputted to an address detection unit to decode address data and at the same time, timings of signals of the first and second prepit areas are detected and on the basis of the timing information, the amplitude (averaged peak-to-peak amplitude) of the first prepit area and that of the second prepit area are stored. The thus stored amplitudes are compared with each other by means of an amplitude comparator to produce tracking offset information which in turn is fed back to the position moving unit (scanning unit). Referring to FIG. 2 , when the optical spot scans a groove, a magneto-optical reproduction signal 11 and a corresponding prepit signal 14 (an upper one in the drawing) are produced and when the optical spot scans a land, a magneto-optical reproduction signal 12 and a corresponding prepit signal 14 (a lower one in the drawing) are produced. Since in this example the optical spot is slightly offset as shown in FIG. 1 , an amplitude difference 13 takes place between a prepit signal from the first prepit area 831 and a prepit signal from the second prepit area 832 . This amplitude difference corresponds to a tracking offset amount.
By using the apparatus of FIG. 3 , the tracking offset could be reduced to ±0.03 μm or less even when various kinds of external disturbance such as aberration of the optical spot are taken into consideration. Under the nominal state devoid of optical aberration, the tracking offset was ±0.015 μm or less.
As described above, in the present invention, prepits are disposed on both sides of a virtual extension of the center line of a groove or a land as shown in FIG. 1 . Consequently, offset is reduced to make tracking offset hardly occur. Since prepits do not exist on both sides of any specific position of the center line of a groove or a land, interference of prepit information between adjacent tracks does not take place within a reproduced spot and hence high-density narrow track recording can be ensured.
Further, if a tracking-offset occurs as shown in FIG. 2 , the tracking offset amount can be detected accurately by comparing amplitudes of signals of prepits located on both sides. Accordingly, by feedback-controlling the information indicative of a comparison result to the scanning unit, the tracking offset can be suppressed.
Furthermore, discrimination between the groove and the land can be effected with ease.
By using the optical recording medium of the present invention, the tracking offset can be suppressed to a practically sufficiently small level (0.03 μm or less) and besides, address data can easily be obtained even during high-density narrow track recording. Through the use of the optical recording/reproducing apparatus of the present invention, the tracking offset can readily be reduced by feedback control.
Embodiment 2
Referring now to FIG. 4 , there is illustrated a second embodiment of the present invention. A medium of the present embodiment differs from that of embodiment 1 in that only synchronous information pits 861 to 864 are disposed on the upper side (as viewed in the drawing) of the center line of a groove 841 , 842 , 843 , 844 or 845 and synchronous information pits 861 to 864 and address data pits 871 to 874 are both disposed on the lower side (as viewed in the drawing) of the center line of each of the grooves 84 . Preferably, the address data pits 871 to 874 are arranged continuously to the synchronous information pits 861 to 864 . For a land 85 , the upper and lower side relation is inverted.
Being different from the embodiment 1, the present embodiment has address data arranged on only the upper or lower side of the center line of the groove or the land and therefore the same address data is allotted to the land and groove. In the present embodiment, four divisional prepits areas 831 to 834 are provided with the aim of improving the reliability of the prepit area but the prepit area is not always divided. In the present embodiment, the synchronous pit 861 in the first prepit area 831 are designed to have a longer length than the synchronous pits in the second to fourth prepit areas by taking into account the influence of aliasing of a signal which has passed through a low pass filter. Preferably, pits disposed on the upper and lower sides are spaced apart from each other by 0.5 μm or more from the view-point of fabrication of the medium. More preferably, they are spaced apart by a distance of about 1 μm which is the diameter of the reproduced optical disc spot.
Embodiment 3
Referring to FIG. 5 , there is illustrated a third embodiment in which identification marks 88 are used to discriminate the land from the groove. In the present embodiment, identification marks 88 for discrimination between the land and the groove are provided independently of the prepit area in the embodiments 1 and 2.
In the present embodiment, a pair of pits (identification marks) 88 are arranged on the upper and lower (as viewed in the drawing) sides of the center line of a groove 841 , 843 or 845 but they are not provided for a groove 842 or 844 . On the assumption that an optical spot relatively moves from left to right as viewed in the drawing when the medium provided with the above identification marks is reproduced to provide a case of “presence” where the identification marks are seen by the optical spot and a case of “absence” where the identification marks are not seen, “presence, presence” is held for the groove 841 , “absence, presence” is held for a land 851 , “absence, absence” is held for the groove 842 and “presence, absence” is held for a land 852 . Further, “presence, presence” is held for the groove 843 , “absence, presence” is held for a land 853 , “absence, absence” is held for the groove 844 and “presence, absence” is held for a land 854 . Namely, either one of “presence, presence” and “absence, absence” is held for the groove and either one of “absence, presence” and “presence, absence” is held for the land. Accordingly, this can be utilized to effect discrimination between the land and groove on the basis of a reproduced signal. To secure reliability, a plurality of pairs of identification marks may preferably be provided and more preferably, the paired pits are spaced apart from each other by several Jim or more in the circumferential direction or information track direction of the medium which is perpendicular to the radial direction. For example, the prepit area in the foregoing embodiments and the identification mark area may preferably be arranged alternately in the circumferential direction.
Embodiment 4
Referring to FIG. 6 , there is illustrated, in enlarged fragmentary plan view form, an optical recording medium according to a fourth embodiment of the present invention. Grooves 84 each having a width of 0.5 μm and a depth of 40 nm and lands 85 each having a width of 0.5 μm are arranged alternately and recorded marks 81 are formed on the two kinds of areas. In other words, each of the land 85 and groove 84 serves as a recording area. In a prepit region 83 , any groove is not formed but substantially circular pits 82 (each having a diameter of 0.3 μm and a depth of 40 nm) are disposed on an extension of the boundary between a land and a groove. The prepit area is divided into a VFO (variable frequency oscillator) area 833 and an address area 834 . Especially, in the VFO area, pits 82 are disposed alternately on the upper and lower sides of the center line of a land 85 . In the address area, pits 82 are disposed alternately at the same period as that in the VFO area. Accordingly, there are no pits which exist on both sides of a position of the center line of the land or the groove.
In addition, in the address area, data for a particular track is so encoded as to differ by one pit from data for an adjacent track. In other words, the data takes the form of a Gray code. With this construction, when an optical spot 21 scans, for example, a land 85 , only pits on either one side are always reproduced and there is no fear that crosstalk will occur between the adjacent tracks. Therefore, address data distributed to the prepits can duly be reproduced without crosstalk. Since pits 82 for adjacent tracks do not adjoin to each other, they can therefore be formed with ease. Also, pits 82 are uniformly disposed on both sides of a track (a land or a groove) and hence the influence on a tracking servo signal which is caused by the pits 82 can be canceled. Accordingly, tracking offset can be suppressed to a minimum.
When the medium of the FIG. 6 embodiment is reproduced with the apparatus of FIG. 3 , reproduced signals as shown in FIG. 7 are generated from the prepit area 83 , indicating that data pieces which differ track by track can be obtained and therefore address data is recorded very highly efficiently. Thanks to the use of the Gray code, an address can be reproduced even in the course of inter-track access, ensuring suitability to high-speed access. Further, with the Gray code used, an error hardly occurs even in the presence of crosstalk, thus ensuring suitability to narrowing of tracks.
Embodiment 5
Referring now to FIG. 8 , there is illustrated in enlarged fragmentary plan view form an optical recording medium according to a fifth embodiment 5 of the present invention. Groove 84 each having a width of 0.7 μm and a depth of 70 nm and lands 85 each having a width of 0.7 μm are arranged alternately in the radial direction and the two kinds of areas serve as information tracks on which recorded marks can be formed.
In other words, each of the land 85 and groove 84 serves as a recording area. In a prepit region 83 , any groove is not formed but pits 82 are disposed on an extension of the boundary between the land and the groove. The prepit area is divided into zones which are arranged in the radial direction over about 1800 information tracks, that is, 900 grooves.
The zones are arranged concentrically of the whole of a disc in such a manner that 24 zones in total are in a disc having a radius of 30 to 60 mm. More specifically, in each zone, the number of prepit areas to be detected during one revolution, that is, the sector number is constant and the sector number is larger in an outer zone than in an inner zone.
An example of structure of each sector 41 is shown in FIG. 9 . The sector 41 has a prepit area 83 at the head of a data recording area.
As shown in FIG. 8 , the prepit area is divided into a first prepit area 831 and a second prepit area 832 . In the first prepit area 831 , pits 82 are arranged on the upper side (as viewed in the drawing) of the center line of a land 85 and in the second prepit area 832 , pits 82 are arranged on the lower side of the center line of the land 85 . Consequently, for example, when an optical spot 21 scans the land 85 , only pits on either one side are always reproduced and there is no fear that crosstalk will occur between adjacent tracks. Accordingly, address data allotted to the prepits can duly be reproduced without crosstalk. Address data represented by the prepits is recorded in the form of a 1–7 modulation code (having a channel bit length of 0.2 μm). In other words, the linear recording density is 0.3 μm/bit. The relation between the prepit area and the groove in the present embodiment is illustrated in enlarged fragmentary section perspective view form in FIG. 10 .
In the present embodiment, a gap area 87 is provided between the first and second prepit areas 831 and 832 to space them apart by about 1.0 μm. Since in this embodiment data is recorded pursuant to the 1–7 recording, the gap distance corresponds to a length of about 5 channel bits. The 5 channel bit length is exactly the middle length between the longest mark length (8 channel bit length) and the shortest mark length (2 channel bit length). Therefore, the gap area between the first and second prepit areas can be reproduced having a length which lies between the shortest mark length and the longest mark length even when the pits undergo changes in shape and position during formation of the pits and the optical spot undergoes a change in shape and a change in scanning position (servo offset) thus ensuring very high reliability. In this example, the marks are designed to undergo, at the worst, a total change in position which is suppressed to 0.6 μm (3 channel bit length) and therefore, the effective length (during reproduction) is 2 channel bits in the case of the shortest length and 8 channel bits in the case of the longest length to match the rule of the 1–7 modulation code, thus raising no problem during reproduction. If the detection length is longer than 8 channel bit length, then it will adversely interfere with a special synchronous pattern such as a recorded address mark. If the detection length is shorter than 2 channel bits, then a small mark results which is less than resolution of the reproduction optical spot and cannot be detected. Accordingly, it is preferable that the gap length be suppressed to the middle between the longest mark length and the shortest mark length as in the present embodiment.
Depending on the specification of a pit forming apparatus, the change in mark position can be suppressed to one channel bit length or less. In this case, the nominal gap length may be suppressed to 3 to 7 channel bit length but the pit forming apparatus for this purpose becomes expensive. There is a high possibility that signals suffer an error attributable to a tracking offset during reproduction and therefore the medium is desired in which preferably, the gap length is exactly the middle between the longest mark length and the shortest mark length permissible for the recording as described hereinbefore.
In the present embodiment, pits 82 are uniformly disposed on both sides of the center line of a track (a land or a groove) and hence the influence on a tracking servo signal which is caused by the pits 82 can be canceled. Accordingly, the tracking offset can be suppressed to a sufficiently small level. In addition, for example, when a land 85 is reproduced, reproduction of address data at the second prepit area 832 is carried out continuously with reproduction of address data at the first prepit area region 831 . Accordingly, when the two areas are united into one area in which information is arranged to provide address data for one track, an address (track number) of a land and that of a groove can be set independently of each other. In other words, by sequentially reproducing the address data pieces in the first and second prepit areas 831 and 832 , discrimination between the land and the groove can be ensured.
More particularly, for reproduction of the groove, address data represented by prepits arranged in the first prepit area is made to be identical to that represented by prepits arranged in the second prepit area but for reproduction of the land, address data represented by prepits in the first prepit area is made to be different from that represented by prepits in the second area. When addresses represented by prepits in the first and second prepit areas are different from each other, a correlation may be set up between the two addresses and the efficiency of error correction code can be increased by utilizing the correlation.
Preferably, synchronous information (VFO) 86 and address data 87 may both be arranged in each of the first and second prepit regions.
While in this example the prepit area is divided into two of the first and second prepit areas, the number of division which Is plural may suffice. For example, when the number of division is four as shown in FIG. 5 , pits in the first and third prepit areas may be arranged on one side of a groove and pits in the second and fourth prepit areas may be arranged on the other side of;: the groove. By increasing the number of division of the prepit area, reliability against, for example, defects can be improved.
Here, a phase change recording material (GeSbTe) is used for the recording film. Accordingly, the recorded mark is formed in the form of an amorphous domain.
Referring now to FIG. 11 , amounts of positional displacement 963 between prepit areas of adjacent tracks, 961 between prepits of adjacent tracks and 962 between grooves of adjacent tracks in the medium are illustrated in greater detail. In the actual medium, positional displacement sometimes occurs between pits of adjacent tracks owing to various causes taking place during pit formation. Because of the positional displacement amounts 961 , 962 and 963 , the length of gap areas 86 and 87 is increased or decreased.
In addition to the above positional displacement, various kinds of variations (aberration, servo error and the like) during reproduction also cause apparent positional displacement of reproduced signals. Accordingly, the positional displacement possibly leads to a serious problem. But in the present invention, the nominal length of the gap area is set to the middle length between the shortest mark length and the longest mark length pursuant to the 1–7 modulation code and hence a positional displacement amount of ±0.6 μm is permissible.
The optical recording medium shown in FIG. 8 can be reproduced with the apparatus shown in FIG. 3 in a similar manner to that described in connection with embodiment 1, bringing about advantages that tracking offset can be reduced to ±0.03 μm or less even when various kinds of external disturbance such as optical aberration are taken into account and in particular, it can be reduced to ±0.015 μm or less under the nominal state devoid of optical aberration.
Embodiment 6
While the embodiment of FIG. 8 uses the 1–7 modulation coding as the recording modulation coding, the present embodiment uses eight to fourteen modulation (EFM) recording. The channel bit length is about 0.2 μm. In the present recording, the shortest mark length is 3 channel bit length and the longest mark length is 11 channel bit length. Practically, a mark having a length of 12 channel bits or more is available but this type of mark is limited to a special application such as a synchronous pattern. Accordingly, data must avoid inclusion of a pattern which may possibly interfere with the special pattern. The prepit area, groove and land are arranged similarly to the embodiment 5 of FIG. 8 excepting points to be described later. Namely, they are arranged as shown in FIG. 10 and especially, each groove and each have a width of about 0.75 μm and each groove and each prepit have a depth of about 0.075 μm.
In the present embodiment, the prepit area and the groove are disposed as shown in FIG. 12 . Four prepit areas 831 , 832 , 833 and 834 are allotted to the head of one sector. In each prepit area, a VFO area for synchronization to reproduced signals and an address area recording address data of the track and sector are arranged sequentially. Start positions of pits as well as end positions are so arranged as to be substantially aligned in the radial direction and a gap area 86 is provided between the end of the groove and the start of the pit area. Likewise, a gap area 87 , 88 or 89 is provided between adjacent prepit areas.
As described previously, details of positional displacement between the start position of a pit and the start position of a succeeding pit is depicted in FIG. 11 . With the displacement as shown in FIG. 11 , the effective length of the gap area 86 is decreased,or increased as in the embodiment 5 of FIG. 8 . In order to align ends of final pits of the prepit areas 831 , 832 and 833 in the radial direction, an additional pit pattern 110 as shown in FIG. 13 is used. The additional pattern selected from four types (a), (b), (c) and (d) in accordance with the preceding data is used. Through this, trailing edge positions 99 of the final pits can always be aligned to the same position regardless of the preceding data and the gap length and pit length can be limited to the lengths allowed for the modulation code. In this manner, the gap area between the succeeding prepit area 120 and the trailing edge position 99 of the final pit can be set to the middle length between the longest mark length and the shortest mark length pursuant to the modulation coding, so that the margin can be greatly increased during prepit formation and reproduction as in the embodiment 5.
In the foregoing embodiments, the medium of the phase change recording material is described but it may be of another material to attain the advantages of the present invention. For example, a magneto-optical recording film may be used as the recording film. In addition, the modulation code has been described as being of 2–7 and 8/9 coding but it may be of another type in which the previously described EFM is extended.
According to the present invention, in the optical recording medium having the lands and grooves, the substrate can be fabricated with a simple mastering apparatus and replica can also be prepared with ease, with the result that the medium fabrication margin and readout margin which are practically sufficiently large can be ensured. Accordingly, a cheap and high-density optical recording medium can be provided.
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A reproducing method for reproducing information from an optical recording medium having an aligned prepit portion straddled on a plurality of tracks in a radial direction, the prepit portion including first and second prepit portions divided in a track direction and arranged on a boundary line of the respective tracks. The first and second prepit portions each have address information prepits arranged at every two-track pitch in the radial direction, and the address information prepit of the first and second prepit portions are arranged with one track displaced in the radial direction. A trailing end of an end prepit of the first prepit portion is aligned with the radial direction. The method includes irradiating an optical spot on the medium, detecting a reflected beam from the medium, and reproducing information on the medium by using a signal obtained by the reflected beam.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to disk drive head positioning. More particularly it relates to a method and apparatus for compensating for non-linearity in the torque constant of the drive actuator motor.
2. Background
One of the most important data storage devices for digital computers is a class of devices known as hard disk drives. A hard disk drive consists of a rotating disk with magnetic media deposited on one or more surfaces in concentric information tracks. Information is stored in the magnetic media by causing magnetic domains to be in one of two polarities. The domains are switched from one polarity to another in a write operation by a transducer. The same transducer also detects the state of each domain. The transducer and its mechanical housing is referred to as a head.
Information is communicated to and from the disk by placing the head over the desired track and performing either a read or write operation. The head is positioned by a mechanical arm called the actuator. The actuator is in turn caused to move by an electric motor which is connected through a digital to analog converter and amplifier to a digital computer.
A servo control loop is used to control head positioning as the head is being moved transversely across tracks and to cause the head to remain over a particular data track as the disk spins. The servo loop controls the acceleration of the head which results from a force supplied by the electric motor on the actuator. The input to the servo system are readings of head position made by the head itself. The head position is determined from position information written directly onto the disk by a servo writer as part of the manufacturing process. The position information, also referred to as servo information, includes the track number as well as an indication of how far the recording head is from the track center line. That is, a certain number of bits of information on each track are reserved for indicating position. As the head passes over the indicators, the track over which the head is sitting is determined by the head itself and supplied to the servo system. The indicators are at regularly spaced locations. Thus the input to the servo is not continuous but is sampled.
A hard disk drive must respond to read and write requests from the host computer that requires the head to move to and hover over any track on which information has been written. In order to be effective, the drive must perform this function very quickly. The time required from the receipt of a read or write request from the host computer until the head has been positioned over the track containing the information and commenced to read the information is called the "the seek time". All disk drive manufacturers work to minimize seek time. The servo system plays a critical role in minimizing seek time.
The transfer function of the servo system at its highest level of abstraction is given by Equation 1 below. ##EQU1## where G is the plant and compensator elements and H is the feedback gain. In this case, the plant includes the actuator, the head, the actuator motor and mechanical parts for moving the actuator arm. The transfer function for the actuator and mechanics (represented in Laplace transform notation) is set out in Equation 2. ##EQU2##
In equation 2, K t is the torque constant of the actuator motor, j a is the inertia of the moving parts and s 2 is the Laplace operator. Thus, in order to have a servo control loop, the torque constant of the actuator motor must be known. The more accurately j a and K t are known, the more accurately the proper current can be called for by the servo system to move the head. This in turn reduces the position and velocity error that the head will have as it approaches the desired track and thus increases the speed of the seek operation.
FIG. 1 is a schematic of a hard disk drive as used with conventional desk top computers. Referring now to FIG. 1, disk drive 10 includes a substrate 12 onto which a rotating disk 14 is mounted around a center of rotation 16. An actuator arm 18 having a head 20 rotates around a center of rotation or pivot point 22. As actuator 18 rotates around point 22, head 20 sweeps across the face of disk 14. A magnet assembly 24 is attached to substrate 12 with a series of screws, not shown. A crash stop 26 is an integral part of actuator 18 and in cooperation with crash pin 32 determines the extreme positions to which head 20 may rotate around pivot point 22. The maximum distance through which head 20 can move as determined by crash stop 26 and crash pin 32 is called the stroke of the head. The stroke in turn determines the operating distance that head 20 can traverse. This in turn determines the total number of tracks on disk 14 that can be addressed by head 20.
FIG. 2 shows actuator 18 and a cutaway of magnet assembly 24. Referring to FIG. 2, actuator 18 rotates around actuator pivot point 22. Actuator 18 is bonded firmly to an electrical coil 32. Coil 32 is the rotor portion of a dc motor. The stator of the dc motor consists of permanent magnets shown schematically at reference numerals 34 and 36 in FIG. 2.
FIG. 3 is a cross section taken through points A--A in FIG. 2. Referring now to FIG. 3, there is a first permanent magnet 38 having its north pole at reference numeral 40 and its south pole at reference numeral 42. There is a second permanent magnet 44 which includes a south pole 46 and a north pole 48. Surfaces 50 and 52 represent the upper and lower surfaces of magnet assembly 24 in FIG. 1. The two permanent magnets 38 and 44 are typically glued to surfaces 50 and 52 in the manufacturing process. The cross section of coil 32 of FIG. 2 is shown at reference numerals 54 and 56 in FIG. 3.
Referring again to FIG. 2, the combination of coil 32 and permanent magnets 34 and 36 form a dc motor. When a dc current is impressed on coil 32, a torque, T, operating around center of rotation 22 is exerted on coil 32 and thus on actuator 18. The torque on actuator 18 is set out in Equation 3 below.
T=K.sub.t I (3)
Where K t is the torque constant and I is the current in coil 32.
FIG. 4 shows a graph of the torque constant, K t , of the dc motor described above as a function of head position over disk 14 of FIG. 1. Referring now to FIG. 4, the Y-axis is the torque constant K t . It is measured in In-oz per ampere. The X-axis is distance across disk 14. For purposes of describing the invention, the units of measure of distance are tracks. However, it is often measured in degrees of rotation of head 20 around actuator pivot point 22. As a matter of convention, track zero is the track closest to the outside diameter of disk 14 and is labeled O/D in FIG. 4. The highest number track number N0 is the track closest to the inside diameter and is labeled I/D in FIG. 4. A disk drive uses a fixed and predetermined number of tracks, such as 2500. Crash stop 26 and crash pin 32 are designed in conjunction with the density of tracks on disk 14 to allow head 20 to traverse no more than 2500 tracks.
FIG. 4 makes it clear that the torque constant, K t , is not, in fact, a constant over the entire range of motion of the head. The torque constant, K t , starts at a value K t1 at track 1 and increases to a maximum, K t2 . It remains at value K t2 for most of the distance across the disk and then gradually decreases to value K t3 for track 2500. A design goal is to operate the actuator such that its operating range is symmetric with respect to the torque constant non-linearity curve.
The reason that K t falls off as the head approaches either edge of the disk is best understood by an examination of FIGS. 2 and 3. From these Figures it can be seen that as head 20 approaches either extreme angular position, segments 54 and 56 of coil 32 approach the ends of permanent magnets 38 and 44. At these positions, coil 32 intersects fewer lines of magnetic flux from the permanent magnets. The force on coil 32 is correspondingly reduced and thus the torque constant is reduced. Making permanent magnets 38 and 44 larger is not a solution since users are demanding smaller not larger disk drives.
The fact that K t is not a constant over the entire stroke of actuator 18 is a problem that has been addressed in the prior art. The deviation of K t from being a constant value can be compensated for by the microprocessor controlling the disk drive. This is accomplished by developing a look up table, called a torque constant multiplier table, and placing it in the memory of the microprocessor that controls the disk drive. The table provides a torque constant multiplier for each track from track 0 to N0. FIG. 5 is a graphic illustration of the torque constant multiplier table. In FIG. 5, the X-axis is track number and the Y-axis is torque constant multiplier. Referring now to FIG. 5, curve 61 has a basic shape that is the inverse of torque constant curve 60 of FIG. 4. The values in the torque constant multiplier table are unity (1.0) in the mid-region where the torque constant is substantially constant and the multiplier increases at the stroke endpoints where the actuator torque constant magnitude decreases.
In operation, when a seek request is received from the host computer, the microprocessor in the disk drive accesses the torque constant multiplier table based upon the track number over which the head is positioned as determined from the servo information encoded on each track. As the actuator moves the heads across the surface of the disk, the microprocessor compensates for the actuator's non constant torque constant by reading a value from the torque constant multiplier table. The value from the torque constant multiplier table is used to adjust the amount of current supplied to the actuator. The result is a drive with actuator dynamics which closely resemble an ideal system in which the actuator torque constant is flat throughout the stroke. During a seek, each time a different track number is read by the head, indicating a new actuator location, a new value is read from the torque constant multiplier table and the actuator current is modified accordingly.
In addition, when the disk drive is initially powered on, the microprocessor performs a mid stroke calibration to additionally compensate for any torque constant magnitude variation from nominal that may be present in that particular disk drive.
However a problem arises because of the mechanical tolerances of the manufacturing process. Of particular relevance in the manufacturing process are the steps of gluing the permanent magnets to the magnet assembly, drilling holes in the magnet assembly and into the disk drive substrate and drilling the crash pin hole. There are mechanical tolerances associated with each of these steps. That is, the magnets will be glued and the holes drilled in slightly different places for each drive as it is manufactured. These tolerances are such that the stroke of actuator 18, while remaining a constant 2500 tracks, cause coil 32 to reach different extreme positions with respect to permanent magnets 38 and 44 for each drive. The results of this variation can best be understood by reference to FIG. 6.
The axes of FIG. 6 are the same as FIG. 4. Curve 62 is a graph of the actual variation of torque constant, K t , as a function of head position for a drive that has been assembled such that the end point of movement of coil 32 with respect to permanent magnets 38 and 44 is quite different from that for the drive represented in FIG. 4. In FIG. 6, the symmetry of the curve with respect to mid stroke is no longer present. The peak value of K t at mid stroke, K t2 , in FIGS. 4 and 6, is not necessarily the same magnitude in both curves. Any differences in the peak value of torque constant, K t2 , is compensated for by the mid stroke calibration performed after the drive is initially powered on. If the torque constant multiplier table resident in the microprocessor memory were that as shown in FIG. 5, seek time performance would not be optimum since the torque multiplier table does not match the actuator torque constant profile for the drive under consideration.
Thus it can be seen that the variations in the mechanical assembly of a drive can cause significant errors in the torque constant multiplier table. So, even with a torque constant multiplier table in memory, the servo loop may not receive an accurate number for torque constant multiplier for tracks close to the beginning or end of the operating range.
OBJECTS OF THE INVENTIONS
It is therefore an object of the present invention to compensate for drives having different physical operating ranges by determining where each drive operates relative to a nominal operating range and accessing the torque constant multiplier table at a track address that adjusts for any offset between the actual and nominal operating range.
It is another object of the present invention to provide a method for accurately determining the torque constant multiplier versus position function of a disk drive.
It is another object of the invention to provide a method for compensating for a torque constant in a disk drive actuator motor that varies randomly as a function of the manufacturing process.
It is yet another object of the invention to provide a method and apparatus for determining the torque constant multiplier versus location on the disk relationship after a disk drive has been assembled.
It is an object of the invention to provide a method for directly calculating the torque constant multiplier at any point in the actuator operating range.
SUMMARY OF THE INVENTION
These and other objects of the invention may be achieved with an improved method for use in a hard disk drive where the drive includes an electric motor used to move an actuator arm which carries a magnetic read/write head any distance across a rotating disk within a mechanically defined operating range and where the torque constant of the electric motor varies across the operating range on a given drive as a function of head location and the operating range varies from drive to drive due to variations in the manufacturing process for the drive, and where the location of the head with respect to magnetic tracks written onto the disk is determined by reading the servo information from the tracks, and where the variation in torque constant may be compensated for with a torque constant multiplier.
The method begins with the step of creating a first table that relates a torque constant multiplier of the motor with the location of the head over the disk for substantially all head locations over the disk possible with the manufacturing process;
The next step includes defining a nominal operating range of head locations within the first table;
The next step includes creating a second table that relates a measurable parameter on each disk drive to the relative location of each disk drive's operating range to the nominal operating range. One such parameter is the ratio of torque constants at two head locations over the possible actuator operating range to a head location offset from the nominal operating range.
The next step includes measuring a parameter directly related to a first and second torque constant at first and second head locations on the disk drive under consideration and calculating the ratio of the parameters at the first and second head locations.
The next step includes determining the head location offset of the operating range of the disk drive under consideration from the nominal operating range from the second table;
The next step includes modifying the head location, as determined by reading the servo information, with the offset to form an offset head location;
Finally, the method includes obtaining the value of the torque constant multiplier associated with the offset head location from the first table.
Preferably the first track is track 0 in the mechanically determined operating range and the second tack is the highest numbered track in the mechanically determined operating range, and the nominal operating range is in the symmetric region.
The head position may be measured in degrees of angle around a pivot point of the actuator or in tracks.
The step of measuring the ratio of the torque constants at a first and second locations comprises causing a predetermined current to be delivered to the electric motor and measuring the distance that head moves for a predetermined fixed time interval at both the first and second locations. The distance is measured by reading the track and position data in the servo information on the disk. The ratio of the distances moved at the second location to the first location is equal to the ratio of the torque constants at the second location to the torque constant at the first location.
A method of creating the first table comprises: measuring the torque constant as a function of head location of a statically significant number of actuator assemblies over a range that extends beyond the nominal operating range. A single representative torque constant as a function of head location curve is created by normalizing the torque constant data for each of the individual actuators that were characterized, finding the axis of symmetry with respect to the track axis for each of the actuator assemblies that were characterized, aligning all the individual axes of symmetry, and then averaging the normalized torque constant values at each track location. The first table is the inverse of the normalized torque values at each track location.
The second table may be created by determining a sample of possible operating ranges from the single representative torque constant curve, calculating the ratio of the torque constant for two head positions for each operating range in the sample, determining the head position offset from the nominal operating range for each of the operating ranges in the sample, and matching the offset with the ratio to form a torque constant ratio vs head position offset table.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described in conjunction with the Drawing wherein:
FIG. 1 is a top view of a typical hard disk drive.
FIG. 2 is the top view of FIG. 1 but including a cut away portion showing the dc motor attached to the actuator arm.
FIG. 3 is a section taken through A--A of FIG. 2 and more clearly shows the arrangement of the motor stator and rotor.
FIG. 4 is a graph of the torque constant of the dc motor that moves the actuator as a function of the location of the head for a disk drive as used in prior art drives.
FIG. 5 is a graph of the torque constant multiplier used in the prior art.
FIG. 6 is a graph of the torque constant of the dc motor that moves the actuator as a function of the location of the head for a disk drive that has been assembled such that the mechanical tolerances in the manufacturing process causes the torque constant for the drive to be different from that set out in the prior art teaching.
FIG. 7 is a graph of wide torque constant data and wide torque constant multiplier table as used in the present invention.
FIG. 8 is a graph of track offset as a function of torque constant ratio.
FIG. 9 is schematic top view of an apparatus for measuring torque constant directly at each track during servo write.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The method of the present invention solves the problem of having drives with different operating ranges by determining where each drive operates relative to a nominal operating range and compensating for any differences.
The first step is to create a wide torque constant multiplier table for all possible locations that the head may reach over the disk assuming the greatest possible cumulative tolerance error. This is a table that is wider than the operating range of any individual drive and therefore wider than the torque constant multiplier table used in prior art drives. A single normalized torque constant curve may be generated from data taken from a statistically significant number of different actuator assemblies made with the same manufacturing process. This is referred to as a wide torque constant curve and is created by normalizing the torque constant data for each of the individual actuators that were characterized (K t =1.0 at mid stroke), finding the axis of symmetry with respect to the track axis for each of the actuator assemblies that were characterized, aligning all the individual axes of symmetry, and averaging the normalized torque constant values at each track location. Typically this might be 50 actuator assemblies. The inverse of the normalized torque constant curve is determined to get the data points underlying the torque constant multiplier curve and torque constant multiplier table. The wide torque constant multiplier table is created and entered into the microprocessor memory.
FIG. 7 is a graph of wide normalized torque constant data and corresponding torque constant multiplier data. The axes of FIG. 7 are somewhat different from the axes of FIG. 4 and 6. The Y-axis of FIG. 7 has been normalized and expanded for clarity, and the X-axis is expanded to cover the equivalent of more tracks than the nominal operating range of an individual drive; the X-axis is labeled "table pointer" in order to differentiate it from tracks although the values have a similar meaning.
In FIG. 7, the wide torque constant curve is indicated by reference numeral 65. The torque constant multiplier curve indicated by reference numeral 66 is simply the inverse of curve 65. Curves 65 and 66 are coincident at a value of 1.0 over their center portion. The torque constant multiplier table is a tabular form of the data underlying curve 66.
The operating range, which is the stroke of actuator arm 18 of FIG. 1, is shown for 3 possible disk drives coming out of the same manufacturing process. The operating range that is symmetrical around the center point of curve 65 is designated as the nominal operating range. In FIG. 7, drive 2 is a nominal drive in that its operating range is nominal. The table pointer that is labeled 0 on the X-axis of FIG. 7 is the starting track (track 0) on the outside diameter for the nominal drive. There are several hundred possible tracks on either side of the nominal operating range of the nominal drive. The torque constant at table pointer 0 is K 2o (o refers to outside diameter and 2 refers to drive 2) and the torque constant at table pointer 2500 is K 2i (where i refers to inside diameter).
Disk drive 1 was assembled with the same manufacturing process as disk drive 2, but due to the mechanical tolerances of the manufacturing process the crash stop and/or the magnetic assembly are located in slightly different places with respect to substrate 12. The operating range of disk drive 1 goes from table pointer -400 to table pointer 2100. These pointers correspond to track 0 and track 2500 as read from the servo information on the disk. Again between table pointer -400 and 2100, there are 2500 tracks. The torque constant at table pointer -400 is K 1o and the torque constant at table pointer 2100 is K 1i . The net effect is that the track numbers as read by the head of disk drive number 1 are offset by -400 with respect to the nominal drive.
The third hypothetical disk drive labeled disk drive 3 in FIG. 7 has an operating range that goes from table pointer +300 to 2800. The torque constant at table pointer +300 is K 3o and the torque constant at table pointer 2800 is K 3i . In this case, the track numbers as read by the head of disk drive 3 are offset by +300 with respect to the nominal drive.
To measure the torque constant at any point on the drive, the head is moved to the track for which the torque is to be measured and stopped. Next a known constant current is impressed on coil 32 which causes actuator 18 to accelerate from a 0 velocity. After a predetermined fixed time has elapsed, the microprocessor that controls the drive records the distance head 20 has traveled via data read from the servo information encoded on the tracks. The acceleration is calculated pursuant to equation 4 following: ##EQU3## where s=distance the head has traversed
t=time taken to traverse a distance
a=acceleration of the actuator and head assembly
S=distance the head moved as measured by the microprocessor.
T=fixed time interval of measurement
Acceleration is directly related to the torque constant according to equation 5 following: ##EQU4## where K t =torque constant
J=inertia of actuator assembly
I=magnitude of constant current supplied to actuator coil
The next step is to calibrate each individual drive by determining its operating range on the wide torque constant table. This is done at power on.
To calibrate each disk drive coming from the production process, a parameter is developed that relates the operating range of each disk drive with the nominal operating range of FIG. 7. While other parameters may be practical, the preferred embodiment uses the ratio of the torque constant on any given disk drive at two spaced apart head locations on the disk or the ratio of a parameter equal to torque constant ratio at two spaced apart head locations. The two spaced apart locations are preferably, but not necessarily, track 0 and track 2500; that is, the outside diameter and the inside diameter of the operating range for that particular disk drive.
To facilitate the calibration procedure, a table relating the ratio of torque constants to the location of its operating range relative to the nominal operating range is developed. A curve representing such a table is shown in FIG. 8. Referring now to FIG. 8, the units on the Y-axis are track offset. Track offset refers to the number of tracks in FIG. 7 that the operating range of a particular drive is offset from the nominal operating range. The units on the X-axis are torque constant ratio.
A method of generating the offset table involves the use of the wide torque constant table or curve. The ratio of the torque constant of the first track to the torque constant of the last track for a series of operating ranges is plotted against the offset of the operating range from the nominal operating range. For example, using the graph of FIG. 7, consider drive 1 as the first in the series of drives used for purposes of generating the curve of FIG. 8. The ratio of the torque constant at table pointer 2100 to the torque constant at table pointer -400 is calculated. The Y-axis offset for this ratio is -400. On the coordinates of FIG. 8 a point is plotted that is -400 on the Y-axis and K 1i divided by K 1o on the X-axis. Using the same method as described for drive 2 for drive 1, on the coordinates of FIG. 8 a point is plotted that is 0 on the Y-axis and K 2i divided by K 2o on the X-axis. For drive 3, the coordinates are +300 on the Y-axis and K 3i divided by K 3o on the X-axis. Similar points are plotted from operating ranges covering different portions of curve 65 of FIG. 7.
In operation, the torque constant multiplier table and the torque ratio-offset table are resident in the memory of the microprocessor that controls the disk drive. When a particular disk drive is powered on, it goes through a calibration routine that is controlled by the microprocessor. The present invention requires that an additional calibration be performed. The new calibration is to move the head and actuator to a first location near the outside diameter of the disk. The microprocessor will then cause a known constant current to be applied to the actuator coil to drive the head assembly towards the inside diameter for a known, predetermined time. The distance traveled from the first location during the predetermined acceleration time is measured by the head as it detects its location from the servo information encoded on the tracks. This distance recorded by the microprocessor. The heads are then moved to a second location near the inside diameter of the disk. The microprocessor then commands that same known constant current (except for sign) be applied to the actuator coil such that the head is driven towards the outside diameter for the same predetermined time that was used in the first location. The distance moved by the head at the second location is recorded by the microprocessor. The microprocessor then calculates a torque constant ratio by dividing the distance traveled at the second location by the distance traveled at the first location. From the table underlying curve 70, the offset for this particular drive is determined and stored in the microprocessor.
Each time a seek request is received by a drive from the host computer, the torque constant multiplier is retrieved from the torque constant multiplier table corresponding to the track over which the head is located as determined from the servo information on the disk. This is done by first modifying the actual head location by the track offset constant loaded at the time that the drive is calibrated. That is, the torque constant multiplier is retrieved from the torque constant multiplier table by adding the track to the offset value and generating a table pointer which "points" to the correct torque constant multiplier value.
Consider disk drive 3 of FIG. 7 as an example. At calibration time, the torque constant is measured at track 0 and at track 2500 and the torque constant ratio is calculated. As shown in FIG. 8, this ratio is approximately 0.82. From the graph of FIG. 8 or the offset table underlying the graph, the track offset is determined. In this case, the offset is +300.
Then in operation, assume the actuator/head assembly is presently located at track 100 and that the disk drive has received a request from the host to access track 200. Since the seek started at track 100, the drive microprocessor first adds the offset, 300, to the track, 100, and then finds the torque constant multiplier for table pointer 400 from the wide torque constant multiplier table. The microprocessor commands that a proper current, modulated by the torque constant multiplier, be supplied to the actuator coil in such a polarity and magnitude to drive the heads towards track 200. As the heads move, track location is read from the servo information. At each new track location read during the seek, the offset is added to the track and the torque constant multiplier is retrieved for the torque constat multiplier table; the current supplied to the actuator is modulated accordingly. This process continues until the heads have reached track 200.
FIG. 9 illustrates yet another aspect of the invention. Common reference numerals in FIGS. 1, 2 and 9 refer to the same elements. In addition to the mechanical components shown in FIG. 1, there is shown a prime mover 80 which includes a push pin 82 and a strain gauge 84. Strain gauge 84 is connected through lead 86 to computer 88.
When a disk is initially assembled into a drive, the disk is blank. There are no tracks on the disk. Writing tracks on the disk is the function of a piece of equipment called a servo writer. The servo writer supplies power to the spindle motor, moves the actuator and head very precisely across the raw disk and writes track address and fine servo information at several specified locations called sectors for each track. Prime mover 80 is the component of the servo writer that precisely moves actuator 18 and head 20. In order to snug actuator 18 up against push pin 82, a small bias current is applied to coil 32 in a direction to oppose the movement of push pin 82. A good value of bias current is 100 milliamps. This insures precision in locating head 20 in the servo track writing process.
This aspect of the present invention takes advantage of the servo writer setup to create a custom torque table for each drive as it goes through the servo write process. This is made possible by recognizing the relationship set out in Equation 4 following:
T=Fr (6)
T=K.sub.t *I (7) ##EQU5## Where
I=current
T=torque
r=radius form the pivot point 22 to push pin 82
F=force
K t =torque constant
In the foregoing equations, I and r are constants. Thus, torque constant, K t , can be measured directly. This is done with strain gauge 84. The measurements are made at servo write time. Each time the servo writer writes a track, the torque constant is measured at that track and stored in the torque constant table in the memory of the servo writer controller. Thus each drive has a customized torque constant table. The precision of strain gauge 84 need not be exceedingly great since a relative torque table may be used. Since the values in a relative table are ratios (torque values divided by torque value at mid stroke) the absolute value of K T as measured by this method is not important. The torque constant table is then inverted to get the torque constant multiplier table. The torque constant multiplier table can be stored either on the disk of the drive being servo written or in some electronically programmed memory on the disk drive.
It will be appreciated from the foregoing that the preferred embodiment is subject to numerous adaptations and modifications without departing from the scope of the invention. Therefore, it is to be understood that, within the scope of the appended claims, invention may be practiced other than as specifically described herein.
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An improved method for compensating for the irregularity in the torque constant of the electric motor used to move the actuator arm carrying the magnetic read/write head in a disk drive is disclosed. The torque constant of the electric motor varies across the operating range on a given drive as a function of head location and the variation in torque constant is compensated for with a torque constant multiplier. The present invention provides a method for accurately determining the torque constant multiplier versus position function of a particular disk drive. In one embodiment, the method of the present invention includes the steps of: determining a nominal operating range for the location of a head over a disk for substantially all disk drives manufactured with the same manufacturing process; determining the offset of the operating range of a particular disk drive relative to the nominal operating range; modifying the location of the head, as determined by reading servo information, of the particular disk drive based on the offset; and obtaining the value of the torque constant multiplier associated with the modified head location.
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BACKGROUND OF THE INVENTION
The present invention relates to a golf club head having a hollow construction.
Recently, large golf club heads having a head volume exceeding 430 cc have been developed. Since the large head has an enlarged sweet area on the head, it has become possible to manufacture an easy-to-use golf club that is less likely to cause a decrease in carry even in an off-center shot. However, if a head having a hollow construction is made large, the thicknesses of members forming a crown part and a sole part must be decreased. Therefore, a ball hitting sound at the time a ball hits tends to be low.
Generally, a high ball hitting sound peculiar to a metal head is to the golfer's liking. Therefore, various ways and means have been devised to control the ball hitting sound of such a large-size and light-weight head. For example, Japanese Patent Application Publication No. 2003-339922 describes a technique in which, to produce a high and clear ball hitting sound, a metallic thin small piece is fixed on the inner surface of a golf club head on the toe side of a sole part in a state in which one plate surface of the small piece adheres closely to the sole part. Also, Japanese Patent Application Publication No. 2006-204604 describes a technique in which, to improve the low ball hitting sound, at least one rib extending from the toe side to the heel side is arranged in the sole part, and this rib is extended curvedly so that the toe-side end and the heel-side end of the rib are nearer to the face side than the central area of the rib.
On the other hand, not all golfers like a metallic and high-pitched sound. Japanese Patent Application Publication No. 2008-200319 and Japanese Patent Application Publication No. 2008-200339 describe a technique in which, to make the ball hitting sound of golf club head loud and to make the reverberation long, the radius of curvature of the sole part, crown part, or side part is made larger than the minimum radius of curvature of the face surface of golf club head, and a rib or a flat plate shaped member is provided in a portion having a larger radius of curvature so that the value of resonance frequency of this portion is within ±10% of the value of resonance frequency of the face surface.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a golf club head having a hollow construction, which produces a characteristic low ball hitting sound to accommodate the diversity of golfers' preferences for ball hitting sounds even if the volume of the golf club head is increased to 430 to 500 cc and the weight thereof is decreased to 160 to 220 g.
To achieve the above object, as one aspect of the present invention, a golf club head in accordance with the present invention has a hollow construction, includes a face part, a sole part, a crown part, and a side part, and is characterized in that the head has a volume in the range of 430 to 500 cc and a weight in the range of 160 to 220 g; and the area of the sole part is in the range such that the primary natural frequency of the sole part is 2400 Hz or lower.
As another aspect of the present invention, a golf club head in accordance with the present invention has a hollow construction, including a face part, a sole part, a crown part, and a side part, and is characterized in that the head has a volume in the range of 430 to 500 cc and a weight in the range of 160 to 220 g; and a weight is formed on the inner surface of the sole part so that the primary natural frequency of the sole part is 2400 Hz or lower.
As still another aspect of the present invention, a golf club head in accordance with the present invention has a hollow construction, including a face part, a sole part, a crown part, and a side part, and is characterized in that the head has a volume in the range of 430 to 500 cc and a weight in the range of 160 to 220 g; and the radius of curvature of the outer surface of the sole part in the toe-to-heel direction is 230 mm or larger so that the primary natural frequency of the sole part is 2400 Hz or lower.
In the above-described second and third aspects, the area of the sole part is preferably in the range of 3000 to 14,000 mm 2 . Also, in the first and third aspects, a weight is preferably formed in a portion of the center of vibration in the sole part on the inner surface of the sole part. Furthermore, in the first and second aspects, the radius of curvature of the outer surface of the sole part in the toe-to-heel direction is 230 mm or greater.
As described above, according to the present invention, even for a large-size and light-weight golf club head having a volume of 430 to 500 cc and a weight of 160 to 220 g, the primary natural frequency of the sole part can be made 2400 Hz or lower by increasing the area of the sole part, by forming a weight on the inner surface on the hollow construction side of the sole part, or by making the radius of curvature of the outer surface of the sole part in the toe-to-heel direction 230 mm or larger. Thereby, a characteristic low ball hitting sound can be obtained.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A is a bottom plan view showing a first embodiment of a golf club head in accordance with the present invention;
FIG. 1B is a front view of the golf club head shown in FIG. 1A ;
FIG. 2A is a bottom plan view showing a second embodiment of a golf club head in accordance with the present invention;
FIG. 2B is a front view of the golf club head shown in FIG. 2A ;
FIG. 3A is a bottom plan view showing a third embodiment of a golf club head in accordance with the present invention;
FIG. 3B is a front view of the golf club head shown in FIG. 3A ;
FIG. 4A is a bottom plan view showing a fourth embodiment of a golf club head in accordance with the present invention;
FIG. 4B is a front view of the golf club head shown in FIG. 4A ;
FIG. 5A is a bottom plan view of a golf club head of comparative example;
FIG. 5B is a front view of the golf club head shown in FIG. 5A .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Embodiments of a golf club head in accordance with the present invention will now be described with reference to the accompanying drawings. FIG. 1A is a bottom plan view showing a first embodiment of the golf club head in accordance with the present invention, and FIG. 1B is a front view of the golf club head shown in FIG. 1A .
As shown in FIGS. 1A and 1B , a golf club head 10 of this embodiment includes a face part 11 , a sole part 12 , a crown part 13 , a side part 14 , and a hosel part 15 . The side part 14 wraps around the head 10 from the toe side 14 a to the heal side 14 b via the back side. Also, the face part 11 and the sole part 12 are formed so as to be adjacent to each other. Although not shown in particular, the head 10 has a hollow construction, and the inner surfaces on the hollow construction side of the parts of head are formed so as to be almost smooth like the outer surface thereof.
In the present invention, a large golf club head having a volume of 430 cc or greater is taken up. A further preferred head volume is 435 cc or greater. On the other hand, the upper limit of the head volume is 500 cc, preferably 470 cc. Also, in the present invention, a lightweight golf club head having a weight of 220 g or less is taken up. A preferred club weight is 195 g or less. On the other hand, the lower limit of head weight is 160 g, preferably 165 g.
In this embodiment, the area of the sole part 12 is designed so as to be large so that the primary natural frequency of vibrations of the sole part 12 caused when a ball is hit by the golf club head 10 is 2400 Hz or less. For example, the area of the sole part 12 is preferably 4000 mm 2 or greater, more preferably 6000 mm 2 or greater. By remarkably increasing the area of the sole part 12 with respect to the head volume in this manner, the amplitude of the sole part 12 is increased, so that the primary natural frequency of the sole part 12 can be made 2400 Hz or less.
The primary natural frequency is preferably 2200 Hz or less, more preferably 2000 Hz or less. The lower limit of the primary natural frequency is preferably 1300 Hz because too large a head volume is not to a golfer's liking. On the other hand, if the area of the sole part 12 is too large, swing is hindered. Therefore, the area of the sole part 12 is preferably 14,000 mm 2 or less, more preferably 13,000 mm 2 or less.
The radius of curvature R of the outer surface of the sole part 12 in the direction directed from the toe side 14 a to the heel side 14 b is preferably 150 mm or greater, further preferably 160 mm or greater. On the other hand, if the radius of curvature R is too large, it is difficult for the golfer to set up the head 10 , which poses a problem of difficulty in assuming a posture. Therefore, the radius of curvature R is preferably 500 mm or less, further preferably 450 mm or less.
To maintain a fixed strength, the wall thickness of the sole part 12 is preferably 0.6 mm or greater, further preferably 0.7 mm or greater. On the other hand, if the wall thickness is too large, the weight increases. Therefore, the wall thickness of the sole part 12 is preferably 1.5 mm or less, further preferably 1.2 mm or less.
In this specification, the “sole part” means a part having a wall thickness different from that of the adjacent side part or face part. In the case in which the wall thickness of the sole part is the same as that of the side part or the face part, a portion in which the radius of curvature R of the outer surface of the sole part changes greatly is made a boundary with the side part or the face part. Also, the “area of the sole part” means an area of the outer surface of the sole part.
FIGS. 2A and 2B show a second embodiment of the golf club head in accordance with the present invention, FIG. 2A being a bottom plan view of the golf club head, and FIG. 2B being a front view thereof. As shown in FIGS. 2A and 2B , a golf club head 20 of this embodiment also includes a face part 21 , a sole part 22 , a crown part 23 , a side part 24 , and a hosel part 25 . In this embodiment, the side part 24 is formed between the face part 21 and the sole part 22 .
In this embodiment, the radius of curvature R of the outer surface of the sole part 22 in the direction directed from the toe side 24 a to the heel side 24 b is designed so as to be large, being 230 mm or greater, so that the primary natural frequency of the sole part 22 is 2400 Hz or less. This radius of curvature R is preferably 350 mm or greater, further preferably 400 mm or greater. By remarkably increasing the radius of curvature R of the sole part 22 in this manner, the shape of the sole part 22 is made flat, so that the primary natural frequency of the sole part 22 can be made 2400 Hz or less. On the other hand, if the radius of curvature R is too large, the above-described problem arises. Therefore, the radius of curvature R is preferably 500 mm or less, further preferably 450 mm or less.
In this embodiment, the area of the sole part 22 need not necessarily be increased, and is preferably 3000 mm 2 or greater, more preferably 4000 mm 2 or greater, and still more preferably 6000 mm 2 or greater. To maintain a fixed strength, the wall thickness of the sole part 22 is preferably 0.6 mm or greater, more preferably 0.7 mm or greater. On the other, if the wall thickness of the sole part 22 is too large, the weight increases. Therefore, the wall thickness of the sole part 22 is preferably 1.5 mm or less, further preferably 1.2 mm or less.
FIGS. 3A and 3B show a third embodiment of the golf club head in accordance with the present invention, FIG. 3A being a bottom plan view of the golf club head, and FIG. 3B being a front view thereof. As shown in FIGS. 3A and 3B , a golf club head 30 of this embodiment also includes a face part 31 , a sole part 32 , a crown part 33 , a side part 34 , and a hosel part 35 .
In this embodiment, a weight 36 is formed on the inner surface on the hollow construction side of the sole part 32 so that the primary natural frequency of the sole part 32 is 2400 Hz or less. Since the weight 36 is formed within the head 30 , the weight 36 is shown by a broken line in FIGS. 3A and 3B . The weight 36 is preferably formed at a position of the center of vibration caused in the sole part 32 at the time of hitting a ball. By forming the weight 36 at the position of the center of vibration in this manner, the primary natural frequency of the sole part 32 can be decreased to 2400 Hz or less. The center of vibration of the sole part 32 usually takes place at a position of the centroid of the sole part 32 if the wall thickness of the sole part 32 is uniform.
The weight of the weight 36 is preferably 3 g or greater, further preferably 4 g or greater. If the weight is too large, an influence is exerted on swing balance, or the whole of head becomes heavy, so that there arises a problem in that the head volume must be decreased. Therefore, the weight of the weight 36 is preferably 10 g or less, further preferably 9 g or less. Also, to control the vibrations of the sole part 32 properly, the area of the weight 36 that is in contact with the inner surface of the sole part 32 is preferably 200 mm 2 or less, further preferably 150 mm 2 or less. The lower limit of this area is preferably 20 mm 2 .
FIGS. 3A and 3B show the case in which the shape of the weight 36 is a rectangular prism. However, the shape of the weight 36 is not limited to this, and a rectangular prismatic, spherical, ellipsoidal, cylindrical, conical, or truncated conical shape, or other polyhedral shapes may be used. Also, the weight 36 may be joined to the sole part 32 , for example, by welding by adhering one surface thereof closely to the inner surface of the sole part 32 , or may be formed integrally, for example, by casting.
In this embodiment as well, as in the second embodiment, the area of the sole part 32 need not necessarily be increased, and is preferably 3000 mm 2 or greater, more preferably 4000 mm 2 or greater, and still more preferably 6000 mm 2 or greater. The wall thickness of the sole part 32 is preferably 0.6 mm or greater, more preferably 0.7 mm or greater as in the second embodiment. Also, the wall thickness of the sole part 32 is preferably 1.5 mm or less, more preferably 1.2 mm or less.
FIGS. 4A and 4B show a fourth embodiment of the golf club head in accordance with the present invention, FIG. 4A being a bottom plan view of the golf club head, and FIG. 4B being a front view thereof. As shown in FIGS. 4A and 4B , this embodiment is a combination of the first embodiment and the third embodiment. That is to say, the area of a sole part 42 is designed so as to be large, and a weight 46 is formed on the inner surface of the sole part 42 .
In this embodiment, the area of the sole part 42 is preferably 4000 mm 2 or greater, further preferably 6000 mm 2 or greater. By making the area of the sole part 42 large and by forming the weight 46 on the inner surface of the sole part 42 as described above, the primary natural frequency of the sole part 42 can be made 2200 Hz or less, further 2000 Hz or less. The upper limit of the area is preferably 14,000 mm 2 , more preferably 13,000 mm 2 . The weight 46 is preferably formed at a position at the center of vibration of the sole part 42 . Although FIGS. 4A and 4B show one weight 46 , since the area of the sole part 42 is large, a plurality of weights 46 can be formed when the center of vibration takes place at a plurality of positions of the sole part 42 .
As described above, in the present invention, the first through third embodiments can be combined. The area and the radius of curvature of the sole part are increased by combining the first and second embodiments, a weight is formed on the inner surface of the sole part having an increased radius of curvature by combining the second and third embodiments, or a weight is formed on the inner surface of the sole part having an increased area and an increased radius of curvature by combining the first through third embodiments. Thereby, the primary natural frequency of the sole part can be made 2200 Hz or less, or more preferably 2000 Hz or less.
In any of these embodiments, the face part, the sole part, the crown part, the side part, the hosel part, and the weight can be made of a metallic material having the same or different composition. These elements are preferably made of, for example, a titanium alloy or an aluminum alloy. For example, a titanium alloy (Ti-6Al-4V) having a composition of 5.5 to 6.75 wt % Al, 3.5 to 4.5 wt % V, the balance being Ti and unavoidable impurities can be used.
EXAMPLES
Golf club heads of examples 1 to 4 and a comparative example having specifications given in Table 1 were manufactured. The “length” in Table 1 means a distance between the toe and the heel of the sole part, and the “depth” in Table 1 means a distance between the face and the back of the sole part. The appearances of examples 1 to 4 and comparative example correspond to FIGS. 1A to 5B . In all of the examples and the comparative example, the Ti-6AL-4V alloy was used, and the head had a volume of 450 cc. The primary natural frequencies of the sole parts of the examples 1 to 4 and the comparative example were determined by FEM analysis. The results are given in Table 1.
TABLE 1
Sole
Primary
Wall
Head
natural
Area
R
thickness
Length
Depth
Weight
weight
frequency
Appearance
[mm 2 ]
[mm]
[mm]
[mm]
[mm]
[g]
[g]
[Hz]
Example 1
FIGS. 1A
7113
234
0.8
119
94
—
180
2150
and 1B
Example 2
FIGS. 2A
7090
425
1.0
91
93
—
182
1919
and 2B
Example 3
FIGS. 3A
4466
165
0.8
63
76
5
183
2112
and 3B
Example 4
FIGS.4A
7113
234
0.8
119
94
5
182
1830
and 4B
Comparative
FIGS. 5A
4466
165
0.8
63
76
—
175
2686
Example
and 5B
As shown in Table 1, for the comparative example having a sole area of about 4500 mm 2 , the primary natural frequency of sole part was very high, being about 2700 Hz. On the other hand, for example 1 having a large sole area of about 7100 mm 2 , the primary natural frequency of the sole part was able to be decreased significantly to about 2200 Hz. Also, for example 2 having a large sole area of about 7100 mm 2 and a large radius of curvature of sole of about 400 mm, the primary natural frequency of sole part was able to be decreased to about 1900 Hz. For example 3 having the same sole area as that of the comparative example and provided with a 5-gram weight in the center of vibration of sole part, the primary natural frequency of sole part was able to be decreased significantly to about 2100 Hz. Furthermore, for example 4 having a large sole area of about 7100 mm 2 and provided with a 5-gram weight in the center of vibration of sole part, the primary natural frequency of sole part was able to be decreased to about 1800 Hz.
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A golf club head having a hollow construction produces a characteristic low ball hitting sound to accommodate the diversity of golfers' preferences for ball hitting sounds even if the volume of the golf club head is increased to 430 to 500 cc and the weight thereof is decreased to 160 to 220 g. In a golf club head having a hollow construction and including a face part, a sole part, a crown part, and a side part, in which the head volume is 430 to 500 cc, and the head weight is 160 to 220 g, the area of the sole part is increased so that the primary natural frequency of the sole part is 2400 Hz or less, and a weight is formed at a position of the center of vibration in the sole part on the inner surface on the hollow construction side of the sole part.
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BACKGROUND OF THE INVENTION
This invention relates to the production of vehicle tires and especially to the processing of tires following their removal from a vulcanizing mold. More particularly, the invention relates to the procedure for removing or trimming from the tire, mold vents, mold flash and the like.
The invention has particular utility in connection with the post-cure processing of larger tires such as truck tires and tires for off-the-road equipment. After such tires are cured in a vulcanizing mold, it is necessary to trim or remove undesired protruberances from the tread and sidewall portions. Such protruberances include material that squeezes into small vents in the mold during the vulcanizing operation and material or flash that squeezes into spaces at the parting lines between mold sections.
According to existing practices, the tire to be trimmed is manually loaded in an apparatus that spins the tire about its axis of rotation while an operator, using one or more drag knives, cuts or trims away the undesired material from the spinning tire. The trimmed tire is then manually removed from the trimming station by the operator.
Truck tires, off the road tires, and the like are quite heavy and difficult to handle manually. Accordingly, the trimming operation for such tires is burdensome and time consuming. Also, manufacturing facilities for such tires are adapted to produce as many as several hundred different types of tires varying greatly in dimension, type of construction (e.g. bias or radial carcass construction) and/or tread design. Nevertheless, it is usually necessary to trim a manufacturing facility's entire production at one trimming station.
One difficulty often encountered with this arrangement is that the surface speed at which a relatively large tire is spun for the trimming operation may be effective for tires of one size but for tires of other sizes the drag knives may catch the tread rubber and be jerked out of the operator's hand. In view of this problem, the general rule is that slower surface speeds be used with tires of larger diameter. Measuring the tire diameter and adjusting the spin speed, however, is a complicated problem and generally not practical with most conventional equipment.
The apparatus of the present invention, however, resolves many of the difficulties indicated above and affords other features and advantages heretofore not obtainable.
SUMMARY OF THE INVENTION
It is among the objects of the invention to automatically load and unload tires in and from a spinning apparatus at a tire trimming station whereat the loaded vulcanized tire is spun about its axis to facilitate the trimming therefrom of undesired protruberances such as mold vents and flash.
Another object of the invention is to spin tires of widely varying construction and dimension about their respective axis of rotation to facilitate trimming therefrom of mold vents, mold flash and the like whereat the surface speed of the spinning tire is automatically adjusted according to the particular tire diameter.
Still another object of the invention is to eliminate the need for manually loading and unloading heavy tires (e.g. truck tires and the like) in and from a spinning apparatus at a trimming station.
A further object is to increase the number of relatively large tires of various sizes and shapes that can be trimmed of mold vents and flash by a single operator in a daily working shift.
These and other objects and advantages are accomplished by the unique apparatus of the invention which is adapted for location at a post-cure tire processing station whereat vulcanized tires of different dimension and construction are to be spun about their axis of rotation to facilitate the trimming therefrom of mold vents, flash and the like.
In accordance with the apparatus of the invention, at least three parallel rollers located as to circumpose the tire, are adapted to engage the tread portion of the tire at spaced circumferential locations and support the tire for spinning about its axis of rotation. Preferably, the tire is supported in an upright position with its axis of rotation generally horizontal. The rollers include a driver roller with variable speed drive means for spinning the tire, a movably mounted retaining roller adapted to apply retaining force to the tire and a retractable idler roller adapted to be shifted between a tire supporting position and a retracted position permitting the tire to be discharged from the trimming station. The apparatus includes adjustable means such as a pair of parallel axis rollers selectively engageable with opposite sides of the tire to be spun to assist in guiding the tire while spinning, and means for sensing and measuring the diameter of each tire to be loaded and for adjusting the speed of the drive means in accordance with the diameter measurement. Generally speaking, slower surface speeds are used with tires of larger diameter.
According to the preferred embodiment, the retractable roller is associated with a carriage movable in a horizontal plane and also supporting an inclined floor portion along which the tire rolls to its spinning position. When the retractable idler roller is removed by retraction of the carriage together with the floor portion, the tire drops out of its position where it is supported by the rollers and falls through a discharge chute.
According to another aspect of the invention the retaining roller is mounted on a pivot arm assembly and is biased by its own weight into force applying engagement with the tire. The pivot arm assembly is movable between a retracted position and an operating position depending upon the diameter of the tire to be spun. Once a trimmed tire is discharged from the trimming station the retaining roller is withdrawn such as by a fluid cylinder to a position preparatory to the loading of another tire to be trimmed. After the tire is rolled into position resting on at least two rollers below, the retaining roller is pivoted into force applying engagement with the tire.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevation illustrating an apparatus for automatically loading and unloading vehicle tires at a trimming station and for spinning a loaded tire about its axis of rotation, in accordance with the present invention;
FIG. 2 is a plan view of the apparatus taken from the line 2--2 of FIG. 1;
FIG. 3 is an end elevation of the apparatus taken from the line 3--3 of FIG. 1, with parts broken away for the purpose of illustration;
FIG. 4 is a fragmentary sectional view on an enlarged scale taken on the line 4--4 of FIG. 2;
FIG. 5 is a fragmentary sectional view similar to and on the same scale as FIG. 4, illustrating the condition of the apparatus during the discharge of a trimmed tire from the trimming station into a discharge chute shown in phantom lines;
FIG. 6 is a fragmentary sectional view with parts broken away taken on the line 6--6 of FIG. 4;
FIG. 7 is a fragmentary sectional view on an enlarged scale with parts broken away, taken on the line 7--7 of FIG. 6;
FIG. 8 is a schematic diagram illustrating the fluid pressure operating system for the apparatus of the invention; and
FIG. 9 is a schematic diagram, partly in block form illustrating the electrical control system for the apparatus of FIGS. 1 through 7.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring more particularly to the drawings, and initially to FIGS. 1, 2 and 3, there is shown an apparatus A embodying the invention for sequentially receiving and locating a tire 10l at a trimming station in a generally upright position, and spinning the tire about its axis of rotation whereupon an operator trims away undesirable protruberances such as mold vents and flash using conventional drag knives or the like. The trimmed tire is automatically removed on the operator's command to a discharge chute 11 shown in phantom lines, the chute 11 being located below the trimming station so that the tire 10 drops downward and then passes beneath the operator.
The apparatus is located at a convenient working space in an elevated position, spaced, for example, seven or eight feet above the floor. The apparatus has a frame 12 formed of structural metal numbers including uprights, cross members and diagonal bracing. Tires are supplied to the apparatus in an upright position along a loading conveyor 13 shown in phantom lines in FIG. 1 and pass on to the appratus A whereupon they roll along an inclined floor 18 between a plurality of upright guide rollers 14.
The tire 10 comes to rest at the trimming station where it is supported by a drive roller 15, and a retractable idler roller 16. An overhead retaining roller 17 of heavy construction swings down onto the top of the tire 10 and applies retaining force through its own weight. The roller 17 is supported to swing into and out of engagement with the tire 10 so that it may be withdrawn from operating position during loading and unloading. The mounting arrangement and operation of the retaining roller 17 will be described in greater detail below.
In the loaded condition the tire 10 is securely held and circumposed by the three parallel rollers 15, 16 and 17 so that it may be spun in a fixed position about its own axis of rotation.
Prior to the operation of the drive roller 15 a pair of opposed parallel pressure rollers 21 and 22 adapted for movement toward and away from one another are moved toward one another until they engage the siewalls of the tire and retain it against axial movement during the spinning operation. The initial positioning of the tire is assisted by a pair of parallel locating rollers 23 and 24 that move with the rollers 21 and 22 respectively to prevent the tire from canting out of its proper vertical plane. The construction and operation of the guide rollers will be described in more detail below.
The retractable idler roller 16 is associated with an unloading assembly including a carriage 25 movable in a horizontal direction between an extended position illustrated in FIGS. 1 and 4 and a retracted position illustrated in FIG. 5. The carriage 25 travels on a pair of spaced parallel guide shafts 26 and 27 mounted on the frame 12. Bronze bushings 31, 32, 33 and 34 mounted at each corner of the carriage 25 slide along the shafts 26 and 27. The carriage 25 supports a retractable floor portion 35 which forms a forward extension of the inclined floor 18 but which is adapted when retracted to move under the rearward portion of the inclined floor 18. At the forward end of the retractable floor portion 35 the retractable idler roller 16 is journaled in a pair of pillow blocks 36 and 37.
The carriage 25 is moved between its extended and retracted position by means of an air cylinder 40 with a rod 41 connected to the carriage 25 and with its rearward end connected to the frame 12. Accordingly, the carriage 25 is movable between an extended position best illustrated in FIGS. 1 and 4 wherein the idler roller 16 is closely spaced relative to the drive roller 15 and wherein the floor portion 35 forms an extension of the inclined floor 18 so that the tire 10 rolls to its position at the trimming station.
When the carriage 25 is retracted by the cylinder 40 to the position illustrated in FIG. 5, the idler roller 16 is sufficiently spaced from the drive roller 15 that the trimmed tire 10 falls through to the discharge chute 11 below. After a trimmed tire is discharged the carriage 25 is immediately returned to the extended position preparatory to the loading of another tire.
The drive roller 15 has a shaft 43 that is journaled in pillow blocks 44 and 45 bolted to the frame, the shaft 43 having a pulley 46 at one end driven by a pair of belts 47 from a drive pulley 48 mounted on the output shaft of a variable speed drive motor 50. The speed of the motor 50 is adjusted depending upon the diameter of the tire so that slower surface speeds are provided for tires of a larger diameter.
The sidewall engaging pressure rollers 21 and 22 and their associated guide rollers 23 and 24 as indicated above are movable toward and away from one another between trimming operations. The rollers 21, 23 and 22, 24 are mounted on carriages 51 and 52 respectively that slide laterally on horizontal guide rods 53 and 54. The upper ends of the shafts of the rollers 21 and 22 are loosely journaled in slots and are urged by springs toward the tire sidewall. When the rollers 21 and 22 initially engage the tire sidewalls, the springs are compressed and the shafts actuate limit switches that halt further inward movement of the rollers against the tire sidewall. The guide rollers 23 and 24 do not engage the tire sidewall during the spinning operation but merely serve to engage and guide the tire during the initial positioning prior to spinning. The carriages 51 and 52 are moved simultaneously toward and away from one another by means of ball nuts 55 and 56 mounted thereon and which are operatively associated with a ball screw 57 with threads of opposite pitch on either side of its center. The ball screw 57 extends horizontally through both of the ball nuts 55 and 56 and the operation thereof is controlled as illustrated in FIGS. 2 and 3 by solenoid operated clutch and brake units 58 and 59 operatively associated with drive motors 61 and 62 one of which is located at each end of the ball screw 57. The motors 61 and 62 are adapted to turn the ball screw 57 in opposite directions and the direction depends on which clutch is engaged. When neither of the clutches is engaged, one of the brakes is engaged to positively fix the position of the carriages 51 and 52.
The overhead retaining roller 17 has a generally conical form and a shaft 63 journaled in a lever arm assembly 64 including a pair of spaced parallel cooperating lever arms 65 and 66 rigidly connected together by cross bracing 67 and 68. The lever arms 65 and 66 are pivoted on a horizontal shaft 69 mounted on the frame 12, between an upwardly swung position preparatory to loading of a tire and as illustrated in dashed lines in FIG. 1, and an operating position illustrated in solid lines in FIGS. 1, 3 and 4. The weight of the roller 17 serves to retain the tire 10 in position for spinning circumposed by the three rollers 15, 16 and 17. Also the weight thereof assists in the discharging of the tire once the carriage 25 is retracted.
As the tire 10 is discharged the lever arms 65 and 66 drop and engage a pair of shock absorbers 71 and 72, after which a limit switch operated by retraction of the carriages 25 actuates a lever retraction cylinder 75 with a rod 76. The lever arm assembly 64 is operatively connected to the rod 76 by means of a short chain length 77 which is used to retract the roller 17. When the roll 17 is in its operating position, however, no pressure can be applied by the retraction cylinder 75. Only the weight of the roller 17 is used to apply retaining force to the tire. The retraction of the roller 17 following a trimming operation permits loading of a new tire 10 after which the cylinder 75 extends to permit the roller 17 to drop into operating position.
CONTROL SYSTEM
As indicated above the tire loading and discharging operations of the apparatus A are performed semi-automatically and the surface speed of the spinning tire is controlled depending upon the diameter of the tire to be trimmed. The surface speed is of course derived from the speed of the drive motor 50 which is a 3 hp. variable speed DC motor. The diameter of the tire is sensed and measured by means of four photo cells 81, 82, 83 and 84 mounted on the frame 12 in vertical alignment whereupon the respective beams are interrupted progressively from bottom to top depending upon the diameter of the tire. The larger the diameter of the tire the greater the number of photo cell beams that will be interrupted. The photo cells 81, 82, 83 and 84 thus provide for four diameter ranges which determine the speed selection. In the present instance four speeds are provided.
The signals from the photo cell units 81, 82, 83 and 84 are supplied to a drive roller motor speed control unit 85 (FIG. 9). The speed control unit 85 is energized continuously, however, the motor 50 is not driven at operating speed until the tire is in its trimming position with the retainer roller 17 lowered into engagement with the tire tread. The carriages 51 and 52 are moved inwardly as soon as the tire is in its trimming position, to bring the pressure rollers 21 and 22 into engagement with the sidewalls of the tire. The inward movement results from the engagement of a clutch solenoid 58a of the clutch brake unit 58. As soon as the clutch 58a is engaged the brake solenoid 58b is deenergized. With the clutch 58a energized the motor 61 turns the ball screw in a direction causing the ball nuts 55 and 56 to move inward. As the pressure rollers 21 and 22 engage the sidewall of the tire the upper ends of the shafts thereof are pushed outward to depress the springs and actuate limit switches 91 and 92 which when both are actuated cause deenergizing of the solenoid 58a and energizing of the brake solenoid 58b to lock the ball screw in the inward position. As the tire 10 is driven at the desired surface speed the operator using drag knives (normally one in each hand) trims mold flash and vents from the spinning tire as necessary.
Once the tire operation has been completed the operator depresses a foot switch to activate the two discharge functions. The brake solenoid 58b is deenergized and the clutch solenoid for the unit 59 is energized to drive the ball screw 57 through the motor 62 and cause opening of the carriages 51 and 52. The solenoid 42b is energized to move the solenoid valve 42 to a position (FIG. 8) causing the cylinder 40 to retract the carriage 25. Accordingly, the tire 10 falls through the resulting space to the discharge chute 11 below (FIG. 5). The retaining roller 17 swings downward to help discharge the tire 10, until the lever arm assembly strikes the shock absorbers 71 and 72. The carriage 25 when retracted operates a limit switch to energize solenoid 78b of valve 78 to cause retraction movement of the air cylinder 75. This lifts the lever assembly 64 to the raised position. Also, a pneumatic brake unit 90 operated by solenoid 90a (FIG. 9) stops the spinning roller 17.
As soon as the carriage 25 reaches its retracted position the limit switch it operates energizes solenoid 42a and deenergizes solenoid 42b to cause its immediate extension back to the operating position preparatory to loading of another tire.
OPERATION
The operation of the apparatus A may best be described with reference to FIGS. 4 and 5 and to the diagram of FIG. 9. For the purpose of this description it will be assumed that the cylinder 75 has lifted the lever assembly 64 to the raised position with the retainer roller 17 at a sufficient height to permit the tire to roll into trimming position. Both motors 61 and 62 are energized and operating and both clutch solenoids 58a and 59a are deenergized and the pressure rollers 21 and 22 are at their widely spaced, outward position. The fluid cylinder 40 has its rod 41 extended to move the carriage 25 to the position shown in FIG. 4. Also the drive motor 50 is turning at a relatively slow speed so as to drive roller 15 at a speed of approximately 400 feet per minute.
With the apparatus A in this condition a tire is released by a suitable mechanism associated with the loading conveyor 13 and a tire 10 to be trimmed rolls along the floor 18 and the floor portion 35 between the upright guide rolls 14 until it reaches the position illustrated in FIG. 4 whereat it rests upon the slowly turning drive roller 15 and the retractable idler roller 16. The relatively slow rotation of the drive roller 15 is necessary in order to stabilize the tire before its spinning speed is increased to the relatively high predetermined operating speed. During the movement of the tire along the floor 18 it passes a vertical alignment of the four photo cells 81, 82, 83 and 84, and one or more of the photo cell beams was interrupted by the tire 10 depending upon its diameter. Accordingly, the photo cells 81, 82, 83 and 84 have served to measure and classify the diameter of the tire between four dimensional categories. The resulting measurement has been transmitted to the drive roller motor speed control unit 85 which is then set to a certain speed condition for the particular tire 10.
As the tire 10 rolls along the floor 35 it interrupts a photo cell beam which through timers energizes the solenoid 78a of the valve 78 to operate the cylinder 75 and cause extension of the cylinder rod 76. This permits the roller 17 to contact the tire just as the tire comes in contact with drive roller 15.
Also, the timers energize the clutch solenoid 58a to connect the motor 61 to the ball screw 57 to turn the ball screw 57 in a direction that causes the carriages 51 and 52 to move toward one another. The tire initially may be canted in such a way that one of the guide rolls 23 and 24 will initially engage and guide it into a position whereat its axis of rotation is parallel to the axis of rotation of the rollers 15, 16 and 17.
As the pressure rollers 21 and 22 reach pressure applying position the upper ends of their respective shafts which are loosely mounted in a slot in the respective carriages 51 and 52 will be pushed slightly backward and actuate limit switch units 91 and 92 (FIG. 7) which, when both are actuated, deenergize the clutch solenoid 58a and energize brake solenoid 58b so that the carriages 51 and 52 will be retained at the desired spacing during the spinning operation.
At this time, the operator depresses a foot switch which speeds up drive roller motor 50 to the higher predetermined surface speed. The operator then applies drag knives or the like to the sidewall surfaces of the spinning tire to remove mold vents, flash, etc.
After the trimming has been accomplished the operator activates a foot switch that activates several functions. As one function, the brake solenoid 58b is deenergized and the clutch solenoid 59a is energized to drive the ball screw 57 in the reverse direction with the motor 62 to cause the pressure rolls 21 and 22 to withdraw from the sidewall of the tire. Also, the solenoid 42b of the valve 42 that controls the fluid cylinder is energized to cause retraction of the cylinder rod 41 and thus withdrawal of the carriage 25 and idler roll 16. Accordingly, the trimmed tire drops into the discharge chute 11 as illustrated in FIG. 5. The discharge is assisted by the force of the retainer roller 17 which is free to swing downward as the tire drops. The downward swing of the lever assembly 64 continues until the assembly engages the shock absorber units 71 and 72. The retraction of the carriage 25 activates a limit switch to energize the solenoid 78b of the valve 78 for the cylinder 75 and causes the cylinder rod 76 to retract and pull the lever assembly 64 and retainer roller 17 upward to the withdrawn position preparatory to receiving another tire 10 for trimming. At the same time that the solenoid 78b is energized, the pneumatic disc brake 90 is activated to stop the rotation of the retainer roller 17. The disc brake 90 is disengaged when the solenoid 78 is energized during the next cycle.
After retraction of the carriage 25 is completed, the limit switch also energizes the solenoid 42b, shifts the control valve 42 for the fluid cylinder 40 and causes prompt extension of the cylinder rod 41 and carriage 25 back to the position illustrated in FIG. 4. Also the control for the drive roller motor 50 reduces the motor speed to its lower rpm to begin the next cycle. Once the carriage 25 is again extended, another tire is released and the trimming cycle repeated.
While the invention has been shown and described with reference to a specific embodiment thereof, this is intended for the purpose of illustration rather than limitation and other variations and modifications of the specific apparatus herein shown and described will be apparent to those skilled in the art all within the intended spirit and scope of the invention. Accordingly, the patent is not to be limited to the specific embodiment herein shown and described nor in any other way that is inconsistent with the extent to which the progress in the art has been advanced by the invention.
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Apparatus for sequentially loading and discharging from a trimming station, vulcanized vehicle tires of various sizes and for spinning a tire preferably while in an upright position to facilitate the removal therefrom of mold vents, flash, etc. The apparatus includes at least three parallel rollers adapted to engage the tire tread and circumpose the tire while spinning it about its axis of rotation. One of the rollers is driven, another applies suitable retaining pressure and one is retractable for discharging a trimmed tire. The spinning tire is held against axial movement by adjustable means adapted to accommodate tires of different widths. The diameter of the tire is automatically measured and the speed of rotation adjusted depending upon the diameter measurement.
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[0001] This application claims priority under 35 U.S.C. 119(e)(1) based on Applicants Provisional U.S. patent application Ser. No. 60/661,618 filed Mar. 14, 2005 and titled “CONCEPT DESIGN FOR COMMERCIAL STYLE HOME BAKING DEVICE/OVEN”.
BACKGROUND OF THE INVENTION
[0002] 1. Field
[0003] The present invention is directed to electrically heated convection baking ovens and the like and particularly concerns, in preferred embodiments, operator control of radiant heat emanating from heating elements and directed down into the oven cooking chamber, specially constructed and functional heated air circulating means for providing more uniform heat transfer throughout the cooking chamber, an upper heating element and a lower heating element with a ceramic or metal heat sink, specially designed partition or divider means for quickly and easily converting the oven cooking chamber from a single chamber to multiple chambers and vise versa, and in a most preferred embodiment uniquely functional electrical control means is provided for regulating heat output of the upper and lower heating elements in a reciprocal manner so as to accurately regulate the temperature of a particular area—sweet spot—within the oven cooking chamber which is most desirable for a particular product.
[0004] 2. Prior Art
[0005] Conventional home ovens for the past 100 years have retained the basic cube configuration for the oven cooking chamber which is typically provided with horizontal interposed cooking racks. Other than the addition of “convection” provided by fan means and the substitution of electronic for electromechanical controls, little has changed. This basic configuration leaves considerable room for improvement.
[0006] Much oven usage involves baking, roasting or broiling of smaller size or number of food products whereby utilization of the large standard oven cavity becomes energy inefficient. Attempts at simultaneous precision baking on multiple racks is usually futile because of the unevenness in heat transfer excepting perhaps for ovens with “pure” or “European style” convection. Simply spoken, most ovens have one “sweet spot” or area that cooks with evenness and consistency for a specific product. Attempts have been made to “fine tune” this “sweet spot” by placing the racks at different heights, however, many conventional ovens still have a tendency to over cook or over brown the food product at the rear of the oven. This can be due to excessive air leaks in the oven door, excessive airflow over the product next to fan intake, or even opening the oven door multiple times to check on the product being baked.
SUMMARY OF THE INVENTION
[0007] The present invention, in one of its most preferred embodiments comprises an oven structure which provides for two or more separate ovens separated by vertical, movable, hinged partition(s) whereby the oven structure may function as one large oven or as two or more smaller independent ovens, and which further provide for highly controlled heating of each cooking chamber by means of a tangential fan for each chamber with air flow therefrom directed over upper elctrical heating elements by means of flow director structure ensuring luminal flow and evenness of heat transfers, wherein the flow director also functions as a radiant heat shield or occluder which is operator movable to either expose or occlude the radiant heat to each chamber from the upper elements depending on the need to roast, bake, or broil the food product. Also provided are lower electrical heating elements positioned below ceramic cooking surfaces for ensuring evenness of radiant heat transfer therefrom. Also provided for is operator controlled top vs. bottom heating using a slide control that reciprocally affects the duty cycle of the top and bottom electrical heating elements, further allowing precision baking control.
[0008] The present oven structure design addresses the aforementioned prior difficulties and in addition, the design concept extends the side walls of the oven and diminishes the vertical oven height, and provides a hinged moveable vertical partition to enable the operator to vary the cooking chamber size for smaller or larger products. This allows for the oven to be employed as a single larger oven or as two or more smaller ovens. Also, independent controls for these partitioned cooking chambers enable the user to perform independent cooking tasks in each separate cooking chamber.
[0009] An even heat transfer is the hall mark of precision baking and is probably more important than the method of transfer (radiant, convective, conductive). This issue is addressed through the present invention by a number of changes or departures from the standard. For example, with the present invention, convective heat is provided by a tangential fan positioned in the rear top of the oven that blows air along its entire length. The inlet air is ducted to the fan from the bottom of the back wall of the cooking chamber and the outflow air is controlled by a flow director that channels the heated air along the top of the oven over the heating elements and down into the cooking chamber resulting in an even laminar air flow.
[0010] The flow director is constructed to function also as a radiant heat occluder to either block or expose the cooking product to direct radiant heat from the upper heating elements depending on the cooking task desired. For example, the air flow director can serve as a radiant shield for the top elements, thereby ensuring evenest in heating but can be repositioned to expose the top heating elements to the food product as would be necessary, for example for broiling. Bottom heat is provided by heating elements preferably beneath a large ceramic plate which forms the floor or bottom wall of the oven cooking chamber on which plate the food product may be placed either directly as with bread or indirectly as in a cooking vessel. The ceramic or metal plate functions as a heat sink and radiates heat evenly. A ceramic plate is preferred since it is a poor heat conductor and thus prevents burning of the bottom of the food product.
[0011] All of the above features of the present invention, in combination, ensure an even heat distribution to the food product. Also, the ultimate in precision baking is the ability to reciprocally adjust the heat delivery from upper and lower heating elements of each oven. This is accomplished by the present invention by means of, e.g., a slide switch (variable resistor) and an appropriate electrical circuit that increases or decreases the cycle time to the upper and lower heating elements in a reciprocal fashion. For example, adjusting the switch upwardly would concomitantly increase the duty cycle of the upper elements and decrease the duty cycle of the lower elements. Preset temperature would be maintained thereby but the top of the product would be exposed to more heat, much like moving the conventional oven rack up or down. Examples would be cooking a steak with the slide switch in the full up position with the heat being generated exclusively by the upper elements such as to effect broiling. In cooking a pizza for example, the switch would be far down to effectively brown the crust.
[0012] The present ovens can be mounted under shelf or over shelf top with appropriate venting provided. This makes the baking process more convenient in minimizing bending or stooping and allows the user to more easily produce the exact “brownness” of the cooked products especially breads, particularly where the provision of a large glass door enhances visualization.
BRIEF DESCRIPTION OF DRAWINGS
[0013] The present invention will be understood further from the following description and drawings wherein certain structures are shown in exaggerated dimensions for purposes of clarity, wherein the figures are not in structural proportion to each other, wherein their structural appearance in the drawings does not, in any way, restrict their methods of manufacture, and wherein:
[0014] FIG. 1 is a frontal isometric view of the present oven with the oven divider or partition and front access door removed for clarity;
[0015] FIG. 2 is a cross-sectional view of the oven in FIG. 1 taken along line 2 - 2 therein;
[0016] FIG. 3 is a cross-sectional view taken alone line 3 - 3 in FIG. 2 ;
[0017] FIG. 3A is an enlarged cross-sectional view of the dotted area in FIG. 3 ;
[0018] FIG. 4 is an isometric cross-sectional view taken along line of FIG. 1 ;
[0019] FIG. 4A is a longitudinal cross-sectional view of a typical tangential fan;
[0020] FIG. 5 is a cross-sectional taken along line 5 - 5 in FIG. 3 depicting circulating air flow paths and a non-blocking position of a portion of the occluder slide plate;
[0021] FIG. 6 is a cross-sectional view taken along line 6 - 6 in FIG. 3 ;
[0022] FIG. 7 is an isometric plan view of the heat radiation shielding or blocking occluder slide plate of FIGS. 5 and 6 ;
[0023] FIG. 8 is a cross-sectional view taken along the axis of a portion of the upper heating cavity and the axis of the two circulating fans showing a coaxial drive mechanism for selectively operating the separate fans;
[0024] FIG. 9 is a cross-sectional view as in FIG. 8 showing a clutch type of driving means for the separate fans;
[0025] FIG. 10 is a variation of the clutch engaging faces of FIG. 9 ; and
[0026] FIG. 11 is a schematic electrical circuit for operating the present oven structure by reciprocating balance of the heat output of the upper and lower heating elements.
DETAILED DESCRIPTION
[0027] Referring to the drawings the present cooking oven structure comprises a single or side by side multiple ovens, wherein each oven comprises spaced inner 10 and outer 12 metal housings formed respectively by first wall means 11 and second wall means 13 . First wall means 11 provides the structural elements of a ceiling 14 , a floor 18 , opposing side walls 22 , 24 , a back wall 30 , and front wall portions 34 provided with a hinged access door 38 . An upper heating cavity 45 and a circulating air feed channel 47 combination generally designated 39 is formed by third wall means 41 having a generally horizontal upper section 43 spaced inwardly from ceiling 14 and by a general vertical side section 49 spaced inwardly from the back wall 30 of the inner housing.
[0028] A heat sink ceramic or steel plate means 44 is adapted to provide a predeterminable heat supply and is spaced upwardly from floor 18 and forms with wall means 11 a lower heating cavity 16 . Section 49 is spaced upwardly from plate means 44 , e.g., 0.5-2.0 in. to provide a circulating air inlet 19 to channel 47 . These structural elements of the inner housing, third wall means and ceramic plate define a cooking chamber 40 .
[0029] The outer housing 12 and second wall means 13 comprises a top or ceiling 91 , end (side) walls 92 , 93 , floor 94 back wall 95 , and front wall portions 34 which interconnect the front perimeter portions of the inner and outer housings. A typical set of dimensions for the present oven structure for dual ovens are as follows:
(a) oven structure outside width 36.0″ (b) oven structure outside depth 17.2″ (c) oven structure outside height 12.0″ (d) oven structure interior width 30.0″ (e) oven structure interior depth 14.0″ (f) oven structure interior height 9.0″
[0030] The center partition means 79 hinges back against the back wall to create an enlaged cooking chamber approximately 30 in. wide, 14 in. deep and 9 in. high. Heat insulation material 42 such as glass wool is positioned between said housings in conventional manner.
[0031] A first electrical resistance heating means 46 for plate means 44 is positioned under the plate within lower heating cavity 16 . A second electrical resistance heating means 48 is positioned under ceiling 14 within upper heating cavity 45 . Heat radiation shielding means generally designated 50 is positioned between heating means 48 and upper section 43 of said third wall means. This shielding means 50 comprises base ledges 51 formed from grooves 52 in the side walls 22 , 24 , and a slide plate 53 formed with air flow slots 54 providing shielding lands 55 . Plate 53 is slidably supported on the base ledges 51 and is operator slidable with respect to heating coils or the like 48 between a heat radiation blocking position 56 ( FIG. 3 ) and a heat radiation non-blocking position 58 ( FIG. 3 ) with respect to said cooking chamber.
[0032] An air flow circulating fan 60 communicating with the cooking chamber 40 and the upper heating cavity 45 is adapted to cycle (circulate) air from the cooking chamber into the air feed channel 47 thru inlet 19 , into upper heating cavity 45 , over the heating elements 48 , down into the cooking chamber thru slots 54 , and across plate means 44 and into inlet 19 .
[0033] The housings 10 and 12 are of conventional construction such as, e.g., 14-26 gauge sheet steel which can be ceramic glazed or otherwise coated with high temperature resistant paint or the like material. In the drawings the structures appear as thick monolithic castings for purposes of clarity, however the sheet metal joints can be made by conventional techniques of welding, brazing, metal interlocking crimping, rivets, sheet metal screws or the like.
[0034] A steam injection system such as shown and described in U.S. Pat. No. ______ is preferably used with the present invention and is show in FIG. 6 as a water inlet tube 91 extending between walls 11 and 13 and connected to a tube 92 containing stainless steel balls 93 . A conventional oven light 94 is set into the oven side wall.
[0035] As shown in FIG. 2 , metal spacers 15 or an equivalent structure can be placed and fixed strategically to the inner and outer housings to maintain a rigid spacing and connection between the two and for providing a dimensioned space for containing the insulation material 42 . Side walls 22 and 24 are shown as grooved as at 52 and 25 for supporting slide plate 53 and heat sink plate means 44 respectively, however other structures such as elongated metal or ceramic angle members 26 welded or riveted to first wall means 11 as shown in FIG. 2A may be employed.
[0036] Referring to FIG. 4 , the ceramic plate rear support 20 comprises a lateral ledge such as 27 at the back of the cooking chamber and 28 at the front thereof It is noted that the shallow ledge 28 allows the plate to be slid into grooves 25 if there is sufficient looseness in the fit of the plate therein such as to accommodate the small drop down 29 . This structure locks the plate horizontally in place. The ceramic plate preferably consists of and has a thickness of from about to about in.
[0037] Each heating means 46 and 48 and thermocouple sensors therefor can be selected from any commercially available types including the finned or tubular heaters and thermocouples as described in the 1999-2005 Watlow Electric Manufacturing Company brochures from WATLOW, 5710 Kenoshat Street, Richmond, Ill. 10071. The doors and handles can be selected, for example, from those shown in the Jun. 23, 2005 brochures of Mills Products, Incorporated, 219 Ward Circle, Suite 2, Brentwood, Tenn. 37027.
[0038] The air circulating fan 60 most preferably is a cross flow or tangential blower type as described in the Jun. 23, 2005 brochure of EUCANIA International, Inc. Such fans give an even laminar air flow from back to front substantially completely across (side to side) of the present oven which greatly facilitates temperature control by the present invention throughout the oven cooking chamber.
[0039] An example of these fans for use in the present invention, referring to FIGS. 3, 4 , 4 A and 5 , comprises a plurality, e.g., 10-30 elongated blades 21 of about 18 in. length and about ⅜-¼ in. width as shown in FIG. 5 and having a radiual curvature and fixed in a circle of about 1.6 in. OD at one end into a disc 31 having a shaft 32 which is rotatably mounted in a bearing housing 33 . The other end of the blades are fixed into a disc 35 having a shaft 36 which is rotatably mounted in a bearing housing 37 . Shaft 36 comprises, e.g., the output shaft of an electrical motor 57 . Bearing housing 33 and 37 are attached to and fixed in position relative to each other by wall means 11 such as portions 59 thereof into which shafts 32 and 36 are respectively mounted. It is noted that where the oven dimensions require long, e.g., 18 in. tangential fans, supporting discs preferably are used to support the blades and fix them in position relative to each other in the middle or other intermediate positions of their length. In order for the fan to have its maximum efficiency, the most preferred configuration for upper wall section 43 is shown in FIG. 5 wherein the fan outlet side is adjacent a vortex tongue portion of 43 delineated “VTP”.
[0040] Referring to FIG. 8 which is an exploded view for clarity, two tangential fans 62 , 64 are used for the two oven chambers 66 and 68 respectively. The drive motor 70 for fan 64 has a tubular drive shaft 72 fixed to the fan disc ends and rotatably mounted in bearings 74 fixed in first wall means 11 . The drive motor 76 for fan 62 has drive shaft 78 fixed to the fan disc ends and rotatably mounted thru the bore 80 of shaft 72 .
[0041] Referring to FIGS. 9 and 10 the separate fans of separate ovens are clutch driven by clutches of FIG. 9 or FIG. 10 or any other conventional clutch faces. In this embodiment equivalent structures to those of FIGS. 3, 4 , 4 A and 5 are numbered the same.
[0042] In FIG. 9 , the adjacent ends of the drive shafts are provided one with a friction clutch disc 82 and the other with, e.g., a smooth steel faced disc 84 . In this fan drive version, a thrust bearing 86 is provided to reduce endwise friction when the clutch is engaged. A comparison spring 61 and thrust bearing 63 are provided to ensure release of the clutch when only on fan is to be operated. The clutch is actuated to drive both fans by means of a lever 69 pivotally mounted at 71 to a stationary portion of the oven and at 73 to thrust bearing 63 . Lever 69 may be connected to the armature 75 of a solenoid 77 incorporated, e.g., into the electronic control system for the oven. Alternatively, the lever may extend outwardly thru the oven front for manual operation.
[0043] Referring to FIGS. 2 and 3 , a partition means generally designated 79 providing aforesaid side walls 24 is mounted on back wall 30 by hinges 81 of any convenient type such that it can be swung back against wall 30 by a user when it is desired to use a single larger cooking chamber. This partition means preferably is hollow core as shown containing heat insulation material 42 . Strips 83 of firm heat insulation adhesive material can be used along the top, bottom, front and rear of the partition to assist in isolation of the two chambers as desired. The strips can be held in place by conventional mechanical means.
[0044] Referring to FIG. 3A the oven doors 38 most preferred comprise a frame 85 surrounding and fixed to an outer glass panel 87 , a middle glass panel 88 , and an inner glass panel 89 . The cavity 90 is vented to protect against excessive heat generated air pressure. A strip such as 83 can be affixed to one or both doors. Conventional hinge means and latching means for the door are employed.
[0045] The invention has been described in detail with particular reference to preferred embodiments thereof, but it will be understood that variations and modifications will be effected with the spirit and scope of the invention.
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A cooking structure which provide for two or more side-by-side ovens separated by vertical, movable, hinged partition(s) whereby the oven structure may function as one large oven or as two or more smaller independent ovens, wherein for each oven a tangential fan blows air substantially evenly over upper electrical heating elements strung generally from side-to-side of the oven, wherein a flow director functions as a radiant heat shield which is operator movable to either expose to or occlude from the oven cooking chamber to direct radiation from its heating elements depending on the need to roast, bake, or broil the food product. Also provided are lower electrical heating elements positioned below a ceramic cooking surface for ensuring evenness of radiant heat transfer therefrom. Also provided for is operator controlled top vs. bottom heating using a slide control that reciprocally affects the duty cycle of the top and bottom electrical heating elements, further allowing precision baking control.
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CROSS REFERENCE TO PRIOR APPLICATIONS
[0001] This is a continuation of International Patent Application No. PCT/EP2010/055111, filed on Apr. 19, 2010, which claims priority to German Application Nos. DE 10 2009 018 552.6, filed on Apr. 24, 2009, and DE 10 2009 037 989.4, filed on Aug. 20, 2009. The entire disclosure of each of the applications is hereby incorporated by reference herein.
FIELD
[0002] The present invention relates to the field of electrical machines.
BACKGROUND
[0003] Double-fed asynchronous machines in the power range from 20 MVA to 500 MVA can be used for variable-speed energy production. These machines are distinguished by a distributed three-phase winding on the rotor. The rotor winding consists of individual bars which are embedded in slots in the rotor laminations. The individual bars are connected in the winding head to form a winding. The arrangement of the bar connections is uniformly distributed around the circumference. As a result of the rotation of the rotor, the winding heads are subjected to centrifugal forces, against which they have to be mechanically secured by means of winding head retention systems. In principle, there are three types of winding head retention systems:
[0004] 1. Fixing by means of a steel cap, as is the case with turbogenerators.
[0005] 2. Fixing wherein a steel cable, wire or plastic film is wrapped around the whole winding head.
[0006] 3. Fixing by means of bolts, screws or U-shaped brackets.
[0007] Such an asynchronous machine 10 is reproduced in section in highly simplified form in FIG. 1 . It comprises a rotor 19 which can be rotated about an axis 18 and is encompassed concentrically by a stator lamination stack 14 with corresponding stator winding and a stator winding head 17 . The rotor 19 comprises a central body 11 which merges with a shaft 11 ′ at each end. The central body 11 is surrounded by a rotor lamination stack 12 in which the rotor winding 13 runs. Slip rings 15 , which are used to supply the rotor winding 13 with current, are arranged on one of the shafts 11 ′. The rotor winding head 16 , which is shown once more enlarged in vertical orientation in FIG. 2( a ), is equipped with a winding head retention system 29 which, according to FIG. 2( a ), is fitted with retention elements which run radially through the rotor winding head 16 in the form of threaded rods 20 or threaded bolts or similar, and which are fitted with nuts 21 .
[0008] The retention elements 20 , 21 absorb the centrifugal forces acting on the rotor winding head 16 during the operation of the machine and pass them into the solid part of the rotor arranged below the winding head. It can now come about that the heavily mechanically loaded retention elements 20 , 21 break or lose their mechanical integrity in some other manner during operation over a longer period. However, it may also be that the nuts 21 or screw fittings come loose and in this way the function of the retention elements 20 , 21 is lost. If, as part of this failure, some of the retention elements 20 , 21 come loose and are flung outwards, the machine can incur consequential damage which leads to extended downtime of the machine and therefore to high consequential costs.
[0009] It is desirable to either prevent such a failure of the retention elements 20 , 21 altogether or at least keep the consequential damage within limits. Furthermore, it would be of advantage if abnormal changes in the winding head could be detected in good time and the machine could be switched off at an early stage in order to limit damage or to prevent it occurring in the first place.
SUMMARY OF THE INVENTION
[0010] In an embodiment, the present invention provides an electrical machine configured to operate in a power range of several MVA including a rotor configured to rotate about an axis. The rotor includes a rotor winding disposed in a rotor lamination stack and having an exposed winding head outside of the rotor lamination stack. The winding head includes a winding head retention system having a plurality of radially oriented retention elements each including a locking device configured to secure a respective one of the retention elements against at least one of an unintentional loosening and a flying away in an event of a breakage.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The present invention will be described in even greater detail below based on the exemplary figures. The invention is not limited to the exemplary embodiments. Other features and advantages of various embodiments of the present invention will become apparent by reading the following detailed description with reference to the attached drawings which illustrate the following:
[0012] FIG. 1 shows in a simplified representation a section of an asynchronous machine with stator and rotor winding and a winding head retention system for the rotor winding head according to the prior art;
[0013] FIG. 2 shows in two part figures the enlarged section of the rotor winding head from FIG. 1 in vertical orientation ( FIG. 2 a ) and two types of safety devices for the retention elements according to exemplary embodiments of the invention ( FIG. 2 b );
[0014] FIG. 3 shows in two part figures the section through ( FIG. 3 a ) and the plan view on ( FIG. 3 b ) a wire locking device of retention elements comprising threaded rods and nuts according to another exemplary embodiment of the invention;
[0015] FIG. 4 shows by way of example the incorporation of monitoring means into the retention system according to another exemplary embodiment of the invention; and
[0016] FIG. 5 shows the schematic diagram of a monitoring device which works with the monitoring means of FIG. 4 .
DETAILED DESCRIPTION
[0017] In an embodiment, the present invention provides an electrical machine of the kind mentioned in the introduction so that damage to the rotor winding head due to the centrifugal forces acting can be prevented or at least limited.
[0018] An embodiment of the invention includes retention elements provided with locking means which secure the retention elements against unintentional loosening and/or flying away in the event of a breakage.
[0019] An embodiment of the invention provides retention elements designed as threaded rods or threaded bolts which extend through the winding head in a radial direction and the outer end of which is provided with a nut or a screw head for supporting the winding head.
[0020] In an embodiment, the locking means can comprise a textile locking device which is stretched, particularly in the form of a textile tape, over the outsides of the nuts or screw heads, preferably in close contact therewith and in a circumferential direction.
[0021] In an embodiment, the locking means can also comprise a wire locking device which is stretched in the form of a wire over the outsides of the nuts and/or threaded rods or screw heads, preferably in close contact therewith and in a circumferential direction.
[0022] In an embodiment, slots, in which the wire locking device, which simultaneously safeguards the retention elements against twisting, is inserted, are preferably provided on the retention elements.
[0023] Another embodiment of the invention is distinguished in that the winding head retention system is equipped with monitoring means, with which the proper functioning of the winding head can be monitored.
[0024] In an embodiment, the monitoring means preferably comprise strain measuring devices, which measure the mechanical strain of the locking means in the winding head retention system and transmit it to a processing unit for evaluation.
[0025] According to an embodiment of the invention, the bolts or screws of the winding head retention system 29 must be secured in the rotor winding head 16 . If the retention elements according to FIG. 2 a and FIG. 3 are threaded rods 20 with nuts 21 , the nuts 21 must be secured against unintended loosening. However, if a screw or bolt should accidentally break, the parts which come free must be retained in order to prevent damage to the machine.
[0026] According to an embodiment of the invention, safeguarding against flying away can be achieved by a wire (wire locking device 23 in FIG. 2 b ) or a textile (textile locking device 22 in FIG. 2 b ) which is stretched over the screw heads or nuts 21 in a circumferential direction. In normal operation, the screws (or threaded rods 20 ) cannot move in the radial direction. The forces, which are absorbed by the screws (or threaded rods 20 ), are large, as these must be able to carry the centrifugal forces which result from the weight of the winding head 16 . If a screw (or threaded rod 20 ) should break, only the centrifugal force of the mass of the piece of the screw which comes free acts on the safety device. This force is relatively small. For this reason, it is possible to retain a broken screw or threaded rod 20 by means of a wire or textile. A highly tear-resistant textile which is stable even at higher temperatures can be used as a suitable material for the textile or textile tape.
[0027] While the textile tape of the textile locking device 22 according to FIG. 2 b can be fed over the width of the nuts 21 or screw heads, when using the wire locking device 23 , it can be of advantage to provide slots 24 in which the wire locking device 23 is laid and which run in a circumferential direction in the nuts 21 or threaded rods 20 or in the screw heads according to FIG. 3 . As a result of the wire running in the slots 24 , the nuts 21 or threaded bolts are unable to turn. At the same time, the wire itself is safeguarded against slipping.
[0028] Advantageously, monitoring can simultaneously be combined with the safeguarding of the retention system. The monitoring is used to protect the machine. It is there to detect and signal accidental breakage of the screw or bolt or an inadmissible expansion of the rotor winding head 16 so that the machine can be stopped in good time and repairs initiated. For this purpose, according to FIGS. 4 and 5 , the strain (tension) in the wire or textile tape is monitored by means of a suitable electronic sensor (strain measuring device 25 ) (for example, by means of a load cell). If part of the screw comes loose due to a breakage, the mechanical strain in the wire (wire locking device 23 ) increases and can be detected. At the same time, the sensor or strain measuring device 25 can be integrated running around the circumference directly in the wire (top part in FIG. 4 ), or can measure the strain of two safety wires in that the sensor is arranged perpendicular to the wires (bottom part of FIG. 4 ). Furthermore, the wires can be fed with appropriate deflections through the crossing points of the winding bars so that the strain can be measured inside the rotor body.
[0029] The signals measured by the different sensors or strain measuring devices 25 in the rotor winding head 16 are fed to an appropriate monitoring device ( 28 in FIG. 5 ) of a central processing unit 26 where they are evaluated. If abnormal changes in the strain pattern of the safety devices of the winding head retention system 29 are detected during operation, a signal is output to and displayed on a downstream display unit 27 . The signal can simultaneously be fed to a central controller for the machine where it can initiate an automatic shutdown so that the machine can be inspected in good time.
[0030] While the invention has been described with reference to particular embodiments thereof, it will be understood by those having ordinary skill the art that various changes may be made therein without departing from the scope and spirit of the invention. Further, the present invention is not limited to the embodiments described herein; reference should be had to the appended claims.
LIST OF REFERENCE NUMERALS
[0000]
10 electrical machine (asynchronous machine)
11 central body
11 ′ shaft
12 rotor lamination stack
13 rotor winding
14 stator lamination stack
15 slip ring
16 rotor winding head
17 stator winding head
18 axis
19 rotor
20 threaded bolt
21 nut
22 textile locking device
23 wire locking device
24 slot
25 strain measuring device
26 processing unit
27 display unit
28 monitoring device
29 winding head retention system
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An electrical machine configured to operate in a power range of several MVA includes a rotor configured to rotate about an axis. The rotor includes a rotor winding disposed in a rotor lamination stack and having an exposed winding head outside of the rotor lamination stack. The winding head includes a winding head retention system having a plurality of radially oriented retention elements each including a locking device configured to secure a respective one of the retention elements against at least one of an unintentional loosening and a flying away in an event of a breakage.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] The present U.S. patent application claims a priority under the Paris Convention of Japanese patent application No. 2011-143659 filed on Jun. 29, 2011, which shall be a basis of correction of an incorrect translation, and is incorporated by reference herein.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a DC power supply and further relates to a voltage regulator which converts DC voltage, and more specifically to a technique effectively applicable to a semiconductor integrated circuit (regulator IC) which configures a series regulator (including low-dropout regulator (LDO)) having an output voltage switching function.
[0004] 2. Description of Related Art
[0005] In DC power supply, there is a demand of switching of output voltage level, for the purpose of suppressing degradation in characteristics of a device which serves as a load to be supplied with electric power. One known control semiconductor integrated circuit composing a conventional series regulator has, as illustrated in FIG. 4 , a control terminal through which an output voltage switching control signal CV is received, and is configured to switch the output voltage level depending on a state (high or low) of the input signal CV at the control terminal.
[0006] The series regulator given the switching function illustrated in FIG. 4 has bleeder resistors R 1 , R 2 , a resistor R 3 and a transistor M 2 . The bleeder resistors R 1 , R 2 divide output voltage V out and supply a feedback voltage V FB to an error amplifier AMP. The resistor R 3 and the transistor M 2 are connected in series, and in parallel with the resistor R 2 , out of the bleeder resistors R 1 , R 2 . By turning the transistor M 2 on or off using the output voltage switching control signal CV, the voltage division ratio by the bleeder resistors may be varied, and thereby the output voltage level may be switched.
[0007] The regulator given the switching function illustrated in FIG. 4 , however, allows discharge of an output capacitor Co only through the load, so that it takes a long time to bring the output voltage V out from a high level down to a low level, proving poor switching response characteristics. One possible solution therefor is, as illustrated in FIG. 5 , to provide a resistor Ro in parallel with the output capacitor Co, so as to improve the switching response characteristics.
[0008] However, in the regulator illustrated in FIG. 5 , the time necessary for the output voltage V out to reach a switched level varies depending on the value of the resistor Ro or state of a device which serves as the load, as illustrated in FIG. 2C . In addition, since current constantly flows through the resistor Ro in the general operation, so that wasteful current will increase.
[0009] Japanese Laid-Open Patent Publication No. 2010-191885 discloses a series regulator aimed at improving the transient response characteristics, which has a switching transistor for bypassing current, provided in parallel with the bleeder resistors. In the series regulator disclosed in Japanese Laid-Open Patent Publication No. 2010-191885, the switching transistor is provided in parallel with the entire bleeder resistors, rather than in parallel with either one of the bleeder resistors. In addition, the invention disclosed in Japanese Laid-Open Patent Publication No. 2010-191885 is aimed at improving the transient response characteristics in case of abrupt changes in the output voltage, rather than improving the transient response characteristics when the output voltage is switched.
SUMMARY OF THE INVENTION
[0010] The present invention was conceived in consideration of the situation described in the above, and an object of which is to provide a semiconductor integrated circuit used for regulators, capable of improving the transient response characteristics when the output voltage is switched, without increasing a wasteful current.
[0011] For the purpose of attaining the above-described objects, according to the present invention, there is provided a semiconductor integrated circuit for regulator including: a control transistor connected between an input terminal and an output terminal; a voltage divider circuit which generates a feedback voltage proportional to an output voltage; a control circuit which controls the control transistor based on difference between the feedback voltage and a predetermined reference voltage; and a terminal through which an output voltage switching control signal is received from the external, and being configured to switch the output voltage into a first voltage or into a second voltage lower than the first voltage, by varying division ratio in the voltage divider circuit in response to an output voltage switching control signal. The semiconductor integrated circuit further comprising: a discharging transistor which is connected between the output terminal and the ground; and a circuit for controlling output fall during switching, which outputs a signal for keeping the discharging transistor turned on over a period from change of the control signal to fall of the output voltage from the first voltage down to the second voltage, based on difference between the feedback voltage and the reference voltage.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The above and other objects, advantages and features of the present invention will become more fully understood from the detailed description given hereinbelow and the appended drawings which are given by way of illustration only, and thus are not intended as a definition of the limits of the present invention, and wherein:
[0013] FIG. 1 is a circuit diagram illustrating a control IC used in a series regulator of this embodiment;
[0014] FIG. 2A is a characteristic diagram illustrating gate control signal (1/CV) of the MOS transistor M 2 of this embodiment;
[0015] FIG. 2B is a characteristic diagram illustrating output voltage of the series regulator of this embodiment;
[0016] FIG. 2C is a characteristic diagram illustrating output voltage of a conventional series regulator;
[0017] FIG. 3 is a circuit diagram illustrating a modified example of the control IC used in the series regulator illustrated in FIG. 1 ;
[0018] FIG. 4 is a circuit diagram illustrating a control IC used in a conventional series regulator having an output voltage switching function; and
[0019] FIG. 5 is a circuit diagram illustrating a series regulator control IC improved in the output voltage response characteristics during switching of output voltage.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0020] Preferred embodiments of the present invention will be explained below, referring to the attached drawings.
[0021] FIG. 1 illustrates one embodiment of a series regulator (including LDO) applied by the present invention. Although not specifically limited, elements composing a circuit surrounded by a one-dot chain line in FIG. 1 are formed on a single semiconductor chip, so as to configure a semiconductor integrated circuit 10 for controlling the regulator (referred to as regulator IC, hereinafter).
[0022] The regulator IC 10 of this embodiment has a voltage input terminal IN, an output terminal OUT, a voltage control transistor M 1 , bleeder resistors R 1 , R 2 , a resistor R 3 , a MOS transistor M 2 , an error amplifier 11 , a reference voltage circuit 12 , a bias circuit 13 , a starting control circuit 14 , and a logic circuit 15 .
[0023] The voltage input terminal IN is applied with DC voltage VDD from an unillustrated DC voltage source. The voltage control transistor M 1 is connected between the voltage input terminal IN and the output terminal OUT. The voltage control transistor M 1 is composed of a P-channel MOSFET (metal oxide semiconductor field effect transistor, referred to as MOS transistor, hereinafter).
[0024] The bleeder resistors R 1 , R 2 are connected between the output terminal OUT and a ground terminal GND. The bleeder resistors R 1 , R 2 divide the output voltage V out . Voltage V FB produced by voltage division by the bleeder resistors R 1 , R 2 is fed back to a non-inverting input terminal of the error amplifier 11 . Output of the error amplifier 11 is fed to the gate terminal of the voltage control transistor M 1 .
[0025] The error amplifier 11 controls the voltage control transistor M 1 , corresponding to potential difference between the feedback voltage V FB and a reference voltage V ref . Resistance ratio of the bleeder resistors R 1 , R 2 is set so as to adjust the output voltage V out to a desired value. The series regulator of this embodiment acts so as to keep the output voltage V out constant, by the feedback control described in the above. The output terminal OUT is externally attached with an output capacitor Co which stabilizes the output voltage V out .
[0026] The reference voltage circuit 12 generates the reference voltage V ref . The reference voltage circuit 12 may be configured by using a constant voltage circuit composed of a Zener diode. Alternatively, the reference voltage circuit 12 may be configured typically by using a reference voltage generation circuit which contains a depletion-mode MOS transistor as a constant current source, and an enhancement-mode MOS transistor connected thereto in series.
[0027] The bias circuit 13 feeds bias current to the reference voltage circuit 12 and the error amplifier 11 .
[0028] The starting control circuit 14 is configured typically by an inverter. The starting control circuit 14 brings the bias circuit 13 into an active state, in response to a chip enable signal CE. The chip enable signal CE is an externally-fed signal for turning the chip on or off.
[0029] The regulator IC 10 of this embodiment has a terminal through which the chip enable signal CE is received from the external, and a terminal through which the output voltage switching control signal CV is received from the external.
[0030] The resistor R 3 and the MOS transistor M 2 are connected in series, and is connected in parallel with the resistor R 2 , out of the bleeder resistors R 1 , R 2 . By turning the MOS transistor M 2 on or off, the voltage division ratio by the bleeder resistors may be varied, and thereby the level of output voltage V out may be switched.
[0031] The logic circuit 15 is configured by an inverter and so forth. The logic circuit 15 generates an internal signal of the chip, in response to the output voltage switching control signal CV. The control signal output from the logic circuit 15 is fed to the gate terminal of the MOS transistor M 2 . When the output voltage switching signal CV is at a high level, the MOS transistor M 2 turns off, the voltage division ratio of the output voltage is determined by the bleeder resistors R 1 , R 2 , and thereby the output voltage V out is kept at the low level. On the other hand, when the output voltage switching control signal CV is at a low level, the MOS transistor M 2 turns on, the voltage division ratio of the output voltage is determined by the resistance of the resistor R 1 and a combined resistance of the resistors R 2 and R 3 , and thereby the output voltage V out shifts from the low level to the high level.
[0032] The regulator IC 10 of this embodiment is further provided with N-channel MOS transistors M 3 and M 4 , and a voltage comparator circuit 16 .
[0033] The N-channel MOS transistors M 3 and M 4 are connected in parallel, between the output terminal OUT and the ground point GND.
[0034] The gate terminal of the MOS transistor M 3 is fed with a control signal from the starting control circuit 14 . When the chip enable signal CE changes from the high level to the low level so as to turn the chip off, the MOS transistor M 3 turns on to discharge the output capacitor Co, and swiftly brings the output voltage V out down to the ground potential (0 V).
[0035] The gate terminal of the MOS transistor M 4 is fed with an output signal of the voltage comparator circuit 16 .
[0036] The voltage comparator circuit 16 compares the feedback voltage V FB and the reference voltage V ref . A differential amplifier circuit intentionally added with offset is used as the voltage comparator circuit 16 of this embodiment. Note that the word “intentionally” herein is used to exclude any offset which naturally occurs due to process variation.
[0037] Methods of adding offset to the differential amplifier circuit typically includes a method of making difference in the ratio of gate width W and gate length L of the differential transistors; a method of making difference in the resistance value of the elements which serve as loads of the differential transistors; and a method of connecting a resistor to an input of only one of the differential transistors.
[0038] When the output voltage switching signal CV changes from the low level to the high level, the MOS transistor M 2 turns off. The feedback voltage V FB then becomes higher than the reference voltage V ref , the output signal of the voltage comparator circuit 16 changes to the high level, the MOS transistor M 4 turns on, and the output capacitor Co starts to discharge.
[0039] On the other hand, when the MOS transistor M 2 turns off, the output voltage V out falls from the high level V 1 down to the low level V 2 . When the output voltage V out falls down to the low level V 2 , the feedback voltage V FB falls down to the reference voltage V ref , the output signal of the voltage comparator circuit 16 falls down to the low level, and thereby the MOS transistor M 4 turns off.
[0040] FIG. 2A is a characteristic diagram illustrating gate control signal (1/CV) of the MOS transistor M 2 of this embodiment, and FIG. 2B is a characteristic diagram illustrating the output voltage of the series regulator of this embodiment.
[0041] When the output voltage switching control signal CV changes from the low level to the high level, and thereby when the gate control voltage for the MOS transistor M 2 output from the logic circuit 15 shifts from the high level down to the low level as illustrated in FIG. 2A , the output voltage V out may be brought down swiftly to the target low level V 2 within a predetermined short time, irrespective of the state of load, as illustrated in FIG. 2B .
[0042] On the other hand, when the output voltage switching control signal CV changes from the high level down to the low level, the feedback voltage V FB temporarily shifts to the low level, whereas the output signal of the voltage comparator circuit 16 remains unchanged, so that the MOS transistor M 4 will not turn on. Since the voltage comparator circuit 16 is configured by using the differential amplifier circuit intentionally added with offset, so that the MOS transistor M 4 will not turn on even if the feedback voltage V FB varies depending on changes in load in the steady state.
[0043] While the regulator IC 10 of this embodiment additionally has a thermal shut-down circuit 17 and a current limit circuit 18 , the present invention is not limited to those having these additional components.
[0044] The thermal shut-down circuit 17 has a temperature detection circuit which terminates operation of the circuit when the chip temperature was detected to exceed a predetermined temperature. The thermal shut-down circuit 17 is disclosed typically in Japanese Laid-Open Patent Publication No. 2007-318028.
[0045] The current limit circuit 18 protects the element from over-current, by reducing the output current while lowering the output voltage V out , when the output current increased and reached a predetermined value due to short-circuiting of the load or the like. The current limit circuit 18 is disclosed, for example, in Japanese Laid-Open Patent Publication No. 2008-052516. The thermal shut-down circuit 17 and the current limit circuit 18 will not be detailed herein, since the both are publicly known.
[0046] As described in the above, the discharging transistors M 3 , M 4 do not conduct electric current in the normal operation, but temporality turn on to swiftly bring down the output voltage V out , when the output voltage switching control signal CV varies and the output voltage V out changes from the high level V 1 down to the low level V 2 , so that the transient response characteristics during switching of the output voltage may be improved without increasing wasteful current in the steady state.
[0047] In addition, by intentionally adding offset to the voltage comparator circuit 16 , a signal which temporarily turns the discharging transistor M 4 during switching of the output voltage may be generated by a relatively simple circuit, so that the transient response characteristics during switching of the output voltage may be improved without increasing so much the circuit scale.
[0048] FIG. 3 illustrates a modified example of the series regulator IC of the embodiment illustrated in FIG. 1 .
[0049] In this modified example, a P-channel MOS transistor M 5 , and a pulse generator circuit 19 are additionally provided. The P-channel MOS transistor M 5 is provided between the source voltage terminal of the voltage comparator circuit 16 and the bias circuit 13 , and functions as a power switch of the voltage comparator circuit 16 . The pulse generator circuit 19 detects change of the output voltage switching control signal CV from the low level up to the high level, and generates an one-shot pulse having a predetermined width. When the P-channel MOS transistor M 5 is turned on by the one-shot pulse generated by the pulse generator circuit 19 , operating current temporarily flows through the voltage comparator circuit 16 , and the voltage comparator circuit 16 starts to operate.
[0050] By temporarily operating the voltage comparator circuit 16 , the modified example may reduce the current consumption as compared with the regulator IC illustrated in FIG. 1 . Another possible configuration may be such as implementing on/off control of a power source of the voltage comparator circuit 16 , making use of the one-shot pulse generated by the pulse generator circuit 19 , rather than providing the MOS transistor M 5 as the power switch of the voltage comparator circuit 16 .
[0051] It is still also possible to provide a CR time constant circuit for specifying the pulse width of the one-shot pulse, to the pulse generator circuit 19 . Alternatively, an external terminal allowing connection of a capacitor, which composes the CR time constant circuit and assumed as an externally attached element, may be provided to the regulator IC 10 , so as to allow the user to arbitrarily set the pulse width by appropriately selecting the capacitor, or to set the operating time of the voltage comparator circuit 16 .
[0052] In the configuration provided with the pulse-width-adjustable pulse generator circuit, the voltage comparator circuit 16 is omissible, phase of the output of the pulse generator circuit may be inverted, and the MOS transistor M 4 for discharging may directly be turned on or off by the phase-inverted output. In this case, a resistor may be provided in series with the MOS transistor M 4 , so as to adjust the fall rate of the output voltage V out based on a resistance value of the resistor.
[0053] While the invention accomplished by the present inventor has been detailed referring to the embodiments, the present invention is not limited thereto. For example, while the embodiments in the above adopted a separate configuration of the MOS transistor M 3 which is directed to drop the output voltage V out in the off time of the chip, and the MOS transistor M 4 which is directed to drop the output voltage V out in the switching of output voltage, an alternative configuration may be such as providing these transistors as a common transistor, and also providing an OR gate which is designed to implement the OR operation of the output of the logic circuit 15 and the output of the voltage comparator circuit 16 , so as to allow on/off control of the common transistor based on the output of the OR gate.
[0054] Provision of the OR gate may otherwise increase the number of elements which compose the circuit. However, in contrast to that the transistors M 3 , M 4 which are designed to allow discharge through the output terminal need a relatively large size for the configuration, the OR gate needs only small-sized elements since the load of the OR gate is only a gate capacitance of the MOS transistor. Accordingly, in the configuration having the MOS transistors M 3 and M 4 replaced by a single element, the total area occupied by the circuit may be reduced.
[0055] While the embodiments described in the above used a MOS transistors as the control transistor for controlling the output voltage, the present invention is also applicable to a regulator which uses a bipolar transistor as the control transistor.
[0056] While the embodiments described in the above used an offset-added differential amplifier circuit as the voltage comparator circuit 16 for controlling the MOS transistor M 4 for discharge, another possible configuration is such as using a general differential amplifier circuit having no offset, and instead feeding the feedback voltage to the differential amplifier circuit after shifted the feedback voltage by a predetermined potential corresponding to the offset.
[0057] In addition, while the description in the above dealt with the case where the present invention was applied to the series regulator IC, the present invention is not limited thereto, and is also applicable to a charging control IC which configures a charger for secondary batteries.
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Disclosed is a semiconductor integrated circuit for regulator including: a control transistor; a voltage divider circuit generating a feedback voltage proportional to an output voltage; a control circuit controlling the control transistor based on difference between the feedback voltage and a reference voltage; and a terminal through which an output voltage switching control signal is received, and being configured to switch the output voltage into a first voltage or into a second voltage lower than the first voltage, by varying division ratio in the voltage divider circuit in response to the signal. The semiconductor integrated circuit further includes: a discharging transistor between the output terminal and the ground; and a circuit outputting a signal for keeping the discharging transistor turned on over a period from change of the signal to fall of the output voltage from the first voltage down to the second voltage.
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BACKGROUND
Petrolatum and its manufacture were initially patented in 1872 by Robert A. Cheeseborough (U.S. Pat. Ser. No. 127,568). Although Cheeseborough cited treating leather as its primary use, petrolatum was also recommended as a hair pommenade and for treating chapped hands. In 1875, the American Pharmaceutical Association found petrolatum “without a superior” for treating burns and scalds. Since then, petrolatum's beneficial properties for skin care and treatment have been extensively studied and reported.
Petrolatum has been found to be the best material for relieving ordinary xerosis (Morrison et al., Cos & Toil . (1996) 111:59). Petrolatum's moisturizing characteristics have been ascribed to the slowed water loss when petrolatum is applied to the skin. Petrolatum has also been used extensively on wound dressings, both as a treatment and as a pharmaceutically acceptable ointment base to deliver other medicinal compositions.
However, the same hydrophobic properties which make petrolatum an effective moisture barrier, also make it difficult to evenly disperse in fluid aqueous preparations. When mixed with water, petrolatum immediately forms a separate distinct layer. Evenly dispersed fluid preparations are essential for commercial manufacturing techniques, such as spraying. This is true for petrolatum encapsulated in lipid vesicles as well as unencapsulated products.
Accordingly, it is an object of the present invention to provide methods and compositions relating to a sprayable petrolatum product consisting of lipid vesicles encapsulating petrolatum, dispersed in an aqueous phase.
Another object of this invention is to provide a stable dispersion of petrolatum containing lipid vesicles in water.
These and other objects and features of the invention will be apparent from the following descriptions.
SUMMARY OF THE INVENTION
The invention features a sprayable petrolatum product having lipid vesicles encapsulating petrolatum dispersed in an external aqueous phase. The vesicles comprise a primary wall forming material and a weighting agent. The primary wall forming material is selected from the group consisting of nonionic and zwiterionic surfactants and the weighting agent is present in an amount sufficient that the lipid vesicles have a density of about 0.95-1.0 g/ml. Examples of preferred weighting agents include, for example, high molecular weight polyoxyethylene sorbitan esters, ester gum, metal oxides (e.g., iron oxide), and combinations thereof. Advantageously, the primary wall forming material has the property that it will form a lipid vesicle in the absence of said weighting agent. Preferably, petrolatum comprises at least about 20%, and more preferably about 30%, by weight of the lipid vesicles.
The invention also pertains to a method for protecting the skin of a mammal by contacting the skin with a sprayable pharmaceutical petrolatum composition product. The sprayable pharmaceutical petrolatum composition product includes lipid vesicles encapsulating petrolatum dispersed in an external aqueous phase. These lipid vesicles comprise a primary wall forming material and a weighting agent. The primary wall forming material is a nonionic or a zwiterionic surfactant, and the weighting agent is present in an amount sufficient that the lipid vesicles have a density of about 0.95-1.0 g/ml. The preferred primary wall forming materials are polyoxyethylene glyceryl fatty acids, C 12 -C 18 fatty alcohols, C 12 -C 18 glycol monoesters, C 12 -C 18 glyceryl mono- and diesters, polyoxyethylene fatty alcohols, betaines, sarcosinates, propylene glycerol stearate, sucrose distearate, glycerol dilaurate, glucosides, and mixtures thereof.
DETAILED DESCRIPTION OF THE INVENTION
The invention pertains to, at least in part, a sprayable petrolatum product having lipid vesicles encapsulating petrolatum dispersed in an external aqueous phase. The vesicles comprise a primary wall forming material and a weighting agent. The primary wall forming material is selected from the group consisting of nonionic and zwiterionic surfactants and the weighting agent is present in an amount sufficient that the lipid vesicles have a density of about 0.95-1.0 g/ml. Preferably, petrolatum comprises at least about 20%, e.g., more preferably 30%, by weight of the lipid vesicles. In a further embodiment, the lipid vesicles are paucilamellar.
Petrolatum has been commercially available since the mid-1870's. Commonly, it is a semisolid mixture of hydrocarbons and is, essentially, both odorless and tasteless to humans. Petrolatum is often obtained through the dewaxing of heavy mineral oils.
The primary wall forming material, which constitutes the greatest structural material by weight of the bilayers (e.g., 10-20%), can be any suitable non-ionic surfactant known in the art to be useful in forming vesicles. For example, suitable surfactants are disclosed in U.S. Pat. No. 5,260,065, entitled “Blended Lipid Vesicles;” U.S. Pat. No. 5,234,767, entitled “Lipid Hybrid Vesicles;” U.S. Pat. No. 5,439,967 entitled “Propylene Glycol Stearate Vesicles;” U.S. Pat. No. 5,405,615, entitled “Sucrose Distearate Vesicles,” and U.S. Pat. No. 5,160,669, entitled “Method of Making Oil Filled Paucilamellar Lipid Vesicles,” the contents all of which are incorporated by reference herein. Advantageously, the primary wall forming material has the property that it will form a lipid vesicle in the absence of said weighting agent. In another embodiment, the primary wall forming material of the vesicle bilayers is selected from the group consisting of polyoxyethylene glyceryl fatty acid esters (e.g., having 1-10 polyoxyethylene groups), such as polyoxyethylene glyceryl monostearate and polyoxyethylene glyceryl monooleate, C 12 -C 18 fatty alcohols, C 12 -C 18 glycol monoesters, C 12 -C 18 glyceryl mono-and diesters, and mixtures thereof. Preferred primary wall forming material are selected from the group consisting of C 16 and C 18 fatty alcohols, glyceryl mono- and distearate, glyceryl dilaurate, glycol stearate, and mixtures thereof. All of the aforementioned compounds are commercially available. Preferred primary wall forming materials include C 16 -C 18 fatty alcohols, glycol stearate, glyceryl mono- and distearate, glyceryl dilaurate, and combinations thereof.
The term “weighting agent” includes substances which affect the specific gravity of the lipid vesicles. Advantageously, the weighting agents increase the specific gravity of the vesicles to aid dispersion of the vesicles through out an aqueous mixture and to deter separation between the aqueous and lipid components of the mixture. Preferably, the inclusion of the weighting agents increases the specific gravity of the vesicles into the desired stable product range, e.g. greater than 0.95 g/mL to about 0.99 g/mL. In some embodiments of the invention, the weighting agents are incorporated directly into the walls of the vesicles. Preferred weighting agents include compounds with a specific gravity greater than 1.0 g/mL, (e.g., greater than 1.0 g/mL to about 2.0 g/mL). Examples include high molecular weight polyoxyethylene sorbitan esters, ester gums, metal oxides (e.g., iron oxide), and combinations thereof.
The lipid vesicles of the invention may further include one or more charge producing agents which minimize flow of the external aqueous phase into the vesicles. Preferred charge producing agents include negatively charged hydrophilic molecules such as sodium lauryl sulfate, sodium laureth sulfate, sodium lactate, sodium pyrrolidone carboxylate, aloe vera, retinoic acid and urea. Other possible negative charge producing agents include oleic acid, dicetyl phosphate, palmitic acid, cetyl sulphate, retinoic acid, phosphatidic acid, phosphatidyl serine, and mixtures thereof. Alternatively, also contemplated is the incorporation of positively charged molecules in order to provide a net positive charge to the vesicles. Examples of suitable positively charged molecules include, for example, long chain amines, e.g., stearyl amines or oleyl amines, long chain pyridinium compounds, e.g., cetyl pyridinium chloride, quaternary ammonium compounds, or mixtures of these can be used. A preferred positive charge producing material is hexadecyl trimethylammonium bromide, a potent disinfectant. The use of this disinfectant as the positive charge producing material within the vesicles provides a secondary advantage as the vesicles deteriorate; they act as a sustained release germicide carriers.
The vesicles may also include targeting molecules, either hydrophilic or amphiphilic, which can be used to direct the vesicles to a particular target in order to allow release of the material encapsulated in the vesicle at a specified biological location. If hydrophilic targeting molecules are used, they can be coupled directly or via a spacer to an OH residue of the polyoxyethylene portion of the surfactant, or they can be coupled, using state of the art procedures, to molecules such as palmitic acid, long chain amines, or phosphatidyl ethanolamine. If spacers are used, the targeting molecules can be interdigitated into the hydrophilic core of the bilayer membrane via the acyl chains of these compounds. Preferred hydrophilic targeting molecules include monoclonal antibodies, other immunoglobulins, lectins, and peptide hormones.
In addition to hydrophilic targeting molecules, it is also possible to use amphiphilic targeting molecules. Amphiphilic targeting molecules are normally not chemically coupled to the surfactant molecules but rather interact with the lipophilic or hydrophobic portions of the molecules constituting the bilayer lamellae of the lipid vesicles. Preferred amphiphilic targeting molecules are neutral glycolipids, galactocerebrosides (e.g., for hepatic galactosyl receptors), or charged glycolipids such as gangliosides.
The vesicles of the invention may further comprise sterols. Sterols useful in forming the lipid bilayers also include any sterol known in the art to be useful as modulators of lipid membranes. Suitable sterols include but are not limited to cholesterol, cholesterol derivatives, hydrocortisone, phytosterol, or mixtures thereof. In one embodiment, the sterol is phytosterol supplied from avocado oil unsaponifiables. The use of this sterol, in particular, to form lipid vesicles is described in issued U.S. Pat. No. 5,643,600, entitled “Lipid Vesicles Containing Avocado Oil Unsaponifiables”, the contents of which are incorporated by reference herein.
In another embodiment, the invention pertains to a method for protecting the skin of a mammal. The method involves contacting the skin with a sprayable pharmaceutical petrolatum composition product which contains lipid vesicles encapsulating petrolatum dispersed in an external aqueous phase. The lipid vesicles are comprised of a primary wall forming material and a weighting agent. The primary wall forming material is a nonionic or a zwiterionic surfactant. The weighting agent is present in an amount sufficient such that the lipid vesicles have a density of about 0.95-1.0 g/mL.
Petrolatum filled vesicles may be formed using either the “hot loading” technique disclosed in U.S. Pat. No. 4,911,928, entitled “Paucilamellar Lipid Vesicles,” or the “cold loading” technique described in U.S. Pat. No. 5,160,669, entitled, “Method of Making Oil Filled Paucilamellar Lipid Vesicles.” The entire contents of both patents are incorporated herein by reference. In either case, a lipid phase is formed by blending a primary wall forming material and the weighting agent, along with any other materials to be incorporated into the lipid bilayers, to form a homogenous lipid phase. In the “hot loading” technique, the petrolatum is blended in the already formed lipid phase, forming a lipophilic phase.
Once a lipophilic phase is made, it is blended with an aqueous phase (e.g., water, saline, or any other aqueous solution which will be used to hydrate the lipids) under shear mixing conditions to form the vesicles. “Shear mixing conditions”, as used herein, means a shear equivalent to a relative flow of 5-50 m/s through a 1 mm orifice. The paucilamellar lipid vesicles of the disclosure can be made by a variety of devices which provides sufficiently high shear for shear mixing. A device which is particularly useful for making the lipid vesicles of the present invention is described in U.S. Pat. No. 4,895,452, entitled “Method and apparatus for producing lipid vesicles.”
In the “cold loading” technique, the lipid phase and the aqueous phase are blended under shear mixing conditions to form vesicles. Once the substantially aqueous filled lipid vesicles are formed, they are combined with the “cargo” material to be encapsulated, e.g., the petrolatum. Droplets of the water immiscible material enter the vesicles, presumably by a process resembling endocytosis. The vesicles are subsequently blended under low shear conditions, as described in U.S. Pat. No. 5,160,669.
The invention is further illustrated by the following Examples, which should not be construed as further limiting the subject invention. The contents of all references, issued patents, and published patent applications cited throughout this application including the background are hereby incorporated by reference.
EXEMPLIFICATION OF THE INVENTION
Example 1
Petrolatum Filled Vesicles
The following procedure was used to make vesicles of the invention. Tables 1-3 describe three different formulations of vesicles of the invention.
The lipid components of each vesicle preparation were weighed out into a stainless steel kettle and heated to 80° C. The materials were mixed together until a clear solution was obtained. Each clear solution was then cooled to 73-75° C.
The aqueous component of each vesicle preparations were weighed into a separate stainless steel kettle. An additional 2% of water was added to compensate for evaporation. Each solution was heated to 58-60° C.
Using a Novamix™ lipid vesicle machine (described in U.S. Pat. No. 4,895,452), the lipid and aqueous components of each vesicle preparation were separately mixed in a 1:1.70 ratio. Each sample was then stirred continuously and allowed to cool to room temperature before being stored. Microscopic analysis revealed small, regular, spherical vesicles for each of the sample formulations.
The vesicles of each sample were transferred directly from storage to a spraying apparatus, without being further diluted. Each of the samples was sprayed onto a black and white surface and analyzed. All of the samples were found to be satisfactory and commercially viable.
TABLE 1
Kg (for 100
Ingredients
%
Kg prep.)
LIPID
Glyceryl Distearate (Kessco, Stepan)
3.60
3.60
PHASE
Steareth-10 (Brij 76, ICI)
2.00
2.00
Cholesterol USP (Maypro)
1.00
1.00
Polysorbate 80 (Protameen)
0.50
0.50
White Petrolatum USP (Penreco)
30.00
30.00
AQUEOUS
DI Water
60.15
60.15
PHASE
Urea USP
2.00
2.00
Germaben II (ISP Van Dyk)*
0.75
0.75
*propylene glycol, diazolidinyl urea, methyl paraben and propyl paraben.
TABLE 2
Kg (for 100
Ingredients
%
Kg prep.)
LIPID
Glyceryl Distearate (Kessco, Stepan)
3.60
3.60
PHASE
Steareth-10 (Brij 76, ICI)
2.00
2.00
Cholesterol USP (Maypro)
1.00
1.00
Polysorbate 80 (Protameen)
0.50
0.50
White Petrolatum USP (Penreco)
30.00
30.00
AQUEOUS
DI Water
63.95
63.95
PHASE
Urea USP
1.00
1.00
Germaben II-E*
0.75
0.75
*propylene glycol, diazolidinyl urea, methyl paraben and propyl paraben.
TABLE 1
Kg (for 1500
Ingredients
%
Kg prep.)
LIPID
Glyceryl Distearate (Kessco, Stepan)
3.60
54.00
PHASE
Steareth-10 (Brij 76, ICI)
2.00
2.00
Cholesterol USP (Maypro)
1.00
15.00
Polysorbate 80 (Protameen)
0.50
7.50
White Petrolatum USP (Penreco)
30.00
450.00
AQUEOUS
DI Water
60.58
908.70
PHASE
Sipon LSB (30% SLS)
2.00
30.00
Methyl Paraben
0.20
3.00
Propyl Paraben
0.03
0.45
Sodium Chloride
0.09
1.35
EQUIVALENTS
Those skilled in the art will recognize, or be able to ascertain using no more than routine experimentation, many equivalents to the specific embodiments and methods described herein. Such equivalents are intended to be encompassed by the scope of the claims.
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A fluid preparation of petrolatum capable of being sprayed on to a surface. The preparation includes paucilamellar lipid vesicles containing the petrolatum. Preferably, petrolatum comprises about 20-30% or more of the total weight of the vesicles. Methods of protecting the skin of mammals using the fluid preparation of petrolatum are also discussed.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present intention relates to a signal receiving circuit and a method for receiving signals and more particularly to the signal receiving circuit and the method for receiving signals used for a receiving terminal carrying out communications with a transmitting terminal in an asynchronous manner.
[0003] The present application claims priority of Japanese Patent Application No.2000-059265 filed on Mar. 3, 2000, which is hereby incorporated by reference.
[0004] 2. Description of the Related Art
[0005] Digital communications for transmitting and receiving digital signals are widely used. In digital communications, in some cases, communications are carried out between terminals in asynchronous transmission, without using synchronous signals. Even in a case of asynchronous digital communications, it is desired that a receiving terminal receives signals at a same sampling frequency as is used when a transmitting terminal transmits signals. To achieve this, each of the transmitting and receiving terminals has a clock signal generating circuit adapted to generate a clock signal of a same frequency and a sampling is attempted at a same sampling frequency.
[0006] However, it is actually impossible that each of the transmitting and receiving terminals generates the clock signal of completely the same frequency and transmits and receives signal at completely the same sampling frequency. For example, when signals are transmitted and received at a sampling frequency of 16 kHz, a frequency difference of about 4 kHz occurs. This means that the number of pieces of sample data contained in a transmitting signal generated by the transmitting terminal differs, by 4 pieces per one second, from that of sample data that the receiving terminal is to receive.
[0007] When the number of pieces of the sample data contained in the transmitting signal generated by the transmitting terminal is different from the number of pieces of the sample data to be received by the receiving terminal, the receiving terminal uses a signal receiving circuit adapted to solve a problem of the difference in the number of pieces of data.
[0008] Such a signal receiving circuit is disclosed in Japanese Patent Application Laid-open No. Hei 8-32562, as shown in FIG. 7. A conventionally known signal receiving circuit 200 is used to receive a digital voice signal. As shown in FIG. 7, the signal receiving circuit 200 is provided with a digital voice input terminal 101 . The digital voice input terminal 101 is connected to a buffer memory 102 . Moreover, the signal receiving circuit 200 has a writing clock input terminal 103 .
[0009] The writing clock input terminal 103 is connected to a writing address counter 104 . The writing address counter 104 is connected to the buffer memory 102 and to a slip monitoring circuit 105 . The signal receiving circuit 200 has further a reading clock input terminal 106 . The reading clock input terminal 106 is connected to a reading address counter 107 . The reading address counter 107 is connected to the buffer memory 102 and to the slip monitoring circuit 105 . The buffer memory 102 is connected to a sound level calibrating circuit 108 . The slip monitoring circuit 105 is connected to the sound level calibrating circuit 108 . The sound level calibrating circuit 108 is connected to a digital voice output terminal 109 .
[0010] Operations of the conventional signal receiving circuit 200 will be described. A digital voice input signal A input from the digital voice input terminal 101 is written into the buffer memory 102 sequentially, A writing clock signal B is input from the writing clock input terminal 103 . The writing clock signal B is in sync with the digital voice input signal A. A writing address C is output from the writing address counter 104 . Signal of the writing address is in sync with the writing clock signal B. The writing address is fed to the buffer memory 102 . The digital voice input signal A is written in an address designated by the writing address C stored in the buffer memory 102 .
[0011] A reading clock C is fed to the reading address counter 107 from the reading clock input terminal 105 . A reading address E is output from the reading address counter 107 . Signal of the reading address E is in sync with the reading clock D. The reading address E is fed to the buffer memory 102 . The buffer memory 102 outputs a signal stored in an address designated by the reading address E as an output digital voice signal F to the sound level calibrating circuit 108 .
[0012] The writing address C and the reading address E are input to the slip monitoring circuit 105 . The slip monitoring circuit 105 monitors the writing address C and he reading address E at all times. The slip monitoring circuit 105 , when a differential between the writing address C and reading address E comes close to a predetermined value, outputs a sound level control starting signal G to the sound level calibrating circuit 108 . The sound level calibrating circuit 108 outputs the output digital voice signal F. The sound level calibrating circuit 108 , by being triggered by the sound level control starting signal G, causes decay to occur in the amplitude of an output digital voice signal F′. The sound level calibrating circuit 108 minimizes the amplitude of the output digital voice signal F′ ten seconds after the sound level control starting signal G has been input.
[0013] The slip monitoring circuit 105 , “t 1 ” seconds after the amplitude of the output digital voice signal F′ has been minimized, that is, “t 0 +t 1 ” seconds after the sound level control starting signal G has been input to the sound level calibrating circuit 108 , outputs a reading address switching signal H to the reading address counter 107 . The reading address E is switched in response to the reading address switching signal H. The output digital voice signal F 1 , “t 1 ” seconds after the reading address E has been switched, is increased in amplitude gradually and is restored to its original level.
[0014] In the signal receiving circuit 200 , if the writing clock signal B is not in sync with the signal of the reading address E, a dropout and/or overlap of data occurs. When the dropout and/or overlap of data occurs, the reading address E is switched. Before the reading address E is switched, the output digital voice signal F′ is gradually decreased in sound level.
[0015] After the reading address E has been switched, the sound level of the output digital voice signal F′ is gradually restored to its original one. When the reading address E has been switched, voice noise that has occurred due to the dropout and/or overlap of data are removed. In the conventional signal receiving circuit 200 , no discontinuity in a signal waveform of the output digital voice signal F′ occurs.
[0016] In the conventional signal receiving circuit 200 , if the dropout and/or overlap of data occurs, the amplitude of the output digital voice signal F′ is minimized for “t 1 ” seconds. The output digital voice signal F′ has time when there is substantially no output for the “t 1 ” seconds after the dropout and/or overlap has occurred. For example, when the output digital voice signal F′ is output via a speaker, the time when there is no sound occurs. The output digital voice signal F′ is discontinuous on a time axis.
[0017] It is desired that the discontinuity in the signal waveform contained in sample data to be received by the receiving terminal on the time axis is difficult to occur even when the number of pieces of sample data to be transmitted by the transmitting terminal does not coincide with that of sample data to be received by the receiving terminal.
SUMMARY OF THE INVENTION
[0018] In view of the above, it is an object of the present invention to provide a signal receiving circuit capable of receiving sample data without causing discontinuity in the received sample data even when a number of pieces of sample data to be transmitted by a transmitting terminal does not coincide with that of sample data to be received by a receiving terminal.
[0019] According to a first aspect of the present invention, there is provided a signal receiving circuit including:
[0020] a converting circuit to perform computations on a plurality of pieces of first sample data contained in n 1 (n 1 is a natural number) pieces of first sample data sequentially input and to sequentially produce n 1 (n 2 is a natural number) pieces of second sample data in response to a clock signal;
[0021] a receiving circuit to sequentially receive the n 2 pieces of the second sample data in response to the clock signal; and
[0022] wherein the number n 2 is determined by the clock signal.
[0023] With the above configuration, discontinuity can be prevented from occurring in the n 2 pieces of the second sample data.
[0024] In the foregoing, a preferable mode is one wherein the converting circuit outputs, in accordance with a difference between a number of the first sample data input to the converting circuit and a number of the second sample data received by the receiving circuit, one piece of the first sample data existing backward, contained in the plurality of pieces of the first sample data, as one piece of the second sample data contained in the n 2 pieces of the second sample data, in a delayed manner.
[0025] With the above configuration, the second sample data properly expressing the first sample data can be produced.
[0026] Also, a preferable mode is one wherein the one piece of the second sample data is one piece of the first sample data existing backward by N pieces of sample data and output in a delayed manner and wherein the value N is a positive number being not less than 0 (zero) and is able to be a value other than an integer.
[0027] With the above configuration, the n 2 pieces of the second sample data can be changed continuously.
[0028] Also, a preferable mode is one wherein the converting circuit has a controller used to produce a control signal in response to the number n 1 and the number n 2 and a computational section used to perform a computation on the plurality of pieces of the first sample data in response to the control signal and to produce the n 2 pieces of the second sample data.
[0029] Also, a preferable mode is one wherein the computational section has a plurality of storing sections each being used to store one different piece of the first sample data contained in the plurality of pieces of the first sample data, a plurality of multipliers each being used to output a computational result obtained by multiplying one different piece of the first sample data by a predetermined coefficient Aj and an adder used to do addition of the computational result and to output the computational result as one piece of second sample data contained in the plurality of pieces of the second sample data.
[0030] Also, a preferable mode is one wherein the predetermined coefficient A j used in the plurality of the multipliers is obtained by an equation:
Aj = sin ( k + δ - j ) π ( k + δ - j ) π h ( k + δ - j )
[0031] where “n” is a number of multipliers making up the plurality of pieces of the multipliers, “j” is an integer from 1 to n, “k” is a natural number being larger than 1 and being smaller than “n” and “h (i)” represents a window function. The value “δ” is determined in response to the control signal.
[0032] Also, a preferable mode is one wherein the value “h (i)” is a Hamming function.
[0033] With the above configuration, since the predetermined coefficient A j has the window function as a factor, at a frequency being not more than a cutoff frequency, a gain of the converting circuit is not influenced by frequency and therefore the “h (i)” can be the Hamming factor.
[0034] Also, a preferable mode is one wherein the predetermined coefficient A j used in the plurality of the multipliers is obtained by an equation:
Aj = sin ( k + δ - j ) π ( k + δ - j ) π
[0035] where “n” is a number of multipliers making up the plurality of the multipliers, “j” is an integer from 1 to n and “k” is a natural number being larger than 1 and being smaller than “n”. The value “δ” is determined in response to the control signal.
[0036] Also, a preferable mode is one wherein, every time the receiving section receives the second sample data, a difference (N 1 −N 2 ) between a number N 1 of the first sample data to be input to the converting circuit for a specified period and a number N 2 of the second sample data to be received by the receiving section for the specified period is added to the value “δ” and, every time the receiving section receives the second sample data, the value “δ” comes close to 0 (zero) by a specified value.
[0037] With the above configuration, the number of sample data by which the first sample data is output in a delayed manner is changed continuously.
[0038] According to a second aspect of the present invention, there is provided a digital voice signal receiving circuit provided with signal receiving circuits as stated above, wherein n, pieces of first sample data and n 2 pieces of second sample data are digital voice data.
[0039] With the above configuration, discontinuity of received digital voice data is held down, thus enabling elimination of noise.
[0040] According to a third aspect of the present invention, there is provided a method for receiving signals including:
[0041] a step of performing sequential computations on a plurality of pieces of first sample data contained in n 1 (n 1 is a natural number) pieces of first sample data;
[0042] a step of producing n 2 (n 2 is a natural number) pieces of second sample data in response to a clock signal; and
[0043] a step of sequentially receiving the second sample data in response to the clock signal.
[0044] In the foregoing, a preferable mode is one wherein the step of producing the n 2 pieces of second sample data includes a step of outputting, in accordance with a difference between a number of the first sample data and a number of the second sample data to be received by a receiving section, one piece of the first sample data existing backward, contained in the plurality of pieces of the first sample data, as one piece of the second sample data contained in the n 2 pieces of the second sample data, in a delayed manner.
[0045] With the above configuration, discontinuity in the n 2 pieces of the second sample data is difficult to occur.
[0046] Also, a preferable mode is one wherein the one piece of the second sample data is the one piece of the first sample data existing backward by N pieces of sample data and output in a delayed manner and wherein the value N is a positive number being not less than 0 (zero) and is able to be a value other than an integer.
[0047] Also, a preferable mode is one wherein toe step of producing the n 2 pieces of second sample data includes a step of using a value S calculated by an equation:
S = ∑ j = 1 n sin ( k + δ - j ) π ( k + δ - j ) π Dj
[0048] as one piece of the second sample data contained in the n 2 pieces of second sample data, where each of D 1 , D 2 , . . . , D n (n is a natural number being not less than 2) is a value of each of the plurality of pieces of the first sample data, “j” is an integer from 1 to n, “k” is a natural number being larger than 1 and smaller than n and wherein the step of producing the n 2 pieces of second sample data includes a step of calibrating a value “δ” in accordance with a difference between the number n 1 and the number n 2 .
[0049] Also, a preferable mode is one wherein the step of producing the n 2 pieces of second sample data includes a step of using a value S calculated by an equation:
S = ∑ j = 1 n sin ( k + δ - j ) π ( k + δ - j ) π h ( k + δ - j ) Dj
[0050] as one piece of the second sample data contained in the n 2 pieces of the second sample data, where each of D 1 , D 2 , . . . , D n (n is a natural number being not less than 2) is a value of each of the plurality of pieces of the first sample data, “j” is an integer from 1 to n, “k” is a natural number being larger than 1 and smaller than n and “h (i)” represents a window function and wherein the step of producing the n 2 pieces of second sample data includes a step of calibrating a value “δ” in accordance with a difference between the number n 1 and the number n 2 .
[0051] With the above configuration, since the one piece of the second sample data is produced using the window function “h (i)” at a frequency being not more than a cutoff frequency, a gain of the converting circuit is not influenced by frequency
[0052] Also, a preferable mode is one wherein the value “h (i)” is a Hamming function.
[0053] Furthermore, a preferable mode is one wherein, every time the receiving section receives the second sample data, a difference (N 1 −N 2 ) between a number N 1 of the first sample data to be input to the converting circuit for a specified period and a number N 2 of the second sample data to be received by the receiving section for the specified period is added to the value “δ” and, every time the receiving section receives the second sample data, the value “δ” comes close to 0 (zero) by a specified value.
[0054] According to a fourth aspect of the present invention, there is provided a method for receiving digital voice signals using methods for receiving signals stated above, wherein n 1 pieces of first sample data and n 2 pieces of second sample data are digital data which shows a voice.
[0055] With the above aspects, even if the number of the sample data to be transmitted from the transmitting terminal does not coincide with that of the sample data to be received by the receiving terminal, the sample data can be received without the occurrence of the discontinuity in received sample data.
BRIEF DESCRIPTION OF THE DRAWINGS
[0056] The above and other objects, advantages and features of the present invention will be more apparent from the following description taken in conjunction with the accompanying drawings in which:
[0057] [0057]FIG. 1 is a schematic block diagram showing configurations of a signal receiving circuit according to an embodiment of the present invention;
[0058] [0058]FIG. 2A is a diagrams showing transmitting sample data used in the signal receiving circuit according to the embodiment of the present invention;
[0059] [0059]FIG. 2B is a diagram showing clock pulses and receiving sample data used in the signal receiving circuit according to the embodiment of the present invention;
[0060] [0060]FIG. 3 is a diagram showing values of a coefficient A j (q) used when δ(q)=0, employed in the signal receiving circuit according to the embodiment of the present invention;
[0061] [0061]FIG. 4 is a diagram showing values of a coefficient A j (q) used when δ(q)=1, employed in the signal receiving circuit according to the embodiment of the present invention;
[0062] [0062]FIG. 5 is a diagram showing values of a coefficient A j (q) used when δ(q)=0.25, employed in the signal receiving circuit according to the embodiment of the present invention;
[0063] [0063]FIG. 6 is a diagram showing operations of the signal receiving circuit according to the embodiment of the present invention; and
[0064] [0064]FIG. 7 is a schematic diagram showing configurations of a conventional voice signal receiving circuit.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0065] Best modes of carrying out the present invention will be described in further detail using various embodiments with reference to the accompanying drawings.
Embodiment
[0066] [0066]FIG. 1 is a schematic block diagram showing configurations of a signal receiving circuit according to an embodiment of the present invention. The signal receiving circuit of the embodiment is used as the signal receiving circuit to receive a digital voice signal. As shown in FIG. 1, the signal receiving circuit is provided with a filter 1 to which a transmitting signal “a” is input.
[0067] The filter 1 is an r-th order FIR (Finite Impulse Response) filter. The “r” is a natural number being not less than three. In this embodiment, the “r”=9. The filter 1 has a shift register 2 . The transmitting signal “a” is input to the shift register 2 .
[0068] The shift register 2 includes registers 2 - 1 to 2 - 9 . To an input terminal of the register 2 - 1 is input the transmitting signal “a”. An output of the register 2 - 1 is input to the register 2 - 2 . An output of the register 2 - 2 is input to the register 2 - 3 . Similarly, outputs of the register “ 2 -(i- 1 )” are input to the register “ 2 -i”. The “i” is a natural number being not less than two and being not more than nine.
[0069] The shift register 2 is connected to a multiplier 3 . The multiplier 3 includes multipliers 3 - 1 to 3 - 9 . An output of the register 2 - 1 is input to the multiplier 3 - 1 . An output of the register 2 - 2 is input to the multiplier 3 - 2 . Similarly, outputs of the registers 2 -j are input to the multipliers 3 -j. The “j” is a natural number being not more than nine. Outputs of the multipliers 3 - 1 to 3 - 9 are input to an adder 4 . The adder 4 outputs a receiving signal “c”.
[0070] The receiving signal “c” is input to a D/A (Digital/Analog) converter 5 . To the D/A converter 5 is input a receiving clock signal “d”. The D/A converter 5 is connected to a speaker 6 .
[0071] The signal receiving circuit of the embodiment further includes a controller 7 . The controller 7 has a counter 8 and a control signal output section 9 . To the counter 8 are input both the transmitting signal “a” and the receiving clock signal “d”. The counter 8 is connected to the control signal output section 9 .
[0072] Next, operations of the signal receiving circuit of the embodiment will be described below. The transmitting signal “a” is input to the filter 1 and to the controller 7 . The transmitting signal “a” is the digital voice signal. The transmitting signal “a”, as shown in FIG. 2A, includes transmitting sample data x ( 0 ) x( 1 ), . . . , x(p), . . . . The “p” is an arbitrary integer being not less than zero.
[0073] At time t=t 0 , the transmitting sample data x( 0 ) is input to the filter 1 and the controller 7 . At time t=t 1 , the transmitting sample data x( 1 ) is input to the filter 1 and the controller 7 . Similarly, at time=tp, the transmitting sample data x(p) is input to the filter 1 and the controller 7 . The time is assumed to be t 0 <t 1 < . . . <tp<tp+1< . . . .
[0074] Each of the transmitting sample data x(p) is made up of 16 bits. The “p” is an arbitrary integer being not less than zero. The number of bits making up the transmitting sample data may be other number of bits.
[0075] The filter 1 , n response to a control signal “b” produced by the controller 7 , converts the transmitting signal “a” to the receiving signal “c”. The filter 1 outputs the receiving signal “c” to the D/A converter 5 . The controller 7 , in response to the transmitting signal “a” and the receiving clock signal “d”, produces the control signal “b”.
[0076] A process of producing the control signal “b” will be described below. The transmitting signal “a” is input to the counter 8 . The counter 8 holds a counter value “K”. The counter 8 , every time when each of the transmitting sample data x(p) is input, increases the counter value “K” by one. The “p” is an arbitrary integer being not less than zero.
[0077] Moreover, to the counter 8 is input the receiving clock signal “d”. As shown in FIG. 2B, the receiving clock signal “d” has clock pulses P 0 , P 1 , P 2 , . . . , Pq, . . . . The “q” is an arbitrary integer being not less than zero. The clock P 0 is input to the counter 8 at time t=t 0 ′. Let it be assumed here that t 0 <t 0 ′.
[0078] The clock pulse P 1 is input to the counter 8 at time t=t 1 ′. Similarly, the clock pulse P q is input to the counter 8 at time t=tq′.
[0079] The counter 8 , every time when any one of the clock pulses P q is input, decreases the counter value K by one. The “q” is an arbitrary integer being not less than zero. The counter value K obtained after the counter value has been decreased by one due to inputting of the clock pulse P 0 becomes a control value δ(0). Similarly, the counter value K obtained after the counter value has been decreased by one due to inputting of the clock pulse P q becomes a control value δ(q). The control value δ(q) is transferred to the control signal output section 9 via a counter signal “f”.
[0080] To the control signal output section 8 is input the receiving clock signal “d”. The time when the clock pulse P q contained in the receiving clock signal “d” is input to the control signal output section q is substantially the same as the clock pulse P q is input to the counter 8 .
[0081] The control signal output section 9 , when the clock pulse P 0 is input, captures the control value δ(0) . Similarly, the control signal output section 9 , every time when the clock pulse P q is input, captures the control value δ(q) . The “q” is an arbitrary integer being not less than zero. The control signal output section 9 , when the clock pulse P q is input, transfers the control value δ(q) to the filter 1 via the control signal “b”.
[0082] The control signal output section 9 , after having transferred the control value δ(q) to the filter 1 via the control signal “b” further outputs a counter control signal “g” to the counter 8 . The counter control signal “g” is a signal used to instruct the counter a to increase the counter value K by Δx or to decrease the counter value K by Δx. It is assumed that 0<Δ×<0.5.
[0083] In response to the counter control signal “g” the counter 8 performs the following operations. That is, when −Km≦δ(q)≦Km (“q” is an arbitrary integer being not less than zero), the counter 8 holds the counter value K as it is. The “Km” is an integer being not less than zero. When δ(q)>Km, the counter 8 decreases the counter value K by Δx. When δ(q)>−Km, the counter 8 increases the counter value K by Δx. The Δx is not an integer. Therefore, the counter value K can take a value being not an integer. The result from the increase of the counter value K by Δx or the decrease by Δx is reflected in the control value δ(q+1) which is transferred by the control signal “b” when the clock pulse P q−1 is input. Since the counter value K held by the counter 8 can take a value other than an integer, the control value δ(q+1) also can take a value other than the integer (“q” is an integer being not less than zero).
[0084] Processes of producing the control signal “b” are described above. Then, processes in which the transmitting signal “a” is converted into the receiving signal “c” by the filter 1 in response to the control signal “b” will be explained.
[0085] The transmitting signal “a” is input to the register 2 - 1 included in the filter 1 . The transmitting signal “a” includes transmitting sample data x( 0 ), x( 1 ), . . . , x(p), . . . .
[0086] Each of the registers 2 - 1 to 2 - 9 has each of data D 1 to D 9 . Each of the D 1 to D 9 is any one of the transmitting sample data x( 0 ), x( 1 ), . . . , x(p), . . . . The data D 1 to D 9 are determined in the following manner.
[0087] When the transmitting sample data x(p) is input to the register 2 - 1 , the register 2 - 1 captures and stores the data x(p) The “p” is an integer being not less than zero. The data D 1 becomes x(p) . At this point, The data D 2 held by the register 2 - 2 becomes x(p−1). The data D 3 held by the register 2 - 3 becomes x(p-2).
[0088] Similarly, when the transmitting sample data x(p) is input to the register 2 - 1 , data Dj held by the register 2 - 1 becomes x(p−{j−1}) . The “j” is a natural number being not more than nine. That is, when the transmitting sample data x(p) is input to the register 2 - 1 , the register 2 -i, immediate before the transmitting sample date x(p) is input to the register 2 - 1 , captures and stores data held by the register 2 -(i−1).
[0089] The register 2 - 1 outputs its holding data D 1 to the multiplier 3 - 1 . The register 2 - 2 outputs its holding data D 2 to the multiplier 3 - 2 . Similarly, the register 2 -j outputs its holding data D j to the multiplier 3 -j.
[0090] The multipliers 3 - 1 to 3 - 9 perform computations in response to the control signal “b”. The multiplier 3 - 1 multiplies the data D 1 by a coefficient A 1 (q) and outputs the result to the adder 4 . The multiplier 3 - 2 multiplies the data D 2 by a coefficient A 2 (q) and outputs the result to the adder 4 . Similarly, the multiplier 3 -j multiplies the data D j by a coefficient A j (q).
[0091] The coefficients A 1 (q) to A 9 (q) used for the multiplication by the multipliers 3 - 1 to 3 - 9 are determined by the control value δ(q) transferred by the multipliers 3 - 1 to 3 - 9 . The coefficients A 1 (q) to A 9 (q) are obtained by an equation:
Aj ( q ) = sin ( k + δ ( q ) - j } π { k + δ ( q ) - j } π h ( k + δ ( q ) - j ) ( 1 )
[0092] where “k” is a natural number. In the embodiment, k=5.
[0093] The h(i) represents a window function. It may be a Hamming function. That is, the window function is given by an equation:
h ( i )=0.54−0.46 cos(2π/9) (2)
[0094] Moreover, the window function “h(i)” may be one other than the Hamming function. By using the Hamming function as the window function “h(i)”, it is made possible that, at a frequency being not more than a cutoff frequency, a gain of the filter 1 is not influenced by frequencies. Moreover, the window function “h(i)” may be one.
[0095] The control value δ(q) is renewed every time the clock pulse P q is input to the counter 8 . Therefore, the coefficients A 1 (q) to A 9 (q) are also renewed every time the clock pulse P q is input to the counter 8 . The “q” is an arbitrary integer being not less than zero.
[0096] The adder 4 does the sum of computed results of each of the multipliers 3 - 1 to 3 - 9 and uses it as receiving sample data “y”. The coefficients A 1 (q) to A 9 (q) that the multipliers 3 - 1 to 3 - 9 use for the multiplication are renewed every time the clock pulse P q is input to the counter 8 . The receiving sample data “y” is also renewed every time the clock pulse P 0 to P m is input to the counter 8 . The receiving sample data “y” which is produced when the clock pulse P q is input to the counter 8 is hereinafter called “receiving sample data y(q)”. The receiving sample data y(q) is given by the following equation:
y ( q ) = ∑ j = 1 9 Aj ( q ) Dj ( q ) ( 3 )
[0097] where the “D 3 (q)” represents data which is held by the register 2 -j the clock pulse P q is input to the counter 8 . Here, of
[0098] the transmitting sample data x (p) input before the clock pulse P q has been input to the counter 8 , transmitting sample data input to the register 2 - 1 the most immediately before the inputting is called the data x(p′). At this point, D 1 (q)=x(p′). D 2 (q)=x(p′−1). Similarly, D j (q)=x(p′−{j−1}). That is, the following equation is obtained:
y ( q ) = ∑ j = 1 9 Aj ( q ) x ( p ′ - ( j - 1 ) ) ( 4 )
[0099] The adder 4 transfers the receiving sample data y(q) to the D/A converter 5 via the receiving signal c.
[0100] The receiving signal “c” Is input to the D/A converter 5 . To the D/A converter 5 is further Input a receiving clock signal “d”. The D/A converter 5 samples the receiving signal “c” in response to the receiving clock signal “d”.
[0101] When the clock pulse P 0 is input to the D/A converter 5 , the D/A converter 5 captures receiving sample data y( 0 ). Similarly, when the clock pulse P q (q is an arbitrary integer being not less than zero) is input to the D/A converter 5 , the D/A converter 5 captures receiving sample data y(q) . The D/A converter 5 receives the receiving sample data y every time, it receives one clock pulse.
[0102] The D/A converter 5 produces an analog voice signal “e” using the receiving sample data y (q) contained in the captured receiving signal “c”. The D/A converter 5 outputs an analog voice signal “e” to the speaker 6 . The speaker 6 outputs a voice in response to the analog voice signal “e”.
[0103] A main function of the signal receiving circuit of the embodiment is that the filter 1 produces the receiving sample data y(q) by using the above equation (4). Computations by the filter 1 using the equation (4) will be described below.
[0104] The coefficient A j (q) used for the multiplication 4 the multipliers 3 - 1 to 3 - 9 has a window function h (k+δ(q)−j) as a factor. The window function is related only to frequency characteristics. The window function has nothing to do with an essential operation of the filter 1 . To simplify the explanation, let it be assumed that the window function h (k+δ(q)−j)=1.
[0105] A condition occurring when δ(q)=0 will be described. FIG. 3 is a diagram showing values of the coefficient A j (q) used when δ(q)=0. In this case, the window function h (i)=1 and k=5. When j≠k, A j (q)=0. When j=k, A j (q)=1.
[0106] The equation y(q)=x(p′−k−1)), that is, the equation y(q)=x(p′−4) can be derived from the equation (4). The following is meant by this equation:
[0107] Here let it be assumed that, while δ(q)=0, the transmitting sample data x(p−4), x(p−3), x(p−2), x(p−1) and x(p) are input sequentially and, immediately after the inputting of the sample data, the clock pulse P q is input to the counter 8 and further p′=p. At this point, the result is that y(q)=x(p−4).
[0108] That is, the filter 1 outputs the transmitting sample data x(p−4) existing backward by four pieces of sample data as the receiving sample data y(q), in a delayed manner. Thus, when δ(q)=0, the filer 1 outputs the transmitting sample data (k−1) existing backward by (k−1) pieces of sample data as the receiving sample data y(q), in a delayed manner.
[0109] When δ(q)=0, each of the coefficients A j (q) (“j” is a natural number being one to nine) is determined so that the transmitting sample data x(p) is output by (k−1) pieces of the sample data in a delayed manner. The filter 1 performs computations of the transmitting sample data using the registers 2 - 1 to 2 - 2 , multipliers 3 - 1 to 3 - 9 and adder 4 . The result of the computation causes the transmitting sample data existing backward by (k−1) pieces of the sample data to be output in a delayed manner.
[0110] [0110]FIG. 4 is a diagram showing values of the coefficient A j (q) used when δ(q)=1. Here, the window function h (i)=1 and k=5. In the case the δ(q) being one, if j≠k+1 (=6), A j (q)=0. When j=k+1 (=6), A j (q)=1. The equation y(q)=x(P′−5) can be derived from the equation (4). That is, when δ(q)=1, the filter 1 outputs the transmitting sample data x(p) existing backward by five pieces of the sample data as the receiving sample data y(q), in a delayed manner. At this point, each of the coefficients A j (q) (“j” is a natural number being one to nine) is determined so that the transmitting sample data x (p) existing backward by five pieces of the sample data is output in a delayed manner.
[0111] The above theory can be extended to a case where δ(q) is not an integer. FIG. 5 a diagram showing values of the coefficient A j (q) used when δ(q)=0.25. Here, k=5. At this point, each of the coefficients A j (q) (“j” is a natural number being one to nine) is determined so that the transmitting sample data x(p) existing backward by substantially 4.25 pieces of the sample data is output in a delayed manner. The filter 1 outputs the transmitting sample data x(p) existing backward by substantially 4.25 pieces of samples as the receiving sample data y(q) in a delayed manner.
[0112] Thus, as described above, the filter 1 serves as a delaying unit adapted to output the transmitting sample data x(p) existing backward by “(k−1)+δ(q)” pieces of the sample data in a delayed manner. When δ(q) is not an integer, the filter 1 outputs the transmitting sample data x(p) existing backward by (k−1)+δ(q) pieces of the sample data in a delayed manner.
[0113] The number of delayed samples (k−1)+δ(q) for the outputting by the filter 1 is calibrated according to the number of pieces of the transmitting sample data x(p) to be input to the counter 8 and to the number of the clock pulse P q contained in the receiving clock signal “d” to be input to the counter 8 .
[0114] Next, calibration of the number of sample data (k−1)+δ(q) by which the filter 1 outputs in a delayed manner will be described below.
[0115] In the embodiment, let it be assumed that k=5, Km=0, h (i)=1 and Δx=0.2. In the signal receiving circuit of the embodiment, after one piece of transmitting sample data is input to the filter 1 , one clock pulse is input to the D/A converter 5 and one piece of receiving sample data is received.
[0116] In the signal receiving circuit, when one piece of the transmitting sample data receives one clock pulse, the number of pieces of delayed samples in the filter 1 is adapted to be four. That is, the signal receiving circuit is so configured that, when the clock pulse P n is input to the counter 8 immediately after the transmitting sample data x(m) has been Input to the counter 8 , the receiving sample data y(n)=x(m−4), y(n+1)=x(m−3), y(n+2)=x(m−2), . . . , y(n+7)=x(m+3). Here, m≧4.
[0117] However, let it be assumed that a clock pulse P n+1 has been lost due to some reasons. The clock pulse P n+1 to be corresponded to a transmitting sample data x(m+1) is not input. At this time, the receiving sample data y(n+1) is not produced. Operations of the signal receiving circuit in this situation will be explained by referring to FIG. 6. Let the counter value K be zero hen time t<t m .
[0118] In the case of t m ≦t<t m+1 :
[0119] At the time t m , the transmitting sample data x(m) is input to the filter 1 and the counter 8 . The counter value K increments by one. K becomes one. Then, at the time t n′ , the clock pulse P n is input to the counter 8 . The counter value K decrements by one. K becomes 0. δ(n) becomes zero.
[0120] At this point, the number of delayed samples “δ(n)+4” in the filter 1 is fore. As a result, y(n)=x(m−4). The counter control signal “g” is input to the counter 8 . It is neither that δ(n)>Km, nor that δ(n)<Km. The counter value K remains as it is.
[0121] In the case of t m+1 ≦t<t m+3 :
[0122] At the time t m+1 , the transmitting sample data x(m+1) is input to the filter 1 and to the counter 8 . The counter value increments by one. K becomes one. The clock pulse P m+1 to be input following the transmitting sample data x(m+1) is not input to the filter 1 and to the counter 8 . The data y(n+1) is not produced.
[0123] At the time t m+1 , the transmitting sample data x(m+2) is input to the filter 1 and to the counter 8 . The counter value K increments by one. K becomes two. Then, at the time t n+2′ , the clock pulse P n+2 is input to the counter 8 . The counter value K decrements by one. K becomes one. δ(n+2) becomes one. At this point, the number of delayed samples in the filter 1 “δ(n+2)+4”=5. As a result, y(n+2)=x(m=3).
[0124] The counter control signal “g” is input to the counter 8 . Here, δ(n+2)>Km (=0). At the time t n+2″ , the counter value K decrements by Δ x. K becomes 0.8.
[0125] In the case of t m+3 ≦t<t<t m+4 :
[0126] At the time t m+3 , the transmitting sample data x(m+3) is input to the filter 1 and to the counter 8 . The counter value K increments by one. K becomes 1.8. Then, at the time t n+3′ , the clock pulse P n+3 is input to the counter 8 . The counter value K decrements by one. K becomes 0.8. As a result, δ(n+3)=0.8.
[0127] At this point, the substantial number of the delayed samples in the filter 1 “δ(n+3)+4”=4.8. The receiving sample data y(n+3) becomes practically data being equivalent to the data x(m−1.8). In FIG. 6, when the receiving sample data y(n+3) is data being substantially x(m−1.8), it is expressed as y(n+3)≈x(m−1.8).
[0128] The counter control signal “g” is input to the counter 8 . Here, δ(n+3)>Km (=0). At the time t n+3 , the counter value K decrements by Δ x. K becomes 0.6.
[0129] In the case of t m+4 ≦t<t m+5 :
[0130] At the time t m+4 , the transmitting sample data x(m+4) is input to the filter 1 and the counter 8 . K becomes 1.6. Then, at the time t m+4 ′, the clock pulse P n+4 is input to the counter 8 . K becomes 0.6.
[0131] At this point, the substantial number of the delayed samples in the filter 1 “δ(n+4)+4”=4.6. The receiving sample data y(n+4) becomes practically data being equivalent to the data x(m−0.6).
[0132] Here, δ(n+4)>Km (=0). At the time t n+4″ , the counter value K decrements by Δ x. K becomes 0.4.
[0133] In the case of t m+5 ≦t<t m+6 :
[0134] At the time t m+5 , the transmitting sample data x(m+5) is input to the filter 1 and the counter 8 . K becomes 1.4. Then, at the time t n+5′ , the clock pulse P n+5 is input to the counter 8 . K becomes 0.4.
[0135] At this point, the substantial number or the delayed samples in the filter 1 “δ(n+5)+4”=4.4. The receiving sample data y(n+5) becomes practically data being equivalent to the data x(m+0.6).
[0136] Here, δ(n+5)>Km (=0). At the t n+5″ , the counter value K decrements by Δ x. K becomes 0.2.
[0137] In the case of t m+6 ≦t<t m+7 :
[0138] At the time t m+6 , the transmitting sample data x(m+6) is input to the filter 1 and the counter 8 . K becomes 1.2. Then, at the time t n+6′ , the clock pulse P n+6 is input to the counter 8 . K becomes 0.2.
[0139] At this point, the substantial number of the delayed samples in the filter 1 “δ(n+6)+4”=4.2. The receiving sample data y(n+6) becomes practically data being equivalent to the data x(m+1.8).
[0140] Here, δ(n+6)>Km (=0). At the time t n+6″ , the counter value K decrements by Δ x. K becomes zero.
[0141] In the case of t≧t m−7 :
[0142] At the time t m+7 , the transmitting sample data x(m+7) is input to the filter 1 and the counter 8 . K becomes 1.0. Then, at the time t n+7′ , the clock pulse P n+7 is input to the counter 8 . K becomes zero.
[0143] At this point, the number of the delayed samples in the filter “δ(n+7)+4”=4. The receiving sample data y(n+7)=x(m+3). The receiving sample data y(n+7) becomes the same as in the case where the clock pulse P n+1 has not been lost.
[0144] In the signal receiving circuit of the embodiment, when the number of pieces of the transmitting sample data to be input to the filter 1 is equal to that of the clock pulses to be input to the D/A converter 5 , the transmitting sample data is output in a delayed manner by four samples.
[0145] Moreover, the signal receiving circuit of the embodiment, when detecting that the number of the transmitting samples to be input to the filter 1 is larger by one than that of the clock pulse to be input to the D/A converter 5 , substantially changes the number of the delayed samples in the filter 1 while decreasing it from five to four by Δ x(=0.2). Thus, the receiving sample data y(n), y(n+1), are continuously changed. When the transmitting sample data x(m), x(m+1), . . . and the receiving sample data y(n), y(n+1) are digital signals, the analog voice signal “e” reproduced by the D/A converter 5 is not discontinuous.
[0146] Similarly, the signal receiving circuit of the embodiment, when detecting that the number of the transmitting sample to be input to the filter 1 is smaller by one than that of the clock pulse to be input to the D/A converter 5 , substantially changes the number or the delayed samples in the filter 1 while increasing it from three to four by Δ x(=0.2). Thus, the receiving sample data y(n), y(n+1), are continuously changed.
[0147] The signal receiving circuit of the embodiment, when detecting that the number of pieces of the transmitting sample data x(p) to be input to the counter 8 differs by one from that of the clock pulse P q contained in the receiving clock signal “d” to be input to the counter 8 , changes the number of the delayed samples in the filter 1 by Δ x while (1/Δ x) pieces of the clock pulses P q are input.
[0148] Here, let it be assumed that the sampling frequency of the transmitting terminal differs slightly from those of the receiving terminal. At this time, the number of pieces, of the transmitting sample data x(p) to be input to the counter 8 differs, at all times, from that of the clock pulses P q contained in the receiving clock signal “d” to be input to the counter 8 .
[0149] Here, let it be assumed that the number required for causing the difference between the nature of the transmitting sample data x(p) to be input to the counter 8 and the number of the clock pulse P q contained in the receiving clock signal “d” to be input to the counter 8 to be one, is defined to be “nP”. In the signal receiving circuit of the embodiment, so long as nP>1/Δ x, the receiving sample data y(n), y(n+1), . . . can be continuously changed.
[0150] For example, let it be assumedly that, when signals are transmitted or received at the sampling frequency of 16 kHz, a difference of 4 Hz occurs between the sampling frequency of the transmitting terminal and of the receiving terminal. If so, every time the receiving terminal receives signal about 400 times, the number of pieces of the transmigrating sample data to be transmitted by the transmitting terminal differs by one from the number of pieces of the receiving sample data to be received by the receiving terminal. At this pliant, so long as 400>(1/Δ x), that is, Δ x>0.0025, the signal receiving circuit of the embodiments can change continuously the receiving sample data y(n), y(n+1), . . . .
[0151] The value Δ x is preferably as small as possible within a range meeting a condition that np>1/Δ x. The reason is that the receiving sample data y(n), y(n+1) can be continuously changed. Specifically, for the digital voice communications in which signals are transmitted or received at the sampling frequency of 16 kHz, the value “1/Δ x” is preferably about 256.
[0152] It is apparent that the present invention is not limited to the above embodiments but may be changed and modified without departing front the scope and spirit of the invention. For example, in the above embodiment, the signal receiving circuit is used as the signal receiving circuit used for receiving the digital voice signal, however, it may be used as signal receiving circuits other than the circuit for the digital voice signal and it nay be used as a signal receiving circuit to receive digital image signals between communication terminals being not in sync with each other. Moreover, the signaled receiving circuited of the embodiment may be used as a signal receiving circuit in which, though complete reproduction of a transmitted signal is not required, continuity in signal waveforms and on a time axis is required.
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A signal receiving circuit is provided which is capable of receiving sample data, even if a number of sample data to be transmitted from a transmitting terminal does not coincide with that of sample data to be received by a receiving terminal without an occurrence of discontinuity in received sample data.
The signal receiving circuit is provided with a converting circuit adapted to perform computations on a plurality of pieces of first sample data contained in n 1 pieces (n 1 is a natural number) of first sample data to be sequentially input and to sequentially produce, in response to a clock signal, n 2 pieces (n 2 is a natural number) of second sample data and with a receiving section adapted to sequentially receive the n 2 pieces of the second sample data in response to the clock signal.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to post structures and, more particularly, to post footings.
2. Description of the Prior Art
It is known to provide a post with a weakened section that allows the post to bend upon impact according to a predetermined pattern. For instance, U.S. Pat. No. 5,860,253 issued on Jan. 19, 1999 to Lapointe discloses a collapsible post comprising an elongated post section adapted to be connected in an end-to-end relationship with an anchoring member or post shoe driven into the ground. The shoe is provided at an upper end thereof with a socket for receiving and retaining the lower end of a connecting member. Likewise, the upper end of the connecting member is received and held in a socket defined in the lower end of the elongated post section, thereby physically connecting the shoe to the post section.
One problem associated with this type of post construction is that when hammered driven into the ground, the shoe can be deformed, for instance, as a result of a collision with an obstacle. In certain instances, the deformation may be such as to interfere with the subsequent insertion of the connecting member into the shoe, thereby preventing the post section from being mounted onto the shoe. In such cases, the shoe has to be removed from the ground and replaced by a new one.
Therefore, there is a need for a new post anchoring footing.
SUMMARY OF THE INVENTION
It is therefore an aim of the present invention to provide a new post footing.
It is also an aim of the present invention to provide a new post footing having a connecting part which is protected against deformations resulting from the collision of the footing with an obstacle while being driven into a ground surface.
Therefore, in accordance with the present invention, there is provided a post comprising a footing adapted to be driven into the ground, said footing including an outer sleeve and a socket member, said outer sleeve having trailing and leading ends, said leading end being adapted to be forcibly driven into the ground in response to a driving force applied to said trailing end, said socket member being fixed within said outer sleeve with said leading end of said outer sleeve extending beyond said socket member to prevent the latter from being damaged in the event that an obstacle be encountered while said footing is being driven into the ground, an elongated post segment, and a connector inserted into said elongated post segment and said socket member for joining said post segment and said footing together in an end-to-end relationship.
In accordance with a further general aspect of the present invention, there is provided a footing for holding a post segment above a ground surface, comprising an outer sleeve having trailing and leading ends, said leading end being adapted to be forcibly driven into the ground in response to a driving force applied to said trailing end, and a socket member fixed within said outer sleeve with said leading end of said outer sleeve extending beyond said socket member to prevent the latter from being damaged in the event that an obstacle be encountered while said footing is being driven into the ground, wherein said socket member defines a socket adapted to receive a structural piece once said footing has been installed in the ground.
BRIEF DESCRIPTION OF THE DRAWINGS
Having thus generally described the nature of the invention, reference will now be made to the accompanying drawings, showing by way of illustration a preferred embodiment thereof, and in which:
FIG. 1 is a vertical elevational view of a post structure having a footing in accordance with a first embodiment of the present invention;
FIG. 2 is an enlarged vertical cross-sectional view illustrating some details of the footing;
FIG. 3 is a top plan view of the footing with a stabilizer installed thereon; and
FIG. 4 is perspective view of the upper end of the footing with the stabilizer installed thereon.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Now referring to FIG. 1 , a post 10 suited for supporting signs 12 and 14 and embodying the elements of the present invention will be described. It is understood that even though the post 10 is herein described as being a signaling post, it could be used without signs 12 and 14 and in any suitable context without departing from the scope of the present invention.
The post 10 is anchored into a volume of suitable material herein referred to as ground 16 . The ground 16 can, for instance, include a layer of asphalt, a layer of compressed crushed rocks or other layers of similar dense material. As will be described hereinbelow, a stabilizer 18 can even be used for allowing the post 10 to be anchored into soft ground surfaces.
The post 10 essentially includes an elongated tubular post segment 20 for supporting the signs 12 and 14 at a desired elevation above the ground 16 , a footing 22 for anchoring the tubular post segment 20 in the ground 16 , and a connector 24 for coupling the post segment 20 and the footing 22 in an abutting end-to-end relationship, as illustrated in FIG. 1 .
As shown in FIG. 2 , the footing 22 includes a protective sleeve 26 and a socket member 28 fixed within the protective sleeve 26 for subsequently receiving therein one end of the connector 24 . The protective sleeve 26 has a square cross-section and is made of non-galvanized steel, whereas the socket member 28 has an elliptical cross-section and is made of galvanized steel. One reason of using a non-galvanized protective sleeve 26 is that while in contact with the surrounding ground material, the sleeve 26 will gradually becomes rusty, which will have the effect of stiffening the sleeve 26 in the ground 16 . It is noted that an acrylic primer can be applied on the protective sleeve 26 .
The socket member 28 is preferably pressure fitted within the sleeve 26 with the major axis of the ellipse defined by the socket member 28 passing through a pair of diagonally opposed corners of the sleeve 26 , as illustrated in FIG. 3 . The elliptical cross-section of the socket member 28 provides for easy angular alignment of the connecting portions of the post segment 20 , the connector 24 and the socket member 28 .
The sleeve 26 and the socket member 28 have respective trailing and leading ends 30 , 32 , 34 and 36 . As can be seen from FIG. 2 , the leading end 32 of the protective sleeve 26 extends beyond the leading end 36 of the socket member 28 . This affords protection to the socket member 28 in that in the event that an obstacle is encountered while driving the footing 22 in the ground 16 , the shock will be absorbed by the protective sleeve 26 , thereby preventing the socket member 28 from being deformed. This constitutes a major advantage in that it ensures the integrity of the socket member 28 while being driven into the ground 16 and thus prevent the same from being deformed, which could interfere with the subsequent insertion of the connector 24 into the socket member 28 and, thus, potentially prevent the on-site assembly of the post 10 .
As shown in FIG. 2 , the leading end 32 of the protective sleeve 26 is preferably flatten so as to form a transversal cutting blade in order to facilitate the penetration of the footing 22 in the ground 16 . The pressing of the leading end 32 of the sleeve 26 can be performed after the socket member 28 has been pressure fitted into the sleeve 26 .
The socket member 28 is preferably inserted down into the sleeve 26 to a depth where the trailing ends 30 and 34 of the sleeve 26 and the socket member 28 are flush, i.e. at a same level.
In the placement of the above-described footing 22 , one uses a post driver, such as a pneumatic hammer. To place the footing 22 , a penetration point is first set and then successive power hammer blows are applied to the trailing end 30 of the sleeve 26 to cause the same with the socket member 28 to be vertically driven down into the ground 16 to a desired depth of insertion. It is noted that in the event that the post 10 has to be installed in a concrete surface, it might be necessary to first drill a pilot hole. However, in most instances, it is not necessary to drill a pilot hole to drive the footing 22 into the ground.
As can be seen from FIG. 2 , the socket member 28 is provided with an internal abutment rod 38 extending transversally therethrough. Once the footing 22 has been driven into the ground 16 , the connector 24 is inserted into the socket member 28 and lowered onto the abutment rod 38 . As seen in FIG. 2 , the abutment rod 38 is received in a recess 40 defined at the leading end of the connector 24 .
The connector 24 is of the type described in U.S. Pat. No. 5,860,253 issued on Jan. 19, 1999, and includes an elongated elliptical body 42 defining a pair of jaws 44 , each of which defines an axially extending channel 46 for receiving a corresponding nail 48 . To secure the connector 24 to the socket member 28 , the nails 48 are forced longitudinally into the channels 46 and over the abutment rod 38 . As the nails 48 pass over the rod 38 , they are diverted laterally outwardly, thereby causing the connector 24 to flare radially outwardly. This radial expansion of the connector 24 causes the same to frictionally engage the surrounding inner surface of the socket member 28 , thereby securing the connector 24 to the socket member 28 .
Thereafter, the tubular post segment 20 is fitted over the connector 24 in abutment with the socket member 28 and bolted in place.
The footing 22 being solidly anchored into the ground 16 , the post 10 will have a tendency to bend about its most frangible section. Since the footing 22 and the post segment 20 are both made of a stronger material that the connector 24 , and since the footing 22 and the post segment 20 both have a greater diameter than the connector 24 , a lateral impact on the post 10 will cause the latter to bend or shear about the connector 24 .
As shown in FIG. 4 , the stabilizer 18 includes a pair of steel strips 50 . Each strip 50 has a first arm segment 52 and a second arm segment 54 extending at right angles from one end of the first segment 52 . A slot (not shown) is defined in each arm segment 52 / 54 for allowing the strips 50 to be inserted one into the other about the protective sleeve 26 . Once assembled about the sleeve 26 , the stabilizer 18 forms first and second pairs of diverging stabilizing arms on opposed sides of the sleeve 26 . The slots are positioned so that when the strips 50 are assembled together, the so formed stabilizer tightly grasps the sleeve 26 .
In use, the footing 22 is partly driven into the ground 16 and then the strips are assembled about the sleeve 26 . Thereafter, the footing 22 is fully driven into the ground 16 so that the stabilizer 18 be buried in the surrounding ground material. It is noted that a number of stabilizers can be installed along the sleeve 26 . Spacers (not shown) can be provided between the stabilizers to maintain the axial spacing between adjacent stabilizers.
In accordance with a further embodiment of the present invention, an above-ground post segment could be directly inserted into a socket member fixed within a protective sleeve without the use of a intermediate piece, such as connector 24 . In this case, a wedge could be used to secure the socket member within the protective sleeve.
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A post footing for holding a post segment above a ground surface comprises an outer sleeve adapted to be forcibly driven into the ground. A socket member is pressure fitted within the outer sleeve with the leading end of the sleeve extending beyond the socket member to prevent the latter from being damaged in the event that an obstacle be encountered while the footing is being driven into the ground. The socket member defines a socket adapted to receive and hold an above-ground post segment once the footing has been installed in the ground.
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This is a divisional of U.S. application Ser. No. 09/273,826, filed Mar. 22, 1999, now U.S. Pat. No. 6,181,352.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to computer display systems and, more particularly, to methods and apparatus for providing a graphics accelerator capable of selectively providing during any clock period color values for at least two pixels blended with a single texture or color values for a single pixel blended with a plurality of textures.
2. History of the Prior Art
In three dimensional graphics, surfaces are typically rendered by assembling a plurality of polygons in a desired shape. The polygons are conventionally triangles having vertices which are defined by three dimensional coordinates in world space, by color values, and by texture coordinates.
To display a surface on a computer monitor, the three dimensional world space coordinates are transformed into screen coordinates in which horizontal and vertical values (x, y) define screen position and a depth value (z) determines how near a vertex is to the screen and thus whether that vertex is viewed with respect to other points at the same screen coordinates. The color values (r, g, b) define the brightness of each of red/green/blue colors at each vertex and thus the color (often called diffuse color) at each vertex. Texture coordinates (u, v) define texture map coordinates for each vertex on a particular texture map defined by values stored in memory.
A texture map typically describes a pattern to be applied to the surface of the triangle to vary the color in accordance with the pattern. The texture coordinates of the vertices of a triangular surface area fix the position of the vertices of the triangle on the texture map and thereby determine the texture detail applied to each portion of the surface within the triangle in accordance with the particular texture. In turn, the three dimensional coordinates of the vertices of a triangle positioned on the texture map define the plane in which the texture map and the surface lie with respect to the screen surface.
A texture which is applied to a surface in space may have a wide variety of characteristics. A texture may define a pattern such as a stone wall. It may define light reflected from positions on the surface. It may describe the degree of transparency of a surface and thus how other objects are seen through the surface. A texture may provide characteristics such a dirt and scratches which make a surface appear more realistic. A number of other variations may be provided which fall within the general description of a texture. In theory, a number of different textures may be applied to any triangular surface.
In order to apply more than one texture to a surface, prior art graphics accelerators initially were designed to progress through a series of steps [is] in which pixel coordinates and color values describing each triangle are first generated one pixel at a time in sequence, a first texture is mapped to the triangle using the texture coordinates of the vertices and texture coordinates are generated for each pixel as the pixel coordinates are generated, texture values describing the variation of each pixel in the triangle for the first texture are generated using the texture coordinates for each pixel, the texture value describing the first texture for one pixel and the diffuse color values describing that pixel of the triangle are blended to produce a textured color value for the pixel, and the resulting triangle generated from all of the textured color values is blended with any image residing in a frame buffer from which the image may be presented on an output display. Then, texture values for a second texture mapped to the same triangle are generated and blended with the same sequence of pixel color values in the same manner, and the triangle blended with the second texture is blended with the image residing in the frame buffer.
The need to transit the graphics pipeline to blend each texture to the surface of each triangle defining an output image slows the process drastically. In many cases involving rapidly changing images, it has limited significantly the number of textures which can be applied. For this reason, a more recent development provides a pair of texture stages and a pair of texture blend stages in the pipeline. The first texture stage generates texture values describing a first texture from texture coordinates provided as each pixel is generated. These first texture values are blended with the pixel color values at the first texture blend stage as each set of pixel color values is generated. The textured color value output of the first texture blend stage is then furnished to the second texture blend stage. The textured color value output of the first texture blend stage is blended with texture values generated by the second texture stage using texture coordinates provided as each pixel is generated. The output of the second texture blend stage is ultimately transferred to the frame buffer blend stage to be blended with the image data already in the frame buffer. This more advanced pipeline allows two textures to be blended with a surface in a single pass through the graphics pipeline.
Although this most recent development is useful in accelerating texture blending in a graphics pipeline, it is limited to producing a single pixel having at most two textures during any clock of the graphics pipeline and cannot be utilized for any other purposes. More complicated functions require the use of the host processor and the frame buffer blending stage and drastically slow the rendering of surfaces by the graphics accelerator.
There are no prior art systems which have been capable of providing two or more textured pixels during each clock period.
It is desirable to provide a new computer graphics pipeline capable of rapidly selectively providing a plurality of textured pixels or a single pixel blended with a plurality of textures during any clock period.
SUMMARY OF THE INVENTION
The present invention is realized by a graphics accelerator pipeline including a rasterizer stage, a texture stage, and a combiner stage capable of producing output values during each clock interval of the pipeline which map an individual texture to a plurality of pixels.
These and other features of the invention will be better understood by reference to the detailed description which follows taken together with the drawings in which like elements are referred to by like designations throughout the several views.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram illustrating a computer graphics pipeline designed in accordance with the teaching of the prior art.
FIG. 2 is a block diagram illustrating another computer graphics pipeline designed in accordance with the teaching of the prior art.
FIG. 3 is a block diagram illustrating a computer graphics pipeline designed in accordance with the present invention.
FIG. 4 is a block diagram illustrating in detail a portion of the computer graphics pipeline of FIG. 3 .
FIG. 5 is block diagram illustrating in more detail another portion of the computer graphics pipeline of FIG. 3 .
DETAILED DESCRIPTION
Referring now to FIG. 1, there is illustrated a block diagram of a computer graphics pipeline 10 constructed in accordance with the prior art. The pipeline 10 includes a plurality of stages for rendering pixels defining a three dimensional image to a frame buffer 12 from which the image may be provided at an output stage 13 , typically an output display.
The pipeline 10 includes a front end stage 15 at which data positioning each of a plurality of triangles defining an output image is received and decoded. The front end stage 15 receives from an application program the data defining each of the vertices of each triangle which is to appear in the output image being defined in the frame buffer 12 . This data may include the three dimensional world coordinates of each of the vertices of each triangle, red/green/blue color values (diffuse color values) at each of the vertices, texture coordinates fixing positions on a texture map for each of the vertices for each texture modifying the color values of each triangle, and various factors for combining the textures and diffuse color values.
The front end stage 15 determines the manner and order in which the pixels of the various triangles will be processed to render the image of the triangle. When this processing order has been determined, the front end stage 15 passes the data defining the vertices of the triangle to a setup stage 16 . The setup stage 16 carries out a number of processes known to those skilled in the art that make the operations of generating pixels and applying textures to those pixels progress rapidly. The processes actually carried out by the setup stage 16 may vary depending on the particular implementation of the graphics accelerator. In some circuitry, certain of these processes are implemented by a rasterizer stage 18 and a texture stage 19 which follow the setup stage.
The setup stage 16 utilizes the world space coordinates provided for each triangle to determine the two dimensional coordinates at which those vertices are to appear on the two dimensional screen space of an output display. If the vertices of a triangle are known in screen space, the pixel positions vary linearly along scan lines within the triangle in screen space and may be determined. The setup stage 16 and the rasterizer stage 18 together use the three dimensional world coordinates to determine the position of each pixel defining each of the triangles. Similarly, the diffuse color values of a triangle vary linearly from vertex to vertex in world space. Consequently, setup processes based on linear interpolation of pixel values in screen space, linear interpolation of depth and color values in world space, and perspective transformation between the two spaces will provide pixel coordinates and color values for each pixel of each triangle being described. The end result of this is that the rasterizer stage generates in some sequence screen coordinates and red/green/blue color values (conventionally referred to as diffuse color values) for each pixel describing each triangle.
The setup stage 16 and the rasterizer stage 18 also cooperate in the computation of the texture coordinates for each pixel in each triangle and send those texture coordinates to a texture stage 19 . The texture coordinates vary linearly from vertex to vertex in world space. Because of this, texture coordinates at any position throughout the triangle may be determined in world space and related to the pixels to be displayed on the display through processes combining linear interpolation and perspective transformation. The texture coordinates generated are then utilized by the texture stage 19 to index into a selected texture map to determine texels (texture color values at the position defined by the texture coordinates for each pixel) to vary the diffuse color values for the pixel. Often the texture stage 19 interpolates texels at a number of positions surrounding the texture coordinates of a pixel to determine a texture value for the pixel. In one arrangement, texels from four positions surrounding the texture coordinates of the pixel are interpolated to determine a texture value for the pixel. The end result of this is that the texture stage 19 generates in some sequence a texture value for each pixel describing each triangle.
The results provided by the rasterizer and texture stages 18 and 19 are furnished to a texture blend stage 20 in which the diffuse color values generated by the rasterizer for each pixel are blended with the texel value for the pixel in accordance with some combinatorial value often referred to as alpha. Typically, an alpha value is carried as a component of the texture values and determines the amounts of each of the diffuse color values and the texture values to be included in the final color defining that particular pixel. The output of the texture blend stage 20 is a sequence of color values defining the pixels of the particular triangle as blended with a first texture.
Although other stages (not shown) may be included in the pipeline for other effects, the sequence of color values defining the pixels of the particular triangle blended with a first texture generated by the texture blend stage 20 are transferred to a frame buffer blending stage 22 . In the frame buffer blending stage, the sequence of color values defining the pixels of the particular triangle blended with a first texture are combined with the pixels already in the frame buffer 12 at the screen position of the triangle in a read/modify/write operation. Then, the color values for the pixels produced by the frame buffer blend stage 22 are stored in the frame buffer 12 replacing the values previously at the pixels positions defining the triangle.
In a prior art graphics pipeline including only one texture stage and only one texture blend stage, only one pixel is produced during any clock interval and only one texture is blended with the diffuse color of the pixel produced. In order to apply an additional texture to the triangle, the pipeline must be traversed a second time. In this second traversal, the rasterizer stage 18 is again utilized to provide the pixels defining the diffuse color output of the triangle and texture coordinates related to a second texture map defining the second texture. The texture coordinates are utilized by the texture stage 19 to produce a second texture value output related to the individual pixels in the triangle. The second set of texture values produced by the texture stage 19 are then blended with the diffuse color values produced by the rasterizer in the texture blending stage 20 . Finally, the destination pixel color values in the frame buffer 12 defining the triangle with a first texture are read out of the frame buffer and combined in the frame buffer blend stage 22 with the pixels providing the second texture for the triangle typically utilizing alpha values associated with the second texture values. The result then replaces the destination pixel color values in the frame buffer 22 .
As those skilled in the art understand, the time required to overlay the pixels of a triangle with two sets of texture values is very significant. In fact, the time is so great that typically only a single texture is applied to any triangle unless the computer processing the images is very fast or the action of the image is quite slow.
Because of this, more advanced graphics pipelines have been designed. In an advanced graphics pipelines known to the prior art illustrated in FIG. 2, two texture stages 29 a and 29 b and two texture blend stages 30 a and 30 b are utilized. In such a pipeline arrangement, each texture stage 29 a and 29 b receives texture coordinates and generates texture values for a distinct one of two textures which are to be blended with the pixels of the triangle being generated sequentially by the rasterizer stage 18 . Thus, as individual diffuse colors are produced by the rasterizer stage 38 to serially describe the pixels of a triangle, a texture value may be produced by each of the texture stages 29 a and 29 b to be blended with the pixel color values.
As each set of color values of each sequential pixel defining the particular triangle is generated, it is blended in the first texture blend stage 30 a with texture values defining a first texture for that pixel furnished by the first texture stage 29 a. Each set of textured color values resulting from the blending is transferred as it is generated to the second texture blend stage 30 b and blended with the second sequence of texture values produced by the second texture stage 29 b. The color values resulting from blending diffuse color values with one or two textures are ultimately transferred to a frame buffer blending stage 22 from the second texture blend stage 30 b and combined with the pixels already in the frame buffer 12 at the screen position of the triangle in a read/modify/write operation. The color values for the pixels produced by the frame buffer blend stage 21 are stored in the frame buffer 12 replacing the values previously at the pixels positions defining the triangle.
Although the advanced prior art pipeline illustrated in FIG. 2 is capable of producing a stream of color values for pixels one pixel at a time defining a surface blended with two textures during a single pass through the pipeline, this is all that the pipeline is able to accomplish.
It is desirable to provide a graphics accelerator which is capable of both (1) producing a sequence of pixels each combined with one or more textures during each clock interval, and (2) producing more than one pixel blended with a texture during each clock interval.
The present invention provides a graphics pipeline that fulfills these requirements. To accomplish this, the present invention provides a new graphics pipeline including unique processing stages. These new processing stages allow a plurality of pixels each modified by the same texture to be produced during any clock interval of the pipeline thereby significantly accelerating the rendering of graphics images. The processing stages also allow texture values for a plurality of different textures to be processed simultaneously through the graphics pipeline and applied to a stream of single pixels. Thus, the new pipeline is faster and much more flexible than are prior art graphics pipelines.
FIG. 3 is a block diagram illustrating components of a new graphics pipeline in accordance with the present invention. The new graphics pipeline includes front end, setup, and rasterizer stages 35 , 36 , and 38 which accomplish the functions described in detail above with respect to similar stages illustrated in FIG. 1 . In addition to the usual functions accomplished by rasterizers of the prior art, the rasterizer 38 is designed to provide pixel coordinates and color values for two adjacent pixels and texture coordinates for each of the two pixels during the same clock interval. This may be accomplished in one embodiment by furnishing output values which include not only the normal X value in screen coordinates, but an X+1 value as well. Alternatively, output values including Y and Y+1 values might be furnished. The pipeline includes a pair of texture stages 39 a and 39 b each of which is adapted to produce texture values in the manner described in detail above for individual textures being applied to a surface. In other embodiments, additional texture stages may be incorporated into the pipeline in the manner described herein.
FIG. 4 illustrates one embodiment of a texture stage 39 a or 39 b. Each texture stage 39 a and 39 b is adapted to receive input signals which include texture coordinates for each of the two pixels of a triangle being rendered as the individual pixel coordinates are simultaneously generated by the rasterizer stage 38 . The texture stages also receive a texture identification (id) value indicating a texture to be mapped to the triangle. The texture identification sent to each of the texture stages may be the same or different.
Each texture stage is capable of selecting one set of texture coordinates furnished to generate a texture value using the texture map identified for one set of pixel coordinates. The texture coordinates may be those for either the first or the second of the two texture coordinates furnished after computation by the rasterizer. In one arrangement, the texture stage uses the typically non-integer set of texture coordinates to determine a set of four integer texture coordinates surrounding the texture coordinate provided and retrieves texels at each of the integer positions from a cache 41 storing texels of the identified texture map. A detailed description of a texture cache arrangement capable of providing such texels to a texture stage is provided in U.S. patent application Ser. No. 09/273,827, entitled Texture Caching Arrangement For A Computer Graphics Accelerator, by G. Solanki et al, filed on even date herewith and assigned to the assignee of the present invention.
The texture stage blends the four texels obtained from the cache 41 and provides a texture value output for the set of texture coordinates utilized. Thus, the outputs produced by the two texture stages 39 a and 39 b are two sequences of texture values defining two textures to be mapped to the triangle the pixels for which are simultaneously being furnished by the rasterizer stage 28 .
Since the rasterizer stage 38 produces a pair of adjacent pixels at each clock interval of the pipeline and furnishes a pair of texture coordinates for these pixels to each of the texture stages 39 a and 39 b, a number of possible output sequences may be selectably produced by the texture stages.
If an application program desires to apply two different textures to each pixel of a sequence of pixels produced by the rasterizer 38 , then each texture stage receives a different texture map identification as an input value so that the coordinates furnished are used with a different texture map. Moreover, in order to apply two textures to each individual pixel of the sequence being generated, each individual texture stage is furnished the unique texture coordinates for the individual texture to be applied by that texture stage to that pixel. This causes the two texture stages 39 a and 39 b to generate sequences of texture values from two texture maps which may be blended in a single pass through the pipeline to the sequence of pixels being generated in the manner described with respect to FIG. 2 .
On the other hand, if an application program desires to produce two sequential pixels having the same texture during any clock interval of the pipeline, then each texture stage receives the same texture map identification as an input value so that the coordinates furnished are used with the same texture map. However, in order to apply a single textures to each of two simultaneously generated pixels of the sequence being generated, one of the texture stages is furnished the unique texture coordinates for the first of the individual pixels, while the other texture stage is furnished the unique texture coordinates for the second of the individual pixels. This causes the two texture stages 39 a and 39 b to generate sequences of texture values from a single texture map each of which may be blended with the diffuse colors of one of the pair of pixels generated by the rasterizer 38 in a single pass through the pipeline in the manner described with respect to FIG. 2 .
In addition to the multiple texture stages 39 a and 39 b, the pipeline of the present invention shown in FIG. 3 also includes two combiner stages 40 a and 40 b and does not include the texture blend stage or stages of the prior art. The combiner stages 40 a and 40 b each are capable of receiving input from a plurality of possible sources. For example, the combiner stages may each utilize as input, among other values, the output texture values produced by either of the texture stages 39 a or 39 b, the diffuse color output of the rasterizer stage 38 , the output of the other combiner stage, and input signals defining various factors useful in combining various textures and colors together. A detailed description of a graphics pipeline including combiner stages is provided in U.S. patent application Ser. No. 09/273,975, entitled Graphics Pipeline Including Combiner Stages, by D. Kirk et al, filed on even date herewith and assigned to the assignee of the present invention.
The combiner stages allow the diffuse color image furnished by the rasterizer stage 38 to be combined with each of at least two individual textures during the same pass through the pipeline. These stages also allow a plurality of other functions to be accomplished which greatly accelerate the operation of the pipeline. FIG. 5 is a block diagram describing the general form of the combiners 40 a and 40 b which should help to better illustrate their facilities. As FIG. 5 illustrates, each of the combiners includes a pair of multiply circuits 43 the output from each of which provides input to an add circuit 44 . Each of the multiply circuits 43 is organized to multiply two input operands together and furnish the result as output. In contrast to prior art circuits which allow the blending of at most two textures and a single set of diffuse color pixels, the two input operands of each of the two multiply circuits may each be selected from any of a number of different sources among which are those described in the figure. This allows combinations to be accomplish in a single pass through the pipeline which could not be accomplished in any realistic manner by prior art circuitry. The add circuit 44 adds the results of the two multiplications accomplished by the multiply circuits 43 and accomplishes certain other operations. Any of the available operands may be selected to be multiplied by another and the result of this multiplication added to the result of another multiplication of two selectable operands. In contrast to prior art circuits in which a texture blend stage allows the blending of a texture and a single set of diffuse color pixels, the two input operands of each of the two multiply circuits may each be selected from any of a number of different sources among which are those described above. This allows operations to be accomplish in a single pass through the pipeline which could not be accomplished in any realistic manner by prior art circuitry.
As those skilled in the art will recognize, the typical operation by which a texture is mapped to a triangle utilizes a factor for selecting the amount of each diffuse pixel color to combine with the texture value color for that pixel. Typically, the factor is included with the texture information as an alpha value between zero and one. One of the two elements to be combined is multiplied by the alpha value while the other is multiplied by one minus the alpha value. When these are added together, the result is the color value of the textured pixel. This assures that each color will be made up of some percentage of diffuse color and a remaining percentage of a modifying texture color as determined by the alpha (or other factor).
As may be seen, the combiners 40 a and 40 b are each adapted to easily handle the blending of textures with diffuse images in this manner. If the diffuse color pixels defining the triangle and an alpha value provided with the texture information are furnished as the two operands to one of the multipliers 43 , the result is the diffuse pixel color multiplied by the alpha value. Similarly, if the texture values related to each of those pixels and one minus the alpha value are furnished as operands to the other of the two multipliers 43 , the result is the texture value for each pixel multiplied by one minus alpha. Then the result may be added by the add circuit 44 to map the texture to the pixels of the triangle.
The two combiner stages are adapted to provide two individual streams of pixels combined with samples from the same texture and thereby provide an output at a rate of two pixels per clock interval of the pipeline. In one embodiment, this is accomplished by sending color values generated by the rasterizer 38 for alternate pixels to the two combiners. For example, each first pixel generated may be sent to the combiner 40 a and each second pixel generated sent to combiner 40 b. Then, each pixel color value is combined with a set of texture values produced by one of the texture stages 39 selected to provide texture values at the correct pixel positions.
Thus, the control circuitry may be utilized to provide diffuse color values of separate pixels to the first and second combiners. In one case, the diffuse color values of sequential pixels may be provided as input values to the first and second combiners. Simultaneously, texture values for these sequential pixels derived from a single texture map may be provided as input values to the first and second combiners to be blended with the diffuse color values of the two sequential pixels. This allows each combiner to blend the same texture with sequential pixels in the same clock interval. This operation produces pixels twice as fast as prior art arrangements.
On the other hand, the diffuse pixel colors for each pixel in the sequence may be provided to the same combiner 40 a. At the same time, the texture values provided to the first and second combiners to be blended with the diffuse color values of the single pixel may differ in accordance with two different texture maps. The combiner 40 a then blends a first texture with the stream of pixel color values and send the resulting stream of textured color values to the second combiner 40 b to be combined with a second different texture in the same clock interval.
FIG. 5 illustrates in detail an embodiment of an input stage 50 for one combiner. The input stage includes a plurality of multiplexors 51 each receiving input from two sources and furnishing output to another multiplexor 52 . One of the multiplexors 51 receives diffuse color values (DIFFUSE.RGB) and a diffuse alpha value (DIFFUSE.ALPHA), another multiplexor 51 receives first texture values (TEX0.RGB) and first texture alpha values (TEX0.ALPHA), and a third multiplexor 51 receives second texture values (TEX1.RGB) and second texture alpha values (TEX1.ALPHA). These operands are used in the manner discussed above. In addition, another multiplexor 51 receives factor values (FACTOR.RGB) and factor alpha values (FACTOR.ALPHA), and a final multiplexor 51 receives input values (INPUT.RGB) and input alpha values (INPUT.ALPHA). It should be understood that where the block diagram illustrates an input which is a color value such as diffuse color or a texture, the circuitry of the multiplexors is actually designed as three essentially identical circuits each designed to process one of the three individual red, green, and blue components of the color value separately. Moreover, as will be discussed later, a fourth circuit arrangement is also provided for accomplishing similar combinations of the alpha values which may be carried with each of the diffuse color values, texture values, factor values, and input values shown.
A COMBINE.ALPHA control signal controls the selection of the particular output furnished by each multiplexor 51 as input to the multiplexor 52 . This COMBINE.ALPHA control signal selects for each multiplexor either the values themselves (those identified by .RGB) or the alpha values associated with the values (those identified by .ALPHA) as the input values to be furnished to the multiplexor 52 to be combined by one of the multipliers 43 . Thus, the color values provided by the diffuse color input, the texture inputs, the factor value, and the undesignated input may be selected by the multiplexors 51 . Alternatively, the plurality of alpha values associated with diffuse color, the different textures, the factor value, and the input value may be chosen.
It should be noted that a constant factor may be used in a computation to determine the weight to be given a diffuse color or a texture, in order to change its brightness, for example. The INPUT.RGB and INPUT.ALPHA values provide an additional undetermined input which a programmer may assign to any of a number of available sources. One manner in which this input may be used is to allow the result produced by one of the combiners to be used as a source for the other combiner.
The values selected by the multiplexors 51 are transferred to the multiplexor 52 . In addition to the values selected by the multiplexors 51 , the multiplexor 52 also receives individual input signals ZERO and LOD 0 . It should be noted that by selecting ZERO, one of the operands of a multiplication will be zero; thus, one result may be effectively eliminated as an input to the adder thereby allowing the adder to provide the sum of two multiplications or the result of either of the individual multiplications. On the other hand, by selecting LOD 0 , a particular level of detail is selected; the level of detail effectively causes a blend of texture values furnished as another input operand to the particular multiplier 43 . Any of these values may be selected by the multiplexor 52 for multiplication by another input operand. Thus, one of the alpha values, one of the many color values, ZERO, or LOD 0 may be selected as an operand by the multiplexor 52 .
The operands provided by the multiplexor 52 are selected in the manner determined by a COMBINE.ARGUMENT control signal which designates the particular multiplicand to be selected. Thus any of the color values, the alpha values, a factor, a level of detail, or zero may be transferred as an operand to a multiplier.
It should be noted that, as a generality, the arrangement provided is adapted to provide as an operand to one of the multipliers, either some form of color value or an alpha value. Thus, the arrangement is especially adapted to furnish one set of three operands by means of the three individual circuits providing operands for the multipliers which are the r,g,b color values and another set of three operands which are the alpha values by which these color values are to be blended. This allows one multiplier to produce an output with any set of color values which is the red color value multiplied by its alpha, the green color value multiplied by its alpha, and the blue color value multiplied by its alpha. These are the usual components of blending operations.
The result furnished by each multiplexor 52 at the input to each multiplier 43 may be inverted by an inverter 55 in response to a control signal COMBINE.INVERSE. In addition to other advantages, this allows a binary number result to be produced which is one minus the particular value, a result which is especially useful in providing the one minus alpha multiplier for color values and is used in other interpolation operations.
The outputs of two input stages 50 are transferred as operands to a multiplier 43 . The multiplier 43 multiplies the two values together. This allows any of the operands to be multiplied by another. For example, any of the color operands such as diffuse color or a texture value may be multiplied by alpha, an inverted alpha value (one minus alpha), a constant factor, a level of detail, or some other input to provide an output value. The results produced by the two multipliers 43 are transferred to the adder 44 .
The operations of adder 44 utilized with a particular embodiment are illustrated (within element 44 ) in FIG. 5 . The adder has as a basic function the addition of the two multiplied results provided to it. Thus, if a diffuse color value and an alpha value are furnished to one multiplier, a texture value and inverse alpha to the other multiplier, the result produced by the adder 44 through a simple addition can be the color value for a pixel in which diffuse color is blended with the texture in accordance with the alpha value. This produces the pixel modified by the desired texture. It should be noted that any of the alpha values provided by any of the diffuse color or texture values may be used in the operation.
The adder in this embodiment is also adapted to provide a number of other output results which the graphics pipelines of the prior art have not been capable of producing efficiently. For example, the adder may be used as a simple multiplexor to select from among the two input values provided. This allows the output from the combiner to be either the result of the addition of the two multiplications or either of the individual results of the multiplications. In addition, the adder allows the output produced to be shifted one or two bits to the left or one bit to the right. This allows the result to be doubled, quadrupled, or halved. These results are especially useful in modifying the intensity of pixels in the output result and in maintaining precision of binary calculations. A value of 128 may be subtracted from the results allowing the transfer between signed values and unsigned values thereby allowing the use of applications utilizing both signed and unsigned numbers. In the particular embodiment, a result from which 128 has been subtracted may also be shifted by one bit.
The combination of the selectable operands, the plurality of functions provided by the adder 44 , and the ability to use the result of one combiner operation as input to the other allows the different input values to be manipulated to provide a myriad of different output values. Not only may the combiners may be utilized to blend a texture and a diffuse image and then to blend the result and a second texture, the combiners may be utilized to accomplish very complicated operations which typically require significantly more hardware and processing time in prior art circuits when those operations are possible at all.
For example, the factor input allows two textures to be combined with one another each as some percentage of a whole. By selecting the LOD input and a texture, a texture value may be multiplied by a value to provide the equivalent of a particular level of detail. The same texture value and a different LOD value as operands for the other multiplier provide a second level of detail. These may be combined by the adder. Any number of other operations typical to graphics accelerators may be accomplished rapidly through use of the combiners. Moreover, each of these operations may typically be accomplished in a single pass through the graphics pipeline of the invention.
In addition to the three r,g,b processing paths for handling the color and texture values discussed with respect to FIG. 5, each of the combiners also includes a fourth path which is quite similar to each of the color paths. However, rather than allowing color and alpha values both to be used as operands, this path is designed to manipulate only the various alpha values. This path includes in one embodiment a pair of multipliers each capable of utilizing as operands all of the alpha value inputs which are available to the circuit of FIG. 5 as well as the LOD 0 value and zero. The inverse of any of these values is also available as an operand. The operands are multiplied by the multipliers and the results furnished as output signals to an adder. The arrangement allows the alpha values to be separately manipulated is the manner described previously where that is a desirable operation. For example, this may be useful in providing a value to be used in furnishing specular lighting attributes. These attributes typically appear as white or colored highlight reflections from an image; the retention of a white value in a final image requires a different combination than the usual texture combination.
As will be understood, if more than two textures are to be mapped, then an embodiment having additional texture stages and combiners may be utilized.
It should also be noted that a pipeline utilizing a single combiner stage may be used to accomplish the same functions since the output of the stage may be routed as input so that multiple textures may be blended to each pixel.
Although the present invention has been described in terms of a preferred embodiment, it will be appreciated that various modifications and alterations might be made by those skilled in the art without departing from the spirit and scope of the invention. The invention should therefore be measured in terms of the claims which follow.
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A method and graphics accelerator apparatus for pipelined generation of output values for a sequence of pixels, with generation of output values for each of at least two textured pixels during each pipeline clock interval. The apparatus includes a combiner stage capable of producing output values during each clock interval of the pipeline, wherein the output values are indicative of a blend of a plurality of textures with a single pixel when the combiner stage operates in a first mode, and the output values are indicative of a blend of an individual texture with two pixels when the combiner stage operates in a second mode.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the priority of Chinese Patent No. 201410478590.9 filed on Sep. 18, 2014 and entitled “Novel Lactobacillus plantarum and Use Thereof”.
TECHNICAL FIELD
[0002] The present invention falls within the technical field of microorganisms, and more specifically relates to a novel Lactobacillus plantarum and use thereof.
BACKGROUND
[0003] Lactic acid bacteria (LAB) are a generic term of a class of bacteria with which large quantities of lactic acid can be produced from fermentable carbohydrates. This class of bacteria is widely distributed in nature, is abundant in species diversity, and has great application value in many important areas intimately related to human life including industry, agriculture and animal husbandry, food, medicines, and others. The use of lactic acid bacteria in food can increase the nutritive value, improve the flavor, and enhance the preservation and added value of the food. Also numerous studies suggest that the lactic acid bacteria may regulate the normal bacteria flora and maintain the micro-ecological balance in the gastrointestinal tract of an organism, enhance the digestion rate and biological value of the food, reduce the serum cholesterol, manage the endotoxins, inhibit the growth and reproduction of spoilage organisms and the production of spoilages in the intestine, produce nutritive substances, and promote tissue development, thus exerting an effect on the nutritional status, physiological functions, cell infection, drug effect, toxic reaction, immune response, tumor formation, aging process and sudden emergency response of an organism. As such, the physiological functions of the lactic acid bacteria are closely linked with the vital activities of the organism. It is believed that once cessation of growth of the lactic acid bacteria occurs, human beings and animals are hard to survive healthily. Accordingly, the lactic acid bacteria are widely used in a variety of light industries, food, medicine, and feed industry etc.
[0004] Pickles are typical traditional special fermented food in China, which are long in history, and deeply rooted in culture. Pickles have the effects of invigorating the spleen and increasing the appetite because they are tender, crisp, and refreshing, and have sour and sweet delicious tastes, thus being popular and favored by most of the consumers. Sichuan pickles are made mainly through fermentation with lactic acid bacteria, during which alcoholic fermentation, acetic fermentation, and other actions of organisms exist. The pickles are produced by cold processing, which is highly beneficial to the preservation of the nutritional ingredients, the color, and the flavor of the vegetables.
[0005] At present, the pickles are produced through conventional spontaneously inoculated fermentation or through pure culture fermentation by artificially inoculating Lactobacillus . The pickles produced through artificially inoculated fermentation are superior to those produced by spontaneously inoculated fermentation in terms of the improvement of the stability of the product quality, the shortening of the fermentation and production cycle, and the maintenance of the stability of the fermentation environment. However, if the tolerance of the start culture for artificial inoculation to the environment is insufficient, the color and flavor of the pickles and especially the number of the viable bacteria are affected. In Chinese Patent Publication No. CN 101720901S, pickles produced through fermentation with a starter culture and production method thereof, and more particularly pickles produced through fermentation with several pure lactic acid bacteria as starter cultures and production method thereof are disclosed. In the patent, the strains used for fermentation are Lactobacillus plantarum LP-115, Leuconostoc mesenteroides LM-57, and Pediococcus acidilactici P-751, which have a low tolerance to the environment, and tend to suffer from decreased number of viable bacteria during the storage and selling of the pickles, so that the healthcare functions of the viable bacteria cannot be highly exerted.
[0006] During the fermentation of the pickles, a safety problem that is difficult to overcome exists, that is, the production of the nitrite. Because the vegetables can easily accumulate nitrogen from the soil during growth, from which the nitrate is formed. The nitrate in the vegetables is reduced to form a nitrite during the process of anaerobic fermentation. The nitrite is very harmful to human body, poisoning may occur upon uptake in an amount of 0.2-0.5 g, and the nitrite is also a precursor of the highly carcinogenic substance nitrosamine. Therefore, there is a need for seeking a method for reducing the nitrite content in the pickles. In Chinese Patent Publication No. CN 102899262A, a Lactobacillus plantarum and a method for rapidly degrading the nitrite during fermentation by using the same are disclosed. In the method, the seed liquid of expanded Lactobacillus plantarum is inoculated in fermentation of Capsicum chinense , and 12% of high salt is added for flavoring after fermentation. The nitrite content in the Capsicum chinense fermented by using the method is significantly lowered, and the original flavor of the pepper is well retained. However, the salt content in the pepper is too high, and long-term consumption of the pepper may cause damage to human body.
[0007] Therefore, it is of great significance for the fermentation process of pickles to seek a starter culture for fermentation that has high acid production and high tolerance, and can reduce the nitrite content.
SUMMARY OF THE INVENTION
[0008] The present invention provides a Lactobacillus plantarum , which has high acid production and high tolerance, and can effectively reduce the nitrite content during the production of pickles.
[0009] Technical solutions of the present invention:
[0010] A Lactobacillus plantarum tlj-2014 is provided, which is deposited on Jul. 2, 2014 in China General Microbiological Culture Collection Center (CGMCC) (Institute of Microbiology, Chinese Academy of Sciences, No. 1 West Beichen Road, Chaoyang District, Beijing, China, 100101) under CGMCC Accession No. 9405.
[0011] The Lactobacillus plantarum tlj-2014 is bred by the following process: original starting strain→in vitro activation→diethyl sulfate (DES) mutagenesis→nitrosoguanidine (NTG) mutagenesis→plasma mutagenesis→primary screening by plate culture→secondary screening by shake flask culture→passage stability test
[0012] The Lactobacillus plantarum tlj-2014 is characterized in that (1) with the strain, the lactic acid production rate can be up to 35 g/L/d, and the concentration of lactic acid after 71 hrs of fermentation is up to 95 g/L; (2) the strain is acid tolerant, and survives well at pH 1.80; and (3) the strain can degrade the nitrite quickly with a decomposition capability of up to 9.8 mg/h/kg (the accumulation rate of the nitrite in the spontaneous fermentation process is about 1.1 mg/h/kg), and is tolerant to 1% bile salt.
[0013] Beneficial effects
[0014] It is found through tests that the Lactobacillus plantarum tlj-2014 provided in the present invention is strongly genetically stable, since it can be continuously slant-subcultured for 10 generations without obvious change in traits and with various performance criteria kept normal. With the strain, the lactic acid production rate can be up to 35 g/L/d, and the concentration of lactic acid after 71 hrs of fermentation is up to 95 g/L. The Lactobacillus plantarum tlj-2014 which can survive at pH 1.80, is tolerant to 1% bile salt, and can degrade the nitrite quickly with a decomposition capability of up to 9 . 8 mg/h/kg. When the strain is used in production of pickles, the nitrite concentration is lower than 5 mg/kg throughout the entire fermentation process, which is far below the content (20 mg/kg) specified in the national standard GB2714-2003.
DETAILED DESCRIPTION OF THE INVENTION
Example 1
Characteristics of the Strain
[0015] The Lactobacillus plantarum tlj-2014 is deposited on Jul. 2, 2014 in China General Microbiological Culture Collection Center (CGMCC) (Institute of Microbiology, Chinese Academy of Sciences, Building 3, No. 1 West Beichen Road, Chaoyang District, Beijing, China, 100101) under CGMCC Accession No. 9405.
[0016] The strain has the following features. When observed under a microscope, the strain is short rod-like and gram positive, has no flagellum, and is asporulate. When cultured on a solid medium, the Lactobacillus plantarum tlj-2014 forms a white colony, which has a smooth surface, and is dense and in a circular morphology with a regular edge.
[0017] The physiochemical properties include hydrogen peroxidase (−), gelatine liquefication (−), indole test (+), mobility (−), gas from fermentation (−), nitrite reduction (−), gas from fermentation (−), hydrogen sulfide production (−), and growth in MRS medium pH 4.0 (+).
Example 2
Screening of the Strain
[0018] The Lactobacillus plantarum tlj-2014 according to the present invention was screened from the original starting strain Lactobacillus plantarum L after mutagenesis, and the original starting strain Lactobacillus plantarum L was collected by Li Zheng from the ensilage in a sheep breezing farm in Yanchi, Ningxia on Sep. 15, 2013.
[0019] When grown in a MRS medium with glucose, the starting strain had a lactic acid production rate of 1.5 g/L/d, almost stopped growing when the culture medium reached pH 3.5, and had a decomposition rate for sodium nitrite of 0.34 mg/h/kg of Chinese cabbage.
[0020] In order to improve the lactic acid production rate, the acid tolerance, and the nitrite decomposition rate, the strain was subjected to DES and NTG mutagenesis sequentially. After mutagenesis, the strains were primarily screened in a plate containing MRS supplemented with calcium carbonate, and then the high production strains were secondarily screened by fermentation in a 500 mL shake flask using a biosensor analyzer, to breed a good Lactobacillus plantarum strain. Subsequently, passage test was carried out to evaluate the genetic stability. The specific operations were as follows.
1. Breeding by DES Mutagenesis
[0021] (1) The Lactobacillus plantarum L was picked up by using an inoculating loop from the test-tube slant on a super clean bench, inoculated in a 250 mL conical flask containing 50 mL MRS medium (agar free, and containing 20 g/L of glucose), and incubated at 200 rpm and 37° C. for about 12 hrs, such that the bacteria were in an earlier exponential growth phase.
[0022] (2) 5 mL of the culture was centrifuged at 5000 rpm for 10 min, to collect a bacterial pellet, which was then washed 2 times with saline.
[0023] (3) The bacteria pellet was diluted with a phosphate buffer (pH 7.0) to a density of 10 7 cells/mL of the bacterial suspension.
[0024] (4) 32 mL of a potassium phosphate buffer (pH 7.0), 8 mL of the bacterial suspension, and 0.4 mL DES were fully mixed in a 150 mL conical flask in which a rotor was placed in advance, such that the final concentration of DES was 1% (v/v).
[0025] (5) The reaction was continued for 30 min at 37° C. in a shaker at 150 rpm, and 1 mL of the mixture was removed, to which 0.5 mL of a 25% Na 2 S 2 O 3 solution was added to quench the reaction.
[0026] (6) The bacteria were appropriately diluted, and then 0.2 mL of the finally diluted bacterial suspension was removed and transferred to a flat plate containing a screening medium containing calcium carbonate (MRS medium supplemented with calcium carbonate and containing 100 g/L of glucose). After incubation at 37° C. for 2-3 days, the strain in the screening plate was transferred by replica plating to an LPHMRS medium (a low pH modified MRS medium) having a pH value of 1.5, 1.8, and 2.0 and a screening medium containing sodium nitrite (modified MRS screening medium with 2 g/L of sodium nitrite as a nitrogen source alone).
[0027] (7) After incubation at 37° C. for 2-3 days, the strain that had a large colony, and could grow respectively in the LPHMRS medium and the screening medium containing sodium nitrite was selected. The colony picked up after primary screening in a screening medium containing calcium carbonate was designated as Lactobacillus plantarum L 1.
2. Nitrosoguanidine (NTG) Mutagenesis
[0028] (1) The Lactobacillus plantarum L1 was picked up by using an inoculating loop from the test-tube slant on a super clean bench, inoculated in a 250 mL conical flask containing 50 mL MRS medium (agar free, and containing 60 g/L of glucose), and incubated at 200 rpm and 37° C. for about 12 hrs, such that the bacteria were in an earlier exponential growth phase.
[0029] (2) 5 mL of the culture was centrifuged at 5000 rpm for 10 min, to collect a bacterial pellet, which was then washed 2 times with saline.
[0030] (3) The bacteria pellet was diluted with a phosphate buffer (pH 6.0) to a density of 10 7 cells/mL of the bacterial suspension.
[0031] (4) 10 mL of the bacterial suspension was transferred to a 100 mL conical flask, to which 10 mg NTG was added to formulate an NTG solution at a final concentration of 10 mg/mL, and 4-5 drops of acetone was also added to facilitate the dissolution of NTG.
[0032] (5) The reaction was shaken for 30 min at 37° C. at 200 rpm, and then centrifuged at 5000 rpm for 10 min, to collect a bacterial pellet, which was then washed several times with sterile saline to quench the reaction.
[0033] (6) The bacterial pellet was appropriately diluted, and then 0.2 mL of the finally diluted bacterial suspension was removed and transferred to a flat plate containing a screening medium containing calcium carbonate (MRS medium supplemented with calcium carbonate and containing 100 g/L of glucose). After incubation at 37° C. for 2-3 days, the strain in the screening plate was transferred by replica plating to an LPHMRS medium (a low pH modified MRS medium) having a pH value of 1.5, 1.8, and 2.0 and a screening medium containing sodium nitrite (modified MRS screening medium with 2 g/L of sodium nitrite as a nitrogen source alone).
[0034] (7) The strain that had a large colony, and could grow respectively in the LPHMRS medium and the screening medium containing sodium nitrite was selected. 100 colonies meeting the above criteria were picked up after primary screening in a screening medium containing calcium carbonate.
3. Secondary Screening by Shake Flask Culture
[0035] (1) The Lactobacillus plantarum was picked up by using an inoculating loop respectively from each of the test-tube slants on a super clean bench, inoculated in a 250 mL conical flask containing 50 mL MRS medium (agar free, and containing 100 g/L of glucose), and incubated at 200 rpm and 37° C. for about 15 hrs, such that the bacteria were in a middle exponential growth phase.
[0036] (2) 5 mL of the culture was inoculated respectively into a flat plate containing 50 mL of a liquid screening medium containing calcium carbonate (MRS medium supplemented with calcium carbonate and containing 250 g/L of glucose), and in an liquid LPHMRS medium (a low pH modified MRS medium) having a pH value of 1.5, 1.8, and 2.0 and a liquid screening medium containing sodium nitrite (modified MRS screening medium with 2 g/L of sodium nitrite as a nitrogen source alone) (note: in a 250 mL conical flask). The incubation was continued at 200 rpm and 37° C. for 3-4 days. The production rate of L-lactic acid in the liquid screening medium containing calcium carbonate, the bio-mass in the liquid LPHMRS medium, and the consumption rate of the nitrite in the liquid screening medium containing sodium nitrite were respectively detected daily. After completion of the fermentation, the production rate of L-lactic acid in the liquid screening medium containing calcium carbonate, the bio-mass in the liquid LPHMRS medium, and the consumption rate of the nitrite in the liquid screening medium containing sodium nitrite were compared for the 100 strains.
[0037] (3) The strain having high L-lactic acid production rate, low pH tolerance (the strain could merely grow in a culture medium having a pH not lower than 1.8), and high nitrite consumption rate was selected, and designated as Lactobacillus plantarum L2.
4. Genetic Stability Test
[0038] The Lactobacillus plantarum L2 was continuously slant-subcultured for 10 generations, and the fermentations with each subculture were detected by secondary screening by shake flask culture. It was found through tests that the strain can be continuously slant-subcultured for 10 generations without obvious change in traits and with various performance criteria kept normal, suggesting that the strain is strongly genetically stable. The strain was designated as Lactobacillus plantarum tlj-2014.
Example 3
Tests in 5 L Fermentor
[0039] (1) The Lactobacillus plantarum L2 was picked up by using an inoculating loop from the test-tube slant, inoculated in a 250 mL conical flask containing 50 mL MRS medium (agar free, and containing 150 g/L of glucose), and incubated at 200 rpm and 37° C. for about 12 hrs, such that the bacteria were in a middle exponential growth phase.
[0040] (2) The strain in the exponential phase was inoculated in a 5 L fermentor containing 3 L of a liquid MRS medium (with glucose in an initial concentration of 150 g/L) in an amount of 10%, and incubated at 37° C. and 100 rpm for 8 hrs. The dissolved oxygen was controlled to be 10% (through aeration at a rate of 0.5 L/min) in the earlier exponential phase, and then anaerobic incubation was continued for 63 hrs in the later phase. After fermentation, the Lactobacillus plantarum L2 was shown to have a lactic acid production of 95 g/L. Such a lactic acid production rate can promote the rapid fermentation of pickles.
[0041] (3) The strain in the exponential phase was inoculated in a 5 L fermentor containing 3-L of a liquid LPHMRS medium (pH 1.8 (with glucose in an initial concentration of 50 g/L) in an amount of 10%, and incubated at 37° C. and 100 rpm for 8 hrs. The dissolved oxygen was controlled to be 10% (through aeration at a rate of 0.5 L/min) in the earlier exponential phase, and then anaerobic condition was maintained in the later phase. The fermentation liquor was controlled to be pH 1.8 with 0.5 mol/L sodium hydroxide throughout the entire process, and the incubation time was 48 hrs in total. After fermentation, the biomass of Lactobacillus plantarum L2 was detected to be 2.5 g/L, indicating that the Lactobacillus plantarum L2 could survive in an environment at pH 1.8.
[0042] (4) The strain in the exponential phase was inoculated in a 5 L fermentor containing 3 L of a liquid screening medium containing sodium nitrite (modified MRS screening medium with 2 g/L of sodium nitrite as a nitrogen source alone) in an amount of 10%, and incubated at 37° C. and 100 rpm for 8 hrs. The dissolved oxygen was controlled to be 10% (through aeration at a rate of 0.5 L/min) in the earlier exponential phase, and then anaerobic condition was maintained in the later phase. During the fermentation, 20 g/L of a sodium nitrite solution was fluidically added, depending on the consumption rate of the nitrite. The incubation was continued for 2-3 days. After fermentation, the degradation rate of sodium nitrite by Lactobacillus plantarum L2 during fermentation was calculated. The results showed that the degradation rate of sodium nitrite by Lactobacillus plantarum L2 under these conditions can be up to 563 mg/h/L.
[0043] (5) 10 mL of the strain in the exponential phase was inoculated to 2 kg of pretreated Chinese cabbage, to produce a pickle following the conventional process. The nitrite content in the pickle was determined every 12 hrs. The results showed that throughout the entire fermentation process, the decomposition rate of sodium nitrite by Lactobacillus plantarum L2 is 9.8 mg/h/kg of Chinese cabbage. The nitrite content in the pickle is consistently lower than 5 mg/kg, which is far below the content (20 mg/kg) specified in the national standard GB2714-2003.
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A novel Lactobacillus plantarum and use thereof are disclosed, which fall within the technical field of microorganisms. The Lactobacillus plantarum tlj-2014 is deposited in China General Microbiological Culture Collection Center (CGMCC) under CGMCC Accession No. 9405. With the strain, the lactic acid production rate can be up to 35 g/L/d, and the concentration of lactic acid after 71 hrs of fermentation is up to 95 g/L. The Lactobacillus plantarum is acid tolerant, survives well at pH 1.80, can degrade the nitrite quickly with a decomposition capability of up to 9.8 mg/h/kg, and is tolerant to 1% bile salt. When the strain is used in production of pickles, the nitrite concentration is less than 5 mg/kg throughout the entire fermentation process, which is far below the content specified in the national standard GB2714-2003.
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RELATED APPLICATIONS
This application is a Continuation of U.S. Ser. No.: 08/609,603, filed Mar. 1, 1996, now U.S. Pat. No. 5,926,473 which is a Continuation of U.S. Ser. No.: 08/304,769, filed Sep. 12, 1994, now U.S. Pat. No. 5,521,913, the entire teachings of the patent and application being incorporated herein by this reference.
BACKGROUND OF THE INVENTION
Ethernet switch architecture can be generally divided into two classes: shared memory and multiprocessor systems. In the shared memory architecture, packets, including a header with a source and destination addresses, a data payload, and a check sum portion at the end of the packet, are received at the ports and then forwarded to a system card via a backplane. Here, the packets are buffered in the same central memory, which is accessed by a single central controller. This controller looks at the destination address of the packet, and possibly other information such as source port and destination port, and then, via an address and other look-up tables, determines what should be done with the packet, such as forward, discard, translate or multicast. This forwarding decision is usually an identification of a LAN Card and a port of that LAN Card in the Ethernet switch that connects to the destination address. The address look-up table tells to which port of the Ethernet switch the packet must be sent to reach the addressed device. The packet is then forwarded to that LAN card. The designated LAN card receives the packet and routes it to the destination port where an Ethernet controller chip sends the packet out on the LAN to the addressed device.
The multiprocessing architecture differs in that a local processor is placed on each one of the cards and each one of these processors accesses and maintains its own address table. As a result, when a multiprocessor-type LAN card receives a packet through one of its ports, it first looks at the destination address and then determines to which one of the other ports on one of the other cards it must be sent and then sends the packet to that card via the backplane connecting the cards. If the port address of the packet happens to be on the same LAN card it was received on, the processor simply sends the packet to that local port address and the packet is never transferred on the backplane. This architecture has certain advantages in that since functionality is replicated between the cards, if any one of the cards should fail the Ethernet switch can still function although this also increases cost. One problem is, however, that a substantial amount of processing and software is devoted to ensuring the address tables on each one of the LAN cards are exact duplicates of each other.
Regarding the handling of the packet within the Ethernet switch, two basic methods are conventional. The first is called store and forward switching. In this switching scheme, a particular LAN card will wait until it has received the entire packet before forwarding it to either another LAN card or the central controller card. This allows the LAN card to confirm the packet is valid and uncorrupted by reference to the check sum information contained at the end of the packet. A new approach has been proposed which is called cut-through switching, a purpose of which is to decrease packet latency. Here, not yet fully received packets are forwarded to the destination port and begun to be sent out or broadcasted from the switch before the entire packet has been received. This both decreases packet latency and also decreases the amount of buffering RAM required by each LAN card. The problem with this approach, however, is that if the packet turns out to be invalid or corrupted there is no way to drop the packet since it is already been started to its destination.
SUMMARY OF THE INVENTION
The present invention is directed to a distributed processing archecture which yields most of the simplicity of the shared memory configuration while attaining the advantages and faster operation of multiprocessing configuration. In general, this is achieved by a packet switching system that includes at least two network cards each receiving data packets via a plurality of associated ports, a system card, and an interconnect for connecting the system card to the network cards. Each one of the network cards comprises a plurality of port controllers for sending and receiving packets to and from a corresponding port and a packet processor for buffering packets received by the port controllers. The packet processor then sends destination addresses to the system card via the interconnect and receives forwarding information from the system card. The processor then forwards the packet in response to the forwarding information.
In specific embodiments, the system card comprises an address look-up table correlating destination addresses with the ports of the system. Also, the packet is forwarded to a different one of the network cards indicated by the forwarding information via the interconnect.
The packet processor can be a hardware processor or even a programmable gate array.
In yet another embodiment, the processor begins forwarding the packet in response to the forwarding information before the packet has been entirely received and checks the validity of the packet by reference to check sum information contained in the packet. Future packets from the source port have their validity checked prior to forwarding in response to receiving an invalid packet from the source port.
In general, according to another aspect, the invention features an adaptive cut-through switching method for a packet switching system receiving and sending data from and to a network via a plurality of ports. This method comprises forwarding received packets to destination ports before the packet has been entirely received as in standard cut-through switching. The validity of the packets is, however, checked after the fact. If it turns out that the packet was invalid, future packets from the port are stored and their validity checked prior to forwarding, a store and forward configuration.
In specific embodiments, the integrity of the packets is checked by reference to check sum information contained in the packets.
In other embodiments, only packets, having source addresses from which invalid packets have been previously received, are placed into a store and forward mode. Alternatively, every packet from a port can be placed on store and forward in response to receiving an invalid packet from that port, regardless of its source address.
The above and other features of the invention including various novel details of construction and combinations of parts, and other advantages, will now be more particularly described with reference to the accompanying drawings and pointed out in the claims. It will be understood that the particular method and device embodying the invention is shown by way of illustration and not as a limitation of the invention. The principles and features of this invention may be employed and various and numerous embodiments without the departing from the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
In the accompanying drawings, like reference numerals refer to the same parts throughout the different views. The drawings are not necessarily to scale and this has instead been placed upon illustrating the principles of the invention. Of the drawings:
FIG. 1 is a block diagram illustrating the general layout of the Ethernet switch of the present invention;
FIG. 2 is a block diagram showing the architecture of a LAN card of the present invention;
FIG. 3 is a block diagram illustrating the architecture of a system card of the present invention; and
FIG. 4 is a flow diagram showing the process steps of adaptive cut-through switching of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Turning now to the figures, the internal architecture of an Ethernet switch constructed according to the principles of the present invention is generally illustrated in FIG. 1 . Here, four LAN cards 100 A- 100 D each have eight Ethernet ports P 1 -P 8 for sending and receiving Ethernet packets. Although four LAN cards are shown specifically, it is generally understood that the number of LAN cards is expandable depending upon system requirements and capabilities. Each of these LAN cards 100 A- 100 D are connected to each other and a system card 200 via a high-speed backplane 20 . Although a backplane interconnect 20 is shown, other interconnects are possible such as crossbar or hierarchial types.
Referring to FIG. 2, a block diagram illustrating the internal architecture of the LAN cards is shown. Each LAN controller 110 A- 110 H sends and receives packets to and from the eight ports, port P 1 -P 8 . Data received into any one of the ports, P 1 -P 8 , is sent out onto the LAN controller bus 105 to a controller-packet bus bidirectional FIFO (first in, first out) buffer 120 . A port controller 115 coordinates the reading and writing by each of the LAN controllers 110 A- 110 H and the FIFO 120 to ensure that no data collisions occur on the LAN controller bus 105 and to drive LED indicators on the card to show port activity. The bi-directional FIFO 120 transfers the data from the LAN controller bus 105 to the packet bus 125 where a hardware packet processor 130 , preferably a programmable gate array or specialty hardware processor, reconstructs the packets in a high speed packet RAM 135 . The packet RAM 135 serves as a packet buffer which stores the packets received in through each of the ports P 1 -P 8 while the packet processor 130 obtains forwarding decisions, such as discard, translate, multicast, or forward to a destination LAN card and port, from the system card 200 . More specifically, the hardware packet processor 130 sends the packet header, which includes source and destination addresses of the received packets now stored in the packet RAM 135 , to the system card 200 on the backplane 20 via the packet-backplane FIFO 140 .
Referring to FIG. 3, the system card 200 receives packet source and destination addresses from each of the LAN cards 100 A- 100 D via the backplane 20 . A backplane arbiter and controller 210 controls access to the backplane 20 by each of the LAN cards to avoid data collisions on the backplane 20 . Packet source and destination information is received from the backplane 20 into the system card 200 via a processor-backplane FIFO 215 . Generally, an address processor 220 , such as a TMS320 signal processor, updates and accesses an address RAM 225 which contains an address look-up table and other forwarding related decision tables including port states. Generally, the address look-up table correlates destination addresses contained in the Ethernet packets with a LAN card and port address of the Ethernet switch. In other words, the look-up tables in the address RAM 225 indicates to which port P 1 -P 8 of which LAN card 100 A- 100 D a particular packet must be forwarded to reach the device indicated by the destination address contained in that packet's header.
The forwarding decision indicating the internal LAN card and port address obtained from the address look-up table in the address RAM 225 by the address processor 220 is sent via the address processor bus 235 through the processor-backplane FIFO 215 and backplane 20 to the requesting LAN card 100 .
Additionally, the system card 200 also contains a system controller which monitors the operation of each one of the LAN cards 100 A- 100 D via the backplane 20 and the status of the address look-up table contained in the address RAM 225 via the address processor bus 235 through the management-address FIFO 240 . Generally, the system controller 230 monitors the health of the Ethernet switch in general, such as the crashing or improper operation of any one of the LAN cards. It also keeps system statistics regarding throughput and packets destinations and sources along with any security considerations. Although, not explicitly shown, a backup system card can be included to increase switch reliability by adding central control redundancy.
Returning to FIG. 2, the forwarding decision is received by the hardware packet processor 130 via the backplane 20 through the packet-backplane FIFO 140 and the packet bus 125 . If the port destination of the packet happens to be local to the particular card, then the packet is transferred to the LAN controller bus 105 via the controller-packet FIFO 120 to one of the LAN controllers 110 A- 110 H for the designated port. If, however, the port destination lies on a different LAN card 100 A- 100 D, then the packet is transferred via the backplane 20 to the designated LAN card where the hardware packet processor 130 of that LAN card transfers the packet to the proper LAN controller 110 on that card.
The present invention generally obtains the advantages associated with the multiprocessing architecture while maintaining the simplicity associated with the shared memory architecture. One of the problems associated with the shared memory architecture is that the entire packet including the data payload must traverse the backplane twice. The packet traverses the backplane when it is first sent from the receiving LAN card to the control card and then when it leaves the control card to go to the particular LAN card which has the address port. In the multiprocessing architecture, the packet is only transferred across the backplane when it must be sent to a different LAN card. Consequently, in some cases, the packet may never enter the backplane in situations in which the source and destination ports are located in the same LAN card. The present distributed processing architecture achieves much of the advantages in this realm as the multiprocessing architecture since the packet's data payload is only transferred across the backplane at most once. It should be noted, however, that the multiprocessing systems do not have to transfer the header across the backplane to obtain a forwarding decision. But, the multiprocessing configuration requires significant intercard traffic to synchronize the information look-up tables, which is not necessary in the present invention.
One advantage of the shared memory architecture has over the multiprocessing architecture is one of simplicity. In the multiprocessing architecture, substantial intelligence must be incorporated into each LAN card to maintain and update the local address look-up table in addition to coordinating between the LAN cards to ensure that the look-up tables are all identical. Here, the intelligence located on each LAN card is only that needed to buffer the packet when it is received, strip off the header and send it to the system card, then receive back the LAN card destination and port, and then send the packet to that LAN card or perform other forwarding decision related processing. As a result, the present invention achieves most of the efficiency of the multiprocessing schemes with cost effectiveness associated with the shared memory architecture.
Adaptive Cut-Through Switching
Turning now to FIG. 4, an adaptive cut-through switching process is described with reference to the hardware architecture shown in FIGS. 1-3. Packets received in through the ports P 1 -P 8 of a LAN card 100 are accumulated in the packet RAM 135 under control of the packet processor 130 in step 405 . As soon as the header of a particular packet has been completely received, the packet processor 130 sends the header information via the backplane to the address processor 220 contained on the system card 200 step 410 . The address processor 220 returns the forwarding decision to the packet processor 130 . The packet processor 130 then begins forwarding the not yet fully received packet contained in the packet RAM 135 to the packet processor of the destination LAN card in step 415 where the packet is started to be sent out the destination port to the addressed device. This occurs before the packet is fully received at the source port. In this way, the present invention operates somewhat the same as convention cut-through switching structures. The packet processor, however, checks the validity of the packet once the check-sum information has been received in step 420 even though the packet is already on its way to its destination device. If it turns out that the packet was in fact valid, the particular port remains in a cut-through switching status in which the packets are forwarded as soon as the forwarding decision is received by returning to step 405 . If, however, it turns out that the packet was invalid, then the entire port is placed in a probationary status of the store and forward mode in the preferred embodiment. Alternatively, only the packets of the particular source address that exhibit invalidity or corruption could be placed into a store and forward mode, rather than the entire port. This second approach is most applicable where a particular sending device, rather than the cabling, is the basis of the packet corruption.
A port placed on probation is essentially converted to the store and forward switching. That is, as the packet is received through the LAN controller of the port, which has been placed on probation, the entire packet is accumulated in the packet RAM 135 in step 430 and its validity checked by reference to the check sum in step 435 before it is forwarded to its destination card and port in step 440 . If it turns out the packet is invalid then the packet processor 130 simply discards that packet without forwarding it. Finally, in step 445 , the packet processor determines whether ten consecutive valid packets have been received from a particular port. If ten consecutive valid packets have been received, the port is removed from probationary status and returned to a cut-through configuration.
The present invention essentially yields the advantages associated with both cut-through switching and store and forward switching. That is, in a properly operating local area network, most of the packets will in fact be valid and the latency associated with the check sum checking is unnecessary. In most cases, the present invention. entirely avoids this latency by essentially defaulting to cut-through switching as long as the transmission rate of the destination port is less than or equal to the rate of the source port. For a particular port receiving garbage either through the improper operation of a device attached to that port or some corruption in the cabling in that port, the present invention insulates the rest of the LAN by placing that port, or in some situations only packets with a particular source address, in a store and forward mode so that invalid packets will be dropped before they are forwarded or broadcasted through the LAN. Certain types of packets such as broadcast packets are always placed in a store and forward mode, however, since they involve every port. This helps to avoid broadcast storms.
While this invention has been particularly shown and described with references to preferred embodiments thereof, 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 defined by the appended claims.
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A packet switching system includes at least two network cards each receiving data packets via a plurality of associated ports, a system card, and an interconnect for connecting the system card to the network cards. Each one of the network cards comprises a plurality of port controllers for sending and receiving packets to and from a corresponding port and a packet processor for buffering packets received by the port controllers. The packet processor then sends destination addresses to the system card via the interconnect and receives forwarding information from the system card. The processor then forwards the packet in response to the forwarding information. The processor begins forwarding the packet in response to the forwarding information before the packet has been entirely received and checks the integrity of the packet by reference to check sum information contained in the packet as in cut-through switching. Future packets from the source port have their validity checked prior to forwarding in response to receiving an invalid packet from the source port as in store and forward switching.
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The present application is a divisional of U.S. patent application Ser. No. 10/389,377, filed Mar. 14, 2003 now U.S. Pat. No. 6,763,974.
FIELD OF THE INVENTION
The present invention relates to a flow switch in a fuel dispenser that is adapted to operate in high flow and low flow situations.
BACKGROUND OF THE INVENTION
In a typical transaction, a consumer may drive a vehicle up to a fuel dispenser in a fueling environment. The consumer arranges for payment, either by paying at the pump, paying the cashier with cash, using a credit card or debit card, or some combination of these methods. The nozzle is inserted into the fill neck of the vehicle and fuel is dispensed into the gas tank of the vehicle. Displays on the fuel dispenser track how much fuel has been dispensed as well as a dollar value associated with the fuel that has been dispensed. The customer relies on the fuel dispenser to measure the amount of fuel dispensed accurately and charge the customer accordingly. One method customers sometimes use to control costs is to pay for a preset amount of fuel based on a dollar or volume amount. Regulatory requirements, namely Weights & Measures, require that these customers receive all of the fuel for which they have paid to a highly accurate degree.
Operating behind the scenes of this process are valves that open and close the fuel flow path and a flow meter that measures the amount of fuel dispensed. The purpose of the flow meter is to measure accurately the amount of fuel that is being delivered to the customer so that the customer may be billed accordingly and inventory tracking may be undertaken. As noted, for preset dollar or volume transactions, the consumer relies on the flow meter to measure the fuel dispensed so as to know when to terminate the fuel flow. Some meters are inferential meters, meaning that the actual displacement of the fuel is not measured. Inferential meters have some advantages over positive displacement meters. Chief among these advantages is that inferential meters typically are smaller than positive displacement meters. One example of an inferential meter that may be used is described in U.S. Pat. No. 5,689,071, entitled “WIDE RANGE, HIGH ACCURACY FLOW METER.” The '071 patent describes a turbine flow meter that measures the flow rate of a fluid by determining the number of rotations of a turbine rotor located inside the flow path of the meter.
As fluid enters the inlet port of the turbine flow meter in the meter of the '071 patent, the fluid passes across two turbine rotors, which causes the turbine rotors to rotate. The rotational velocity of the turbine rotors is sensed by pick-off coils. The pick-off coils are excited by an a-c signal that produces a magnetic field. As the turbine rotor rotates, the vanes on the turbine rotors pass through the magnetic field generated by the pick-off coils, thereby superimposing a pulse on the carrier waveform of the pick-off coils. The superimposed pulses occur at a repetition rate (pulses per second) proportional to the rotors' velocity and hence proportional to the measured rate of flow.
A problem may occur when using a turbine flow meter. When fuel flows across the rotors, the rotors acquire some rotational momentum. When the fuel flow stops, the rotational momentum causes the turbine rotors to continue to rotate, despite the absence of fuel flow. This continued movement causes the turbine flow meter to continue generating measurement signals as if fuel were still flowing. The control system that receives the measurement signals from the pick-off coils of the turbine flow meter continues to register fuel flow falsely.
A solution to the aforementioned problem must be found to use a turbine flow meter as an accurate flow meter in a fuel dispenser. The present invention provides a solution to this problem.
The fact that not all valves that open and close the fuel flow path are well suited for preset cost or preset volume transactions is also of concern when designing fuel dispensers. Typically, to assist consumers in dispensing a fuel amount corresponding to the preset amount, some fuel dispensers are equipped with a two stage valve that allows high flow conditions throughout the majority of a fueling transaction and slow flow conditions at the terminating portion of the transaction. In slow flow conditions, the rate of fuel being dispensed slows dramatically to enable the dispenser to hit the predetermined volume or desired monetary amount. The slow flow portion of a preset transaction generates a consistent flow-rate so that the two stage valve may be de-energized at the proper time to achieve the desired termination point. In this manner, the consumer may stop squeezing the nozzle handle at the appropriate time when the desired amount of fuel is dispensed. To date, the two-stage valves that achieve the slow flow and high flow conditions work reasonably well, but may not be optimized to interact with inferential flow meters. Thus, any solution that improves the use of an inferential flow meter should also address this concern.
SUMMARY OF THE INVENTION
The present invention provides a technique through which a control system in a fuel dispenser is cognizant of when fuel is flowing so that the control system may ignore extraneous signals from a flow meter. This allows the use of inferential turbine flow meters in fuel dispensers without the risk of a false reading in the amount of fuel dispensed. This technique is achieved by providing a dual piston/poppet flow switch in the fuel path within the fuel dispenser that works well in both slow flow and high flow conditions.
The dual piston/poppet flow switch acts as a valve. The valve operates in one of three modes. The first mode is the fully closed mode where both pistons are closed and no fuel flows through the valve. The valve has an optional indicator that informs the fuel dispenser control system if the valve is in this mode. The second mode is a slow flow open mode. In this mode, a secondary or bypass fuel path is open and fuel flows relatively slowly through the valve. The indicator, if present, tells the control system that the bypass fuel path is open and thus, the control system knows to accept inputs from the flow meter as non-spurious. The third mode is a high flow open mode. In this mode, a primary fuel path is open concurrently with the secondary fuel path, and fuel flows quickly through the valve. Because the secondary fuel path is open, the indicator, if present, tells the control system to accept input from the flow meter. The two fuel path arrangement helps optimize the valve for use with an inferential flow meter in slow flow and high flow situations regardless of the existence of the indicator. The indicator helps the control system of the fuel dispenser know when to accept inputs from the flow meter.
The valve has a housing with a primary fuel flow path on a primary axis of the housing. The primary fuel flow path is blocked by a normally closed primary piston. The primary piston is kept normally closed by a primary spring. A secondary fuel flow path routes around the primary piston. The secondary fuel flow path is blocked by a normally closed secondary piston. The secondary piston is likewise kept normally closed by a secondary spring. The force required to open the secondary piston is comparatively less than that required to open the primary piston. The secondary piston is also connected to a magnet or other position sensible element that acts as the indicator such that movements of the secondary piston may be detected.
In use, the valve initially receives fuel at a slow rate. This fuel hits the primary piston and is blocked. The fuel is thus shunted into the secondary fuel flow path where the fuel encounters the secondary piston. The secondary spring on the secondary piston is weak enough such that the slow rate of fuel is sufficient to compress the secondary spring, thereby opening the secondary fuel flow path. Opening the secondary piston moves the position sensible element such that a sensor may detect the movement of the position sensible element. The rate of fuel flow increases until the pressure on the primary piston is enough to compress the primary spring, thereby opening the primary fuel flow path. Fuel then flows through both the primary fuel path and the secondary fuel path during the majority of the fueling transaction.
As the fueling transaction ends, the process is reversed. The fuel flow rate slows, lowering the pressure on the primary piston. The primary spring closes the primary piston, leaving the secondary fuel path open. When the fuel flow is terminated, such as at the end of the transaction, the pressure on the secondary piston abates, and the secondary spring closes the secondary piston. The closing of the secondary piston moves the position sensible element, and the control system is informed to ignore further signals from the flow meter. Even when fuel flow is terminated abruptly and both pistons close at the same time, the movement of the position sensible element informs the control system to ignore further signals from the flow meter.
In exemplary embodiments, the indicator may be a Hall Effect sensor, an ultrasonic sensor, a magnetic reed switch, or the like, so as to help track the movement of the secondary piston.
Those skilled in the art will appreciate the scope of the present invention and realize additional aspects thereof after reading the following detailed description of the preferred embodiments in association with the accompanying drawing figures.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawing figures incorporated in and forming a part of this specification illustrate several aspects of the invention, and together with the description serve to explain the principles of the invention.
FIG. 1 illustrates a fuel dispenser involved in a fueling transaction;
FIG. 2 illustrates a partial front view of a fuel dispenser including its display;
FIG. 3 illustrates a schematic view of a first embodiment of the fuel flow components of the fuel dispenser;
FIG. 4 illustrates a schematic view of a second embodiment of the fuel flow components of the fuel dispenser;
FIG. 5 illustrates a first embodiment of the valve of the present invention in a first, closed position;
FIG. 6 illustrates the embodiment of FIG. 5 in a second, partially open position;
FIG. 7 illustrates the embodiment of FIG. 5 in a third, fully open position;
FIGS. 8A and 8B illustrate in a flow chart the process of using the valve of the present invention; and
FIG. 9 represents an exploded view of the primary piston with a relief valve illustrated.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The embodiments set forth below represent the necessary information to enable those skilled in the art to practice the invention and illustrate the best mode of practicing the invention. Upon reading the following description in light of the accompanying drawing figures, those skilled in the art will understand the concepts of the invention and will recognize applications of these concepts not particularly addressed herein. It should be understood that these concepts and applications fall within the scope of the disclosure and the accompanying claims.
The present invention is directed to a valve that preferably operates in a fuel dispenser to acknowledge slow and high flow conditions. Before the valve is disclosed, an overview of a fueling system is herein presented. The novel structure of the valve is discussed beginning at FIG. 5 below.
FIG. 1 illustrates a typical fueling environment 10 with a vehicle 12 being fueled by a fuel dispenser 14 . The fuel dispenser 14 includes a housing 16 with a hose 18 extending therefrom. The hose 18 terminates in a manually operated nozzle 20 adapted to be inserted into a fill neck 22 of the vehicle 12 . Fuel flows from an underground storage tank (not illustrated) through the fuel dispenser 14 , out through the hose 18 , down the fill neck 22 to a fuel tank 24 as is well understood. The fuel dispenser 14 may be the ECLIPSE® or ENCORE® sold by assignee of the present invention or other fuel dispensers as needed or desired such as that embodied in U.S. Pat. No. 4,978,029, which is hereby incorporated by reference in its entirety.
The front of the fuel dispenser 14 is illustrated in FIG. 2 . The fuel dispenser 14 may have a video display 26 proximate the top of the housing 16 and a second display 28 at eye level. The second display 28 may be associated with auxiliary information displays relating to an ongoing fueling transaction such as a number of gallons of fuel dispensed 30 and a price 32 corresponding to the fuel dispensed. The displays 26 , 28 , 30 , 32 may include video capable screens or liquid crystal displays (LCDs) as needed or desired.
The present invention is well suited for use inside the housing 16 of a fuel dispenser 14 . Specifically, the present invention is well suited for positioning in the fuel path of the fuel dispenser 14 as better illustrated in FIG. 3 . Fuel may travel from the underground storage tank (UST, not illustrated) via a pipe 34 , which may be a double walled pipe as is conventional in the fueling industry. An exemplary underground fuel delivery system is illustrated in U.S. Pat. No. 6,435,204, which is hereby incorporated by reference in its entirety. Pipe 34 may pass into the housing 16 through a shear valve 36 . A two-stage valve 37 may be positioned in the fuel line. The two-stage valve 37 may be closed, such as when no fuel is flowing; open to a first degree, such as a slow flow condition; or open to a second degree, such as a high flow condition. An exemplary two-stage valve is illustrated in U.S. Pat. No. 3,724,808, which is hereby incorporated by reference in its entirety.
In most fuel dispensers 14 , a submersible turbine pump associated with the UST is used to deliver fuel to the fuel dispenser 14 . Some dispensers 14 may be self-contained, meaning fuel is drawn to the fuel dispenser 14 by a pump controlled by a motor (neither shown) positioned within the housing 16 . A valve 40 , according to the present invention, may be positioned upstream of a flow meter 38 . Alternatively, the valve 40 may be positioned downstream of a flow meter 38 (see FIG. 4 ). The flow meter 38 and valve 40 are positioned in a fuel handling chamber 42 of the housing 16 as is well understood. The fuel handling chamber 42 is isolated from any sparks or other events that may cause combustion of fuel vapors as is well understood in the fueling industry.
The flow meter 38 and valve 40 communicate through a barrier 44 to a control system 46 positioned within an electronics chamber 48 . An exemplary two-chambered fuel dispenser 14 is described in U.S. Pat. No. 4,986,445, which is hereby incorporated by reference in its entirety. The control system 46 may be a microcontroller, a microprocessor, or other electronics with associated memory and software programs running thereon as is well understood. The control system 46 controls other aspects of the fuel dispenser 14 , such as the displays 26 , 28 , 30 , 32 and the like, as is well understood. While not shown explicitly, it should be appreciated that the two-stage valve 37 is controlled by the control system 46 . Specifically, the control system 46 can command the two-stage valve 37 to close, partially open, or open all the way to vary fuel flow rates between no flow, slow flow and high flow states.
The valve 40 of the present invention is illustrated in FIGS. 5-7. The valve 40 of FIG. 5 is in a closed position such that no fuel flows through the valve 40 . The valve 40 includes a housing 50 that is formed from a material that does not corrode in the presence of hydrocarbons or has been treated to avoid corrosion. A primary piston 52 is positioned within the housing 50 . The primary piston 52 is held in its normally closed position by a primary spring 54 . An o-ring 56 may be used to help ensure a tight seal between primary piston 52 and housing 50 .
A secondary piston 58 is likewise present. The secondary piston 58 is held in its normally closed position by a secondary spring 60 . The secondary piston 58 is connected to a position sensible element 62 . A sensor 64 is positioned proximate the housing 50 of the valve 40 and is used to sense the position of the position sensible element 62 . The sensor 64 communicates with the control system 46 to indicate the position of the secondary piston 58 . In an exemplary embodiment, the position sensible element 62 is a magnet and the sensor 64 is a Hall Effect sensor. Alternative position sensible element 62 /sensor 64 combinations include, but are not necessarily limited to: magnetic-reed switches, ultrasonic, and capacitive combinations.
The valve 40 will be in the fully closed position illustrated in FIG. 5 when the two-stage valve 37 is closed. This represents those times when no fuel is supposed to flow through the fuel dispenser 14 . In a preferred embodiment, the force required to compress the secondary spring 60 is lower than the force required to compress the primary spring 54 . Specifically, the secondary spring 60 is adapted to compress during a slow fuel flow condition, such as when the two-stage valve 37 is open to a slow flow mode. The primary spring 54 is adapted to compress during a high fuel flow condition, such as when the two-stage valve 37 is open to a high flow mode.
The valve 40 is illustrated in a partially open mode in FIG. 6 . As illustrated, secondary spring 60 has compressed due to pressure on the secondary piston 58 . Compression of the secondary spring 60 opens the secondary or bypass fuel path (noted variously by arrows 66 ). Additionally, the movement of the secondary piston 58 that compressed the secondary spring 60 causes the position sensible element 62 to move such that the sensor 64 detects the movement and sends a signal indicative of the movement to the control system 46 . The control system 46 , upon receipt of the signal indicating movement of the position sensible element 62 , begins accepting input from the flow meter 38 and registering the flow of fuel through the fuel dispenser 14 .
The valve 40 is illustrated in a fully open mode in FIG. 7 . When the two-stage valve 37 fully opens, the fluid pressure builds up in valve 40 to the point where the primary spring 54 is forced to compress. This opens the primary fuel path (shown variously by arrows 68 ) and allows fuel to flow through the fuel dispenser 14 at a high flow rate.
The use of the valve 40 is better explicated with reference to the flow chart of FIGS. 8A and 8B. Initially, a consumer arrives and pre-pays for fuel (block 100 ). Pre-payment for fuel may be paying for a certain dollar amount of fuel. For example, an individual may wish to pre-pay for ten dollars of fuel. This pre-payment may be by way of credit card, debit card, or cash. In contrast, a non-preset amount of fuel may be purchased. This typically occurs when the consumer desires to fill up the vehicle and is not sure how much fuel may be required to do so. The consumer then inserts the nozzle 20 into the fill neck 22 and initiates fuel flow (block 102 ), such as by squeezing the handle on the nozzle 20 . Squeezing the handle causes the two-stage valve 37 to open partially (block 104 ). This allows fuel to flow through the fuel dispenser 14 to the valve 40 where it exerts pressure on the primary piston 52 and the secondary piston 58 . However the amount of pressure is relatively low, so only the secondary spring 60 compresses, opening the secondary fuel path 66 (block 106 ). As the secondary fuel path 66 opens, the position sensible element 62 moves and is detected by the sensor 64 , which reports the movement to the control system 46 (block 108 ). The control system 46 begins accepting the input signal from the flow meter 38 (block 110 ). Fuel is then dispensed in a slow flow state (block 112 ). Slow flow rates range, in an exemplary embodiment, between zero and two gallons per minute (gpm) and preferably approximately 0.25 gpm.
After a small amount of time, on the order of five seconds or less, the two stage-valve 37 opens fully (block 114 ). This allows more fuel to flow through the fuel dispenser 14 to the valve 40 . The volume of fuel is now great enough to exert enough pressure on the primary piston 52 to cause the primary spring 54 to compress, thereby opening the primary fuel path 68 (block 116 ). Fuel is then dispensed in a high flow state (block 118 ).
In due course, the amount of fuel that the fuel dispenser 14 has dispensed will approach that paid for by the pre-payment of block 100 (block 120 ). As the transaction nears completion, the two-stage valve 37 closes partially (block 122 , FIG. 8 B). For example, if the consumer paid for ten dollars of fuel, the two-stage valve 37 may close partially when the amount total reaches nine dollars and eighty cents ($9.80). This slows the amount and volume of fuel that reaches the valve 40 , thereby reducing the pressure against the pistons 52 and 58 . As the pressure has been reduced on the primary piston 52 , the primary spring 54 decompresses and closes the primary fuel path 68 (block 124 ). Fuel continues to be dispensed in the slow flow state (block 126 ).
The consumer may continue to squeeze the handle on the nozzle 20 as the final ounces of fuel are dispensed into the fill neck 22 . Once the pre-paid amount of fuel has been dispensed, the two-stage valve 37 closes (block 128 ). This stops the flow of fuel to the valve 40 (block 130 ), thereby reducing the pressure on the pistons 52 and 58 . With no pressure on the secondary piston 58 , the secondary spring 60 decompresses and closes the secondary fuel path 66 (block 132 ). The sensor 64 detects the movement of the position sensible element 62 that results from the movement of the secondary piston 58 and informs the control system 46 of the movement (block 134 ). The control system 46 then stops accepting input from the flow meter 38 (block 136 ). This prevents spurious signals from the flow meter 38 that may be the result of rotational momentum or the like from being reported as part of a transaction.
It should further be appreciated that the valve 40 may have a relief valve to comply with the appropriate UL requirements for power operated dispensing devices for petroleum products, such as UL 79 paragraph 20.1 and UL 87 paragraph 10.1. More detail on this is seen in FIG. 9 . FIG. 9 illustrates an exploded view of the piston 52 into which the relief valve is incorporated. Specifically, piston 52 may be associated with a valve body 200 , a relief valve 202 , a poppet head 204 , the o-ring 56 , the primary spring 54 and a washer 206 . Thus, the relief valve 202 sits in the middle of the poppet head 204 . In an exemplary embodiment, the relief valve 202 has an expanded mandrel set-up as is well understood in the art.
Those skilled in the art will recognize improvements and modifications to the preferred embodiments of the present invention. All such improvements and modifications are considered within the scope of the concepts disclosed herein and the claims that follow.
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A dual piston/poppet valve in a fuel dispenser works with a two-stage valve to help eliminate errors from an inferential flow meter. When the two-stage valve opens partially, a secondary fuel path is opened in the dual piston/poppet valve. A sensor detects the opening of the secondary fuel path and reports its opening to a control system. The two-stage valve opens fully and a primary fuel path is opened concurrently. During transaction completion, the two-stage valve partially closes, resulting in the closing of the primary fuel path. When the two-stage valve closes completely, the secondary fuel path closes. The sensor detects the closing of the secondary fuel path and reports the closing to the control system. Based on the outputs of the sensor, the control system accepts or declines input from a flow meter.
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FIELD OF THE INVENTION
This present invention relates in general to coupon reading systems, and more particularly to a novel coupon validation terminal for extracting bar code information from a coupon and in response indicating either a win or a loss, or voiding the coupon in the event that it is invalid.
BACKGROUND OF THE INVENTION
Annually, millions of dollars worth of coupons are distributed by retail businesses to attract new customers and encourage more purchases from existing customers. Although coupons are a successful way to promote, they are fraught with serious problems which negate the total effectiveness of the coupon program. For example, coupons may be redeemed by customers well before or after their valid dates, and in many cases whole books cf coupons may be redeemed at one time regardless of the valid date on the coupon. Mystery prizes or discounts (often concealed by a concealment device which is scratched off to reveal the prize won or discount to be received) are often illegally and fraudulently misused in order to reveal the prize to the retailer before the customer is given the coupon. Coupons which have a concealment device to conceal a winning prize are also often fraudulently redeemed by dealers/franchisers. Coupons distributed by one retailer are often redeemed by his or her competitors. Millions of potential promotional dollars have been lost by the promoting companies because of these fraudulent practices.
The need exists for ensuring that coupons will be redeemed as intended so that the company issuing the coupons fully obtains the benefits of their couponing programs.
Recently, systems have been developed for reading bar codes applied to coupons or tickets for the purpose of validating same.
U.S. Pat. No. 3,937,926 (Jones et al) discloses a bar code reader for sensing a plurality of patterns on a document in a predetermined sequence. The Jones et al Patent provides a general overview of well known prior art bar code readers.
U.S. Pat. No. 4,677,553 (Roberts et al) discloses a lottery ticket device which incorporates sensors for reading a bar code, a printer for indicating a win to the purchaser as well as printing on the bar code a validation mark, and a sensor for determining the presence of the validation mark. The validation information is embedded within a "V" sector of the bar code.
The invention of Roberts et al suffers from the disadvantage that there is no mechanism by which the system is capable of determining whether a coupon has been presented within a valid time frame, with the result that coupons may be redeemed fraudulently by customers well before or after the valid dates, as discussed above.
SUMMARY OF THE INVENTION
In order to overcome the serious problems inherent with coupons and also to add an element of fun and chance to couponing programs, the coupon validation terminal of the present invention incorporates a number enhanced features.
The coupon validation terminal includes a coupon bar cods reader and printer. Coupons are designed for use with the system incorporating a bar code having a validation date and a number or message code. The bar code on the coupon is read by the bar code reader incorporated within the validation terminal. In the event that the coupon is valid, the bar coded number on the coupon read by the bar code reader will match a number previously programmed into a central microcomputer of the validation terminal. The microcomputer software tests the number or code embedded in the bar code to determine if it is a winning coupon.
Upon recognition of a winning number or message incorporated within the coupon bar code, the validation terminal of the present invention prints on the coupon the prize which corresponds to the pre-programmed number or the message incorporated within the coupon's bar code. Otherwise, the validation terminal prints an appropriate "sorry, try again" message.
However, in the event that the coupon presented is not valid (i.e. it is presented prior to or after the period for which the coupon is valid), the validation terminal prints an appropriate "void" message. In this regard, the validation date extracted from the coupon bar code is compared to an internal free running real time clock incorporated within the validation terminal.
Thus, according to the present invention a system is provided for coupon validation which effectively eliminates the possibility of fraudulent redeeming of the coupon outside of a predetermined validation time frame.
In general, according to an aspect of the present invention there is provided a coupon validation system for interpreting coupons presented thereto, each of said coupons incorporating a bar code having a range of validation dates and a message code, said system comprising:
a) a real time clock for maintaining a current time and date record;
b) means for storing one or more winning number codes;
c) means for receiving a coupon presented to said system and in response reading said bar code; and
d) means for comparing said range of validation dates with said current time and date record and in the event said current time and date record is not within said range of validation dates then rejecting said coupon, and in the event said current time and date record is within said range of validation dates then comparing said one or more winning number codes with said message code and in the event they are equal generating a message for indicating that said coupon is a winner, and in the event said one or more winning number codes and said message code are not equal then generating an alternative message for indicating that said coupon is not a winner.
INTRODUCTION TO THE DRAWINGS
The invention is described further, by way of illustration with reference to the accompanying drawings, in which:
FIG. 1 is a perspective view of the coupon validation terminal of the present invention,
FIG. 2 is a block diagram of functional circuitry incorporated within the coupon validation terminal of the present invention,
FIGS. 3A-3D illustrate a series of messages appearing on an LCD display cf the coupon validation terminal on FIG. 1:
FIG. 4 shows the coupon validation terminal of FIG. 1 in an open position;
FIG. 5 is a plan view of a movable scanner in the coupon validation terminal of the present invention;
FIGS. 6A-6C are front elevation views of the movable scanner of FIG. 4 in successive positions;
FIG. 7 is a side elevation view of the scanner of FIG. 4 and a coupon feeder; and
FIG. 8 is a rear perspective view of the movable scanner of FIG. 4.
DETAILED DESCRIPTION OF THE INVENTION
With reference to FIG. 1, the coupon validation terminal 1 is shown for receiving a coupon 3 which is inserted along a horizontal surface 5 beneath a shroud or cover 7 housing a bar cods scanner (FIG. 2). Upon inserting the coupon 3 in the direction designated by arrow 9, a clutch within the cover 7 descends and engages the coupon 3 for positioning the coupon relative to the bar code scanner.
The bar code scanner is mounted on a movable scanner head for scanning the bar code 11 as will be discussed in greater detail below with reference to FIG. 3. To this and, optical sensors are provided for detecting the edges of the coupon 3 and conveying this information to an internal microcomputer for controlling the positioning cf coupon 3 relative to the bar code scanner.
An LCD display 17 and speaker 43 are provided for generating visual and audio message prompts to a user of the system.
Turning to FIG. 2, a microcomputer 21 is shown connected to a voice synthesizer 23, a real time clock 25, a bar graph decoder 27 and a printer and position controller 29. The microcomputer 21 and voice synthesizer 23 are also connected via appropriate interface couplers to a removable memory card 31.
Removable memory card 31 is programmed with data in the form of specific numbers indicative of a winning coupon. Also, memory card 31 stores pre-recorded digital voice message for indicating the type of prize won, discount received, or a message indicating that the coupon redeemer has not won a prize and should try again. This data is accessed by microcomputer 21 periodically during operation of the coupon validation terminal. The data is preferably encoded within removable memory card 31 by a central terminal leasing authority in such a way as to be inaccessible to employees or operators of the terminal. This way, tampering and fraudulent use of the equipment is avoided.
As an alternative to physically removing memory card 31 from the terminal and transporting to a central programming site (i.e. leasing authority), it is contemplated that the leading authority may program the memory card remotely by means of a serial link such as modem and telephone lines.
In operation, optodetectors 35 detect an edge of a coupon, and in response microcomputer 21 generates a control signal to printer mechanism 29 for causing clutch mechanism or roller 33 to engage the coupon 3 and in conjunction with the optodetectors 35 positions the coupon 3 for correct reading of the bar code 11 via bar code scanner 7. The display 17 will simultaneously generate a message such a "READING . . . PLEASE WAIT" (FIG. 3A). Bar code scanner 37 preferably includes a light emitting device 34 for generating light to be reflected off the bar code surface 11, and a light detecting device 41 for detecting variations in reflected light and transmitting the detected variations to bar code decoder 27. In response, bar code decoder 27 formulates a digital code indicative of the range of validation date data encoded within bar code 11 as well as the coupon number data encoded therein and passes this data onto microcomputer 21.
Microcomputer 21 then compares the validation date data with the real time and date information received from real time clock 25. In the event that the date data of coupon 3 indicates that the coupon is valid, microcomputer 21 further compares the coupon number data with the predetermined coupon number stored in the memory card 31. In the event a match, microcomputer 21 activates voice synthesizer 23 to generate an audible message via loudspeaker 43 responsive to predetermined digital messages stored within removable memory card 31, indicating that the coupon redeemer has won a specific prize. At the same time, microcomputer 21 generates control signals for causing printer 29 to print a hard copy indication of the prize won directly on the coupon 3, and for generating a further message via display 17, such as "YOU ARE A WINNER---" (FIG. 3D).
As an alternative, a predetermined time frame may be stored as data within removable memory card 31. The microcomputer 21 can then compare the time frame data rom bar code 11 with the time frame data from memory card 31 and the actual time and date from real time clock 25 and detect therefrom whether or not the coupon is valid.
If, on the other hand, the validation time frame data received from bar code 11 indicates that the coupon is invalid, the microcomputer 21 activates voice synthesizer 23 to so indicate, and generate a message at display 17 such as "EXPIRED DATE", (FIG. 3B). Likewise, printer 29 is activated to print a series of X's on coupon 3 or voiding the bar code 11.
Finally, in the event that the validation time frame data from bar code 11 indicates that the coupon is valid, yet the coupon number data is different from the winning number data stored within removable memory card 31, microcomputer 21 activates voice synthesizer 23 to generate an audible message such as "sorry, try again". At the same time, printer 29 prints a similar message on the coupon 3.
As an alternative, removable memory card 31 may be programmed to store a plurality of specific numbers for comparison with the number stored in bar code 11, in the event that multiple prizes are to be offered. In this case, printer 29 prints onto the coupon a message which corresponds to the specific prize won.
Upon completion of bar code reading and print out, the display 17 generates a message such as "REMOVE TICKET" for prompting a user to extract the coupon 3 from the system, (FIG. 3C).
Thus, each coupon validation terminal is a stand-alone unit with its own microcomputer, coupon feed mechanism, power transformer (not shown), 40 column printer 29, internal clock 25, bar code scanner 37, memory card 31 and plastic or metal packaging or shroud 7.
By providing a removable memory card 31, the validation terminal of the present invention can be updated with new winning numbers and validation date periods as well as new messages to be printed and voices synthesized. The memory cards can be mailed or otherwise sent to various point of sale operators each time there is a change in coupon promotion strategy.
According to a successful prototype of the invention, the real time clock 25 supplies the exact time and day to microcomputer 21. Furthermore, a battery is incorporated into the real time clock 25 that keeps the clock running for at least ten years without a requirement for change of battery.
The voice synthesizer 23 may be used to control recording and play back of digitized voice. The synthesizer 23 can generate preferably up to 16 messages at a digitizing rate of up to 32 kilobytes per second for control of up to 4 megabytes of voice.
LCD display 17 consists of 2 lines by 16 characters for each line. The display s preferably backlit for night view and is controlled by microcomputer 21.
The housing or cover 7 consists of two parts, as shown in FIG. 4. A bottom part holds the printer 29 and bar code scanner 37, and an upper part holds microcomputer 21, speaker 43 and LCD display 17. The upper part is normally closed with a key lock and, when unlocked, the upper part can swivel around the bottom part for service or changing of the removable memory 31.
In operation, microcomputer 21 executes application software for implementing a data storage and winning number algorithm. The software implements two modes of operation.
According to the first mode of operation, all coupons are printed identically (i.e. there is no distinction between coupons). The coupons are provided with a bar code 11 that corresponds to the valid date (one day only), or a valid date interval (e.g. up to one year maximum), which may be determined by the central leasing authority.
The software algorithm allows for drawing of random numbers in up to 9 categories, in which a category is defined by the probability of winning and the prize associated with such winning. For each draw, the leasing authority decides how many categories of winning numbers there will be.
The categories are organized as follows:
Cat 9=lowest category, which has highest probability of winning. It consists of 4 bit numbers, for a total of 16 numbers. The leasing authority decides the probability of winning desired for this category. The available probabilities are:
1 out of 16=6.26%
2 out of 16=12.5%
3 out of 16=18.7%
4 out of 16=25.0%
5 out of 16=32.2%
6 out of 16=37.5%
7 out of 16=43.7%
8 out of 16=50.0%
9 out of 16=56.2%
10 out of 16=62.5%
11 out of 16=68.7%
12 out of 16=75.0%
13 out of 16=81.2%
14 out of 16=87.5%
15 out of 16=93.7%
16 out of 16=100%
Cat 8=next higher category. It consists of 6 bit numbers, for a total of 64 numbers. The leasing authority decides the probability of winning desired for this category. The available probabilities are:
1 out of 64=0.015625=1.56%
2 out of 64=0.031250=3.12%
3 out of 64=0.046875=4.68%
4 out of 64=0.062500=6.25%
Cat 7=next higher category. It consists of 7 bit numbers, for a total of 128 numbers. The leasing authority decides the probability of winning desired for this category. The available probabilities are:
1 out of 128=0.007813=0.78%
2 out of 128=0.015625=1.56%
3 out of 128=0.023439=2.34%
4 out of 128=0.031252=3.12%
Cat 6=next higher category. It consists of 8 bit numbers, for a total of 256 numbers. The leasing authority decides the probability of winning desired for this category. The available probabilities are:
1 out of 256=0.4%
2 out of 256=0.78%
3 out of 256=1.17%
4 out of 256=1.56%
Cat 5=next higher category. It consists of 10 bit numbers, for a total of 1024 numbers. The leasing authority decides the probability of winning desired for this category. The available probabilities are:
1 out of 1024=0.097%
2 out of 1024=0.195%
3 out of 1024=0.292%
4 out of 1024=0.390%
Cat 4=next higher category. It consists of 12 bit numbers, for a total of 4096 numbers. The leasing authority decides the probability of winning desired for this category. The available probabilities are:
1 out of 4096=0.0244%
2 out of 4096=0.0488%
3 out of 4096=0.0732%
4 out of 4096=0.0976%
Cat 3=next higher category. It consists of 14 bit numbers, for a total of 16,384 numbers. The leasing authority decides the probability of winning desired for this category. The available probabilities are:
1 out of 16,384=0.0061%
2 out of 16,384=0.0122%
3 out of 16,384=0.0183%
4 out of 16,384=0.0244%
Cat 2=next higher category. It consists of 16 bit numbers, for a total of 65,536 numbers. The leasing authority decides the probability of winning desired for this category. The available probabilities are:
1 out of 65,536=0.0015%
2 out of 65,536=0.0030%
3 out of 65,536=0.0046%
4 out of 65,536=0.0061%
Cat 1=next higher category. It consists of 18 bit numbers, for a total of 262,144 numbers. The leasing authority decides the probability of winning desired for this category. The available probabilities are:
1 out of 262,144=0.00038%
2 out of 262,144=0.00076%
3 out of 262,144=0.00114%
4 out of 262,144=0.00152%
Cat 0=highest category. It consists of 20 bit numbers, for a total of 1,048,576 numbers. The leasing authority decides the probability of winning desired for this category. The available probabilities are:
1 out of 1,048,576=0.000095%
2 out of 1,048,576=0.000191%
3 out of 1,048,576=0.000286%
4 out of 1,048,576=0.000381%
Once the probability has been decided for each category, all winning tickets will win the same prizes in that category. A category can be "enabled", or "disabled" by means of programming microcomputer 21 via emory card 31, by the leasing authority. A disabled category means that no tickets are participating in that category, i.e. there can be no "wins" in that category). The "enable", "disable" function is programmed in an internal EPROM of microcomputer 21, and cannot be changed, unless the EPROM is also changed.
Consider the following example in which categories 0, 2 and 9 are enabled; cat 0 has one winning ticket, (prize=a car); cat 2 has two winning tickets (prize=a trip to Las Vegas); and cat 9 has sixteen winning tickets (prize=10% discount).
Assuming 10 million tickets are distributed, one ticket may win the grand prize (i.e. the car). This event is not guaranteed, because it is statistically possible that no random draw will produce a winner in the 1 out of 1,048,575 category, when the total number of draws is 10 million.
Two or a few more tickets may win in cat 2 (i.e. the trip). The exact number of winners cannot be guaranteed, because of the random nature of the draw, and the limited number of tickets.
However, all tickets will win the 10% discount, because cat 9 has been enabled with 100% chance of winning.
According to the second mode of operation, the bar code 11 is used to identify the valid date or date interval, and a ticket number. Typically, each ticket will have its own number of up to 6 decimal digits. This number or a subset of it is compared with a predefined "winning" number, (or numbers) stored in the EPROM.
The machine converts internally the ticket's decimal number into a binary representation for faster calculations, and to allow the tickets to participate in any of the nine categories. A category is defined as in mode 1 by the number of binary digits that are used for comparison with the winning number. The highest category will require all 20 bits to match. The next lower category will require the lower 18 bits to match, the next lower category will require the lower 16 bits to match, etc.
In this mode, the leasing authority can decide up to four winning numbers in each category. Each category can be enabled, or disabled, as decided by the leasing authority. This ion mode has the advantage that the number of winning tickets in each category can be tightly controlled, or predicted by the leasing authority, as a function of
a) the winning number or numbers selected
b) the enabled, or disabled categories, and
c) the total number of tickets issued.
Just as in mode 1, all winning tickets in the same category will have the same prize.
Considering the following additional example, there is a single winning number per category, and a predefined winning #=057,912. In the event all tickets have a 6 digit serial number, and 1 million tickets are distributed, Cats 0, 1, 2, 8 and 9 are enabled, with 1 match allowed per category e.g. cat 0, prize=a car; cat 1, prize=a trip; cat 2, prize=a TV; cat 8, prize=$10; cat 9, prize=$1,) then there will be one winner of the car, four winners of the trip, sixteen winners of the TV and 16,384 winner of the $10, and 65,536 winners of $1.
The memory card 31 contains a byte of data indicating the number of categories. Each category consists of three variables. The first variable consists of 2 bytes and indicates a winning population out of a total population. The second byte indicates the total population. The third byte is an index into voice and printer messages, with a maximum of 16 such messages.
Returning to a consideration of the mode of operation of the invention with reference to FIG. 2, the LCD display 17 will initially indicate a READY condition. When a coupon is inserted into the system, optodetectors 35 sense the paper, and generate signals to the microcomputer 21 for fast feeding the paper forward via roller 33, and immediately activating the scanner head movement with backward feed of paper. The scanner 37 detects the bar code 11. If the bar code is not detected, the distal end optodetector 35 will detect the far edge of this coupon, the scanner head gear motor 49 is stopped, the coupon 3 is fed in reverse, and the display 17 and voice synthesizer 23 are activated to generate a TRY AGAIN message (with the LCD backlight). If no try occurs within 1 second, the LCD backlight will go off and the READY message will appear.
If the bar code 11 is detected, the microcomputer 21 compares the date cf the coupon with the current record from time clock 25, (12 characters=6 for start and 6 for end corresponding to day/month/year). There are also six characters for the number that is read that might be or may not be a winner.
There are five different categories. The first category is a number that ends with a specific single digit that can be compared with a number stored in a memory location which, according to the successful prototype was location FF000, FF001, (FF002 functions as a check sum of FF000 and FF001). The second category matches two digits at location FF003, FF004, (FF005 will be check sum). The third category matches 3 digits stored in location FF004. The fourth category matches 4 digit number locations FF006, FF007, FF008, FF009, (FF00A=check sum). The fifth category will be like the others with 5 digits.
Each category match results in a predetermined appropriate message being generated by voice synthesizer 23 and memory locations FF3FE, FF3FF indicate which messages are valid (e.g. messages 1,2,3,4,5, 16 may correspond to FF3FE=00011111, FF3FF=10000000). Location FF3F0 stores a code for allowing the set up of real time clock 25. Location FF3F1 stores a code to allow recording of voice messages. All the data is preferably secured by encryption there of in a well known manner. To encrypt the data, the microcomputer uses a key code stored in location FF3FD.
Of course, the specific memory locations referred to above are illustrative only of the successful prototype of the present invention. Other memory locations and data values may be used in alternative embodiments of the invention.
The scanning and printing apparatus of the invention is shown in greater detail with reference to FIGS. 4-8. More particularly, the scanner mechanism comprises a bar code scanner and A/D converter 37 mounted on a movable carriage that travels laterally along a pair of rail guides 48 under the influence of a small gear motor 49 and linkage 51.
As shown best with reference to FIGS. 6A-6C, the rotational movement of gear motor 49 is translated to lateral movement of scanner 37 by means of the linkage 51. The scanner 37 incorporates an LED emitter/sensor 53 as discussed above with reference to FIG. 2. The emitter/sensor 53 is shown n FIGS. 6A, 6B and 6C traversing the width of coupon 3 for reading the bar code disposed thereon.
As shown in the perspective view of FIG. 8, the scanner 37 is in the form of a miniature printed circuit board for incorporating the emitter/sensor 53 and associated scanner circuitry and analogue-to-digital (A/D) converter 57.
Turning to FIG. 7, the printer mechanism 29 is shown in greater detail comprising a pair of optodetectors 35 for sensing location of the leading edge of coupon 3. The coupon is fed into and out of the printer mechanism 29 by means of a roller 33. In addition, printer mechanism 29 incorporates a ribbon and print head 56 for applying printed messages to the coupon 3 or for voiding the coupon by printing a series of X's through the bar code 11.
In summary, the microcomputer controlled coupon validation terminal of the present invention is expected to virtually eliminate mis-redemption of coupons by use of an internal real time clock coupled with a bar code scanner for detecting time frame data from a coupon and thereby ascertaining whether or not the coupon is valid. The voice synthesis circuit provides a novel and friendly indication to the coupon redeemer as to whether or not he or she has won a prize.
Modifications are possible within scope of this invention as defined by the claims appended hereto.
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A coupon validation system for interpreting coupons presented thereto, each of the coupons incorporating a bar code having a validation date and a message code. The system comprises a real time clock for maintaining a current date record, a memory for storing one or more winning number codes, apparatus for receiving a coupon presented to the system and in response reading the bar code, and a microcomputer for comparing the validation date with the current date record and in the event the current date record is not equal to the validation date then rejecting the coupon, and in the event the current date record is equal to the validation date then comparing the one or more winning number codes with the message code and in the event they are equal generating a message for indicating that the coupon is a winner, and in the event the one or more winning number codes and the message code and are not equal then generating an alternative message for indicating that the coupon is not a winner. The system also includes a voice synthesizer for generating audio messages. The memory is removable and includes data for implementing a voice synthesis algorithm.
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BACKGROUND OF THE INVENTION
The present invention relates generally to the field of power management in computer systems, and in particular to a method and apparatus for ensuring that a pointing device and its associated driver maintain synchronization when the computer system is in a low-power state.
With the increasing popularity of mobile computers, as evidenced by the growth in the market for so-called "notebook" or "laptop" computers, power consumption has become an important consideration for computer designers. Power conservation efforts have been directed at virtually every aspect of such computers, including hardware, firmware and software. For example, most of today's popular processors, such as Intel's Pentium® family of processors, are capable of operating in a low-power mode. In addition, many computers now include power management functionality as part of an installed BIOS (Basic Input-Output System). Software designers are also becoming more power-conscious, writing "green" applications which are themselves power efficient while cooperating with the aforementioned hardware and firmware facilities.
One of the problems faced by computer designers, firmware developers and software developers with respect to power management is how to deal with users. Users present an unpredictable source of potential interference with power management efforts through intentional and unintentional interactions with the computer system, creating conflicts between normal processing and power management processing. For example, a user may be unconsciously moving a pointing device, such as a mouse, a track ball, or a light pen, for no processing-related reason, but such a movement may have the unintended effect of postponing power conservation in many power management schemes.
Another problem may occur when the user initiates power management processing by, for example, pressing the "suspend/resume" button or closing the lid, while the computer is in the middle of processing information from a pointing device. This can result in the pointing device losing synchronization with its associated foreground operating system (OS) device driver, causing the OS device driver to misinterpret or ignore movements of the pointing device when the computer "wakes up" from a suspended condition. A common symptom of such a problem is a lack of correspondence between movements of a mouse and the on-screen cursor.
There is presently no satisfactory solution to the problem of interference with power management in computer systems caused by user interactions with input devices.
SUMMARY OF THE INVENTION
The present invention relates to the control of user input devices in a computer system having a processor capable of selectively operating in at least first and second modes of operation. According to an embodiment of the invention, directed to a computer system having a processor capable of selectively operating in a first and second mode and a user input device managed by a controller, a method for maintaining synchronization between a user input device and an associated device driver includes initiating a transition of the processor from the first mode to the second mode upon occurrence of a predetermined event; detecting a user interaction with the user input device; initiating a transition of the processor back to the first mode; instructing a controller coupled to the user input device to process the user interaction and issue a signal to the processor upon completion; and initiating a transition of the processor back to the second mode upon receipt of the signal from the controller.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram illustrating an embodiment of the present invention.
DETAILED DESCRIPTION
Many modern computer systems, including most battery-powered mobile computers, employ a central processing unit (CPU) capable of selectively operating in either a "normal mode" or a system management mode (SMM mode). In a typical arrangement, occurrence of a predetermined power management event causes the CPU to transition from normal mode to SMM mode for implementing a low-power state of operations. With respect to a typical mobile computer, for example, such an event may be the user pressing a suspend/resume button or closing the lid of the computer.
While in SMM mode, the CPU no longer executes the system's operating system code. Rather, the CPU executes an SMM handler comprising code resident in BIOS firmware. The SMM handler is responsible for managing the system's low-power state by, for example, performing any necessary initialization processing and reactivating the system upon occurrence of some "wake up" event (such as the user again pressing the suspend/resume button or raising the lid of the computer. To reactivate the system, the SMM handler causes the CPU to return to its normal mode, and the CPU resumes executing the operating system code.
FIG. 1 illustrates an exemplary computer system 1 in which an embodiment of the present invention is implemented. Computer system 1 may be virtually any computer system or similar data processing device, including a mobile computer, a desktop PC, and a dedicated network server computer. In the present embodiment, computer system 1 may be configured according to a PS/2 architecture. An example of such a computer is the Compaq LTE 5000; however, this and other embodiments are readily applicable to other types of power-managed computers and data processing devices.
Computer system 1 includes a CPU 2 coupled to a microcontroller 3. In this embodiment, CPU 2 is capable of selectively operating in a normal mode and an SMM mode. During normal mode operations, CPU 2 executes an operating system (not shown) which controls the operations of computer system 1; during SMM mode, CPU 2 does not execute the operating system code, but instead executes an SMM handler 6 comprising code resident in a BIOS (not shown).
In this particular embodiment, microcontroller 3 includes a system management controller 4 and a keyboard controller 5. System management controller 4 and keyboard controller 5 may be implemented, for example, as firmware in separate Hitachi H8 microcontrollers electronically coupled to one another. Alternatively, these components may be implemented in a single Hitachi H8 microcontroller. A chipset 9 is coupled between system management controller 4 and CPU 2. Keyboard controller 5 is capable of asserting a signal to chipset 9 (through system management controller 4) over a dedicated coupling 10.
Keyboard controller 5 may be coupled to a plurality of user input devices, such as PS/2 pointing devices. In this embodiment, for example, keyboard controller 5 is coupled to a keyboard 8 and a mouse 7. Other examples of such user input devices include a light pen and a track ball. When a user of computer system 1 moves mouse 7, keyboard controller 5 translates each unit of physical movement into a three-byte data packet which it sends one byte at a time to CPU 2 for processing by an appropriate OS device driver (not shown). Keyboard controller 5 typically sends a stream of such data packets to CPU 2 representative of a segment of continuous movement of mouse 7.
In this embodiment, where keyboard controller 5 is coupled to a PS/2 pointing device, keyboard controller 5 and an associated OS device driver may attempt to maintain synchronization by respectively decrementing/incrementing counters associated with the transmission/receipt of a given data packet. For example, keyboard controller 5 may initialize a transmission counter to "3" and the OS device driver may initialize a corresponding counter to "0". Upon sending the first byte of a three-byte data packet, keyboard controller 5 decrements its counter to "2"; upon receiving that first byte, the OS device driver increments its counter to 1. Under normal conditions, this continues until keyboard controller 5 has sent all three bytes, at which time its counter is at "0", and the OS device driver has received all three bytes, at which time its counter is at "3".
According to the present embodiment, CPU 2 may be configured to cause both computer system 1 and itself to enter a low-power state upon occurrence of some predetermined power management event. Such an event will result in generation of a system management interrupt (SMI) to CPU 2. Detection of an SMI causes CPU 2 to transition from normal mode to SMM mode, suspending execution of the operating system and initiating execution of SMM handler 6. At this point, SMM handler 6 (executed by CPU 2) controls the operations of computer system 1.
In some cases, a power management event may cause CPU 2 to initiate low-power processing in the midst of a transmission sequence between keyboard controller 5 and CPU 2. When CPU 2 is subsequently reactivated, keyboard controller 5 will typically be reinitialized, including a reset of the above-referenced transmission counter. The OS device driver, on the other hand, will typically not be reinitialized, meaning its transmission counter will still be set to the value it held at the time it was suspended. When the user moves mouse 7 again, keyboard controller 5 may begin transmission of a new three-byte data packet, but the OS device driver may interpret the transmission as a continuation of the earlier transmission, thus putting mouse 7 and its associated OS device driver out of synch.
According to the present embodiment, SMM handler 6 may include instructions for ensuring that mouse 7 and its associated OS device driver remain synchronized while CPU 2 is in its low-power state. While SMM handler 6 is implementing the low-power state, it preferably polls an output port (not shown) of keyboard controller 5 for data. The existence of a byte on the output port indicates the user has moved mouse 7 during low-power processing. To avoid a loss of synchronization, SMM handler 6 may send a command to microcontroller 3 while passing control back to the operating system. In this particular embodiment, the command may instruct keyboard controller 5 to disable mouse 7, thereby ensuring the user cannot generate data packets indefinitely by continuing to move mouse 7. Keyboard controller 5 may also disable any other user input devices coupled to it, including keyboard 8, to close off other possible sources of interfering user input. In addition, the command may instruct keyboard controller 5 to issue an external SMI once it completes sending the current data packet to the OS device driver to notify CPU 2 that it may resume low-power processing. In this embodiment, keyboard controller 5 (through system management controller 4) issues this external SMI as a signal to chipset 9 over dedicated coupling 10. Chipset 9 may in turn generate an SMI to CPU 2 via an SMI# signal line 11.
Assertion of the SMI at CPU 2 causes CPU 2 to again switch from normal mode to SMM mode, once again suspending execution of the operating system and initiating execution of SMM handler 6. Once SMM handler 6 begins execution, it may attempt to determine the cause of the triggering SMI. Although SMM handler 6 had not been executing since completion of the previous SMI (presumably the one that initially triggered the low-power state), SMM handler 6 may nevertheless be configured to retain a record of its activity from SMI to SMI. This may be accomplished in any number of ways known in the art. For example, a "flag" may be set within SMM handler 6 signifying that SMM handler 6 was trying to implement a low-power condition during processing of the last SMI. Then, upon being initiated and detecting that the flag is set, SMM handler 6 may interpret the most-recent SMI as a signal to complete the interrupted processing and automatically resume where it left off. Alternatively, SMM handler 6 may be configured to actively determine the cause of the most-recent SMI before resuming low-power processing, since it is conceivable that some event more critical than a power management event generated the SMI. This type of active determination may be facilitated, for example, by including an indication of the reason for the SMI in the signal generated by chipset 9 to CPU 2. Other methods of determining the reason for a generated SMI are also possible, and fall within the scope of the present invention.
Regardless of the technique used, upon determining that the most-recent SMI is signaling the resumption of low-power processing, SMM handler 6 may resume implementing the low-power state with assurance that no additional data packets will be transmitted by keyboard controller 5 because mouse 7 is now in a known disabled state. In addition to ensuring synchronization of mouse 7 and its OS device driver, disabling the user input devices ensures that a user cannot inadvertently thwart power management by, for example, continuing to move mouse 7 for no processing-related purpose.
Embodiments of the present invention can facilitate power management in computer systems and other data processing devices by ensuring user input devices remain synchronized with their associated OS device drivers during power management. Avoiding such synchronization problems promotes increased user-perceived quality and reliability of power-managed computer systems. Moreover, in contrast to known power management techniques, embodiments of the present invention disable pointing devices during low-power processing to ensure a user does not inadvertently interfere with the power management functions, providing an added benefit of extended battery life.
The foregoing is a detailed description of particular embodiments of the present invention as defined in the claims set forth below. The invention embraces all alternatives, modifications and variations that fall within the letter and spirit of the claims, as well as all equivalents of the claimed subject matter. For example, in another embodiment of the present invention, rather than issuing an SMI to instruct a CPU to resume previously-interrupted low-power processing, a keyboard controller (or an equivalent controller) may set a status bit which is polled by an SMM handler executing periodically. Upon detecting that such a status bit is set, the SMM handler may resume low-power processing in the same manner described above. Persons skilled in the art will recognize that many other alternatives, modifications and variations are also possible.
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In a computer system having a processor capable of selectively operating in a first and second mode and a user input device managed by a controller, a method for maintaining synchronization between a user input device and an associated device driver includes initiating a transition of the processor from the first mode to the second mode upon occurrence of a predetermined event; detecting a user interaction with the user input device; initiating a transition of the processor back to the first mode; instructing a controller coupled to the user input device to process the user interaction and issue a signal to the processor upon completion; and initiating a transition of the processor back to the second mode upon receipt of the signal from the controller.
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FIELD OF THE INVENTION
The present invention relates to quilting machines, and particularly to an apparatus and methods for automatically changing a bobbin on a quilting machine.
BACKGROUND OF THE INVENTION
In quilting machines of various types, threads are applied and manipulated on opposite sides of a fabric to form one or more patterns of stitches. The proper formation of the stitches of each series requires the movement and precise timing of cooperating stitching elements. Some quilts are stitched with continuous patterns along webs of material that is later cut, without the need to start and stop the quilting of a pattern in the midst of a quilted product. Many standard mattress covers are quilted on multi-needle quilting machines in this manner. Other patterns start and stop on a quilted product, which might include a number of discrete disconnected pattern components on a given quilted product. Multi-needle quilting machines can quilt mattress covers in this manner, as described in commonly assigned U.S. Pat. Nos. 5,154,130 and 5,544,599, hereby expressly incorporated herein by reference. Comforters and certain more expensive mattress covers are quilted as single panels on single needle quilting machines in this manner, as described in commonly assigned U.S. Pat. Nos. 5,650,916, 5,685,250 and 5,832,849, hereby expressly incorporated by reference herein. When a pattern starts or stops on a product, at the end of the stitching of a pattern, a tack is usually sewn, thread is cut, and the relative position of the fabric and the stitching elements is changed to sew another stitched pattern on the same or on another product.
Multi-needle quilting machines and some single needle quilting machines for quilting mattress covers and other quilted products having only one outer finished side use a double lock chain stitch. The chain stitch is formed by poking loops of a bottom thread through loops of a top thread, and can be employed using large spools of top and bottom threads, but because the loops are visible on the underside of the product, one side of the product is unattractive. Single needle machines and some multi-needle machines for quilting comforters and mattress covers and other products use a lock stitch. The lock stitch is formed by passing the bottom thread once through each loop of the top thread, which, by taking up the top thread loop so that the thread crossings are essentially within the quilted material, produces a line of stitches that appear the same from both sides. Forming of a lock stitch requires passing the entire bottom thread supply through each top thread loop. As a result, lock stitch machine use small quantities of thread would on a bobbin so that the top thread loop can be hooked and rotated around the bobbin and hence the single strand of bottom thread.
Many lock stitch quilting machines have a common structure in which a reciprocating needle is mechanically coupled to an upper sewing head motor located above a layered fabric. The needle reciprocates through layered fabric and through a needle plate supporting the layered fabric. With a lockstitch quilting machine, a lower sewing head includes a hook drive that is mechanically coupled to a bobbin case containing a spool of thread. The lower sewing head may be linked to and driven by the needle drive motor or by the hook drive motor, synchronized to the needle motion, to move the hook drive around the bobbin case to pick up thread from the spool in synchronization with the motion of the needle and thread below the layered fabric. The thread from the reciprocating needle and the thread from the bobbin case form a lockstitch securing the layers of fabric together in a known manner.
The nature of the lockstitch requires that the bobbin thread be reduced to a minimum size in order to allow the thread from the needle to be rotated about the bobbin case thread to form the stitch. The limited size of the bobbin case limits the quantity of thread that can be stored within the bobbin case. Usually, in commercial lockstitch quilting, some scheme is used to alert a machine operator when there is insufficient thread left on the bobbin to quilt a complete quilted product, so that the operator can change bobbins manually before starting a product. Otherwise, it is necessary for the operator to manually operate the machine to cut thread, tack the stitches if necessary, and change bobbins in the middle of a quilted patter.
When quilting larger workpieces, for example mattress covers, a particular stitch pattern may require more thread than can be stored in a common, commercially available bobbin case. Therefore, the thread spool and bobbin case would have to be changed in the middle of a workpiece quilting cycle. An manual operation to change a bobbin, particularly in the middle of the quilting of a pattern, requires that a machine operator stop the operation of the upper and lower sewing head motors, manually command the quilting machine to move the sewing heads to a maintenance position and remove the bobbin case with the empty thread spool. Thereafter, the machine operator must install a bobbin case with a full thread spool, command the quilting machine to move the sewing heads back to the position where the bobbin thread ran out and reinitiate the stitching cycle. Such a bobbin case changing operation is labor intensive, time consuming, inefficient, extends the time required for part production and thus, adds significant cost to the production of the workpiece.
Therefore, there is a need to provide apparatus and methods for automatically changing a bobbin case on a quilting machine, thereby substantially improving its efficiency.
SUMMARY OF INVENTION
The present invention provides methods and apparatus for operating a quilting machine that are more efficient than known methods and apparatus. The methods and apparatus of the present invention improve the state of automation of a lock stitch quilting machine by reducing the labor required, reducing the time required to stitch patterns and thus, substantially reducing the production of patterns stitched with the quilting machine. The invention is especially useful when stitching large patterns of layered fabric which exceed the amount of thread stored in the bobbin case and require the bobbin case be changed in the middle of stitching the pattern.
In accordance with the principles of the present invention and the described embodiments, the invention provides an apparatus that automatically changes a bobbin case on a quilting machine having a hook drive operatively supporting the bobbin case during a stitching operation. The apparatus includes a bobbin staging station adapted to support at least one bobbin case normally having a full spool of thread, and a carriage movable between the bobbin staging station and the hook drive. A finger is movably mounted on the carriage, and the finger moves a release lever on the bobbin case to an unlock position and clamps the release lever at the unlock position.
In one aspect of the invention, the finger engages a rear side of the release lever and pivots the release lever to the unlock position. In another aspect of the invention, the lever clamps the release lever against a stop, for example, a stop made from a resilient material. In a further aspect of the invention, the finger is operated by a reciprocating cylinder. In a still further aspect of the invention, the carriage is movable in mutually perpendicular directions in moving between the bobbin staging station and the hook drive.
In another embodiment, the present invention includes a method of automatically changing a bobbin case on a quilting machine having a hook drive operatively supporting the bobbin case during a stitching operation. The method first moves a carriage to a position adjacent a first bobbin case mounted on the hook drive. Next the release lever of the first bobbin case is mechanically pivoted to an unlock position, thereby unlocking the first bobbin case from the hook drive. The release lever of the first bobbin case is then mechanically clamped in the unlock position; and the carriage is moved away from the hook drive, thereby removing the first bobbin case from the hook drive. The release lever of the first bobbin case is then unclamped, thereby permitting the first bobbin case to drop from the carriage; and the carriage is moved to a position adjacent a second bobbin case. The release lever of the second bobbin case is mechanically pivoted to the unlock position, and the release lever of the second bobbin case is mechanically clamped at the unlock position. The carriage is then moved to the location adjacent the hook drive; and the release lever of the second bobbin case is unclamped, thereby mounting the bobbin case onto the hook drive.
Thus the method and apparatus of the present invention automatically changes a bobbin case on a quilting machine with the advantages of eliminating the labor, time and cost of changing bobbin cases manually in the middle of stitching a large pattern on a lock stitch quilting machine.
The invention also provides automatic operation of the bobbin change mechanism between the stitching of different patterns, or during the stitching of a pattern by determining the need therefore through, for example, the counting of stitches. The bobbin changes may be performed in sequence with the cutting of the bobbin thread only or the cutting of both top and bottom threads, and/or in sequence with the sewing of tacking stitches before and/or after the thread cut and bobbin change.
Various additional advantages, objects and features of the invention will become more readily apparent to those of ordinary skill in the art upon consideration of the following detailed description of the presently preferred embodiments taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a perspective view of an automatic bobbin changer mounted in relation to known components of a quilting machine in accordance with the principles of the present invention.
FIG. 2 is a perspective view partially broken away of the automatic bobbin changer of FIG. 1, however, the hook drive is not shown in FIG. 2 .
FIG. 3 is another perspective view of the automatic bobbin changer of FIG. 1 and includes a schematic block diagram of control elements operating the bobbin changer.
FIG. 4 is a partial cross-sectional view taken along line 4 — 4 of FIG. 3 and illustrating a first operation of the automatic bobbin changer of FIG. 1 .
FIG. 5 is a side view of the carriage of the automatic bobbin changer of FIG. 1 .
FIG. 6 is a partial cross-sectional view taken along line 4 — 4 of FIG. 3 and illustrating a second operation of the automatic bobbin changer of FIG. 1 .
FIG. 7 is a perspective view of only the bobbin staging station of the automatic bobbin changer of FIG. 1 .
FIGS. 8A-8I illustrate each step of a cycle of operation of the bobbin changer of FIG. 1 .
DETAILED DESCRIPTION OF THE INVENTION
The components of FIG. 1 that are shown in phantom are known quilting machine components that form a lockstitch in a known manner. The layers of fabric 20 to be stitched are laid out on top of a needle plate 22 of a quilting machine. A needle 24 is mounted in an upper sewing head motor and drive (not shown) which is located above a presser foot 28 in a known manner. The needle 24 and thread 25 reciprocate vertically through a hole 26 in the presser foot 28 , through the layers of fabric 20 and then through a hole 30 of the needle plate 22 . When sewing a lockstitch, a lower sewing head motor 34 is mechanically coupled to a hook drive 36 supporting a bobbin case 38 containing a spool of thread (not shown). The lower sewing head motor 34 , in a known manner, moves the hook drive 36 around the bobbin case 38 to pick up thread (not shown) from the spool in synchronization with the motion of the needle 24 and the thread 25 below the layered fabric. The thread 25 from the reciprocating needle 24 and the thread from the bobbin case 38 are thus formed into a lockstitch securing the layers of fabric 20 together.
The motion of the thread 25 with respect to the lower thread from the bobbin case 38 requires that the bobbin case be of a relatively small size. The small size limits the quantity of thread that can be stored in the bobbin case. Consequently, a bobbin case may run out of thread in the middle of sewing the layered fabric 20 , require changing. When a quilting machine control, such as a programmed controller 140 (FIG. 3 ), determines that the spool within the bobbin case 38 is empty, a bobbin changer 40 is commanded by the control to execute a bobbin change cycle. In the bobbin change cycle, a carriage 42 is moved from a rest position, as illustrated, upward to a position opposite the hook drive 36 , and the bobbin case 38 is removed from the hook drive 36 to the carriage 42 . The carriage 42 then moves to a position over a used bobbin tray 44 , and the bobbin case 38 with the used thread spool is dropped into the tray 44 . The carriage 42 then moves into alignment with a bobbin staging station 46 , which is the position illustrated in FIG. 1 . The staging station 46 contains a plurality of bobbin cases 38 each containing a full spool of thread. At the staging station, the carriage 42 picks up one of the full bobbin cases 38 , moves it to a position opposite the hook drive 36 and loads the full bobbin case 38 onto the hook drive. The quilting machine is then ready to resume its sewing operation.
Referring to FIGS. 2 and 3, the automatic bobbin changer 40 has a mounting block 50 that functions to mount the automatic bobbin changer 40 to a lower sewing head base mount 52 (FIG. 1) by means of fasteners 54 . The mounting block 50 is rigidly connected to a first drive 56 , for example, a horizontal cylinder and upper and lower horizontal guides, 58 , 60 , respectively. The horizontal cylinder 56 is a fluid operated cylinder, for example, a cylinder operated with pressurized air and commercially available as part no. TE-021 from Bimba Manufacturing of Monee, Illinois. A horizontal slide 62 is rigidly connected to a distal end of a horizontal cylinder rod 64 extending from the horizontal cylinder 56 . The horizontal slide 62 is also connected to the distal ends of upper and lower rails 66 , 68 that slidingly mount within the respective guides 58 , 60 . Thus, the cylinder 56 operates to translate the horizontal slide 62 back and forth along a first axis of motion, for example, in the horizontal direction.
A second drive, which includes a vertical cylinder 74 , is rigidly mounted at its ends within a C-shaped frame 72 on the horizontal slide 62 . The vertical cylinder 74 is a fluid operated cylinder, for example, a cylinder operated with pressurized air and commercially available as part no. NCY2B6H-1.75 from SMC Pneumatics of Indianapolis, Indiana. A cylinder slide 70 is magnetically coupled to a piston within the cylinder 74 . A vertical guide rail 76 is mounted to an interior portion of the C-shaped frame 72 and, referring to FIG. 4, has a bearing slide 77 slidably mounted thereon. The bearing slide 77 and cylinder slide 70 are rigidly attached to a connecting link or plate 79 , for example, by welding, with fasteners or other appropriate means. The connecting plate 79 is attached to the carriage 42 by fasteners 78 (FIG. 3 ). The assembly of the cylinder 74 , guide rail 76 and connecting plate 79 function to translate the carriage 42 along a second axis of motion, for example, up and down in a vertical direction. Thus, the horizontal cylinder 56 and the vertical cylinder 74 are used to move the carriage 42 along mutually perpendicular axes of motion between the hook drive 36 and the bobbin staging station 46 (FIG. 1 ).
Once the carriage is aligned with either the hook drive 36 or the bobbin staging station 46 , the bobbin case 38 containing the thread spool is transferred to or from the carriage 42 . Referring to FIGS. 4-6, a finger cylinder 80 is mounted in a bore 82 of the carriage 42 , for example, by threads 84 or other appropriate structure. The fluid cylinder 80 is a fluid operated cylinder, for example, a pressurized air operated cylinder with an internal return spring and commercially available as part no. AL2RRO-1/4 from Watson Pneumatics of Cleveland, Ohio. A finger 86 is mounted on a pivot pin 87 within a slot 88 in the forward side 90 of the carriage 42 . When the finger 86 is at its first disengaged position as illustrated in FIG. 4, the outer end or tip 92 of the finger 86 extends slightly beyond the plane of the forward side 90 of the carriage 42 . The inner end 94 of the finger 86 is pivotally mounted to a distal end 96 of the rod 98 extending from the finger cylinder 80 . While the finger 86 may be mounted to the finger cylinder rod 98 with several different constructions, in this embodiment, the inner end 94 of the finger 86 has an elongated slot 100 . A pin 102 extends through the slot 100 and is fixed at its ends to opposite sides of a U-shaped clevis 104 mounted on the distal end 96 of the finger cylinder rod 98 . A stop 106 in the form of a deformable, resilient pad, for example, a rubber pad, is rigidly fixed within the slot 88 of the carriage 42 .
The bobbin case 38 is operatively connected to the hook drive 36 in a known manner. A release lever 108 is pivotally mounted to the front of the bobbin case 38 , and an outward, clockwise pivoting motion of the lever 108 causes a locking tab 110 to translate to the left as viewed in FIG. 4 . The leftward translation moves the locking tab 110 out of a slot 112 of a center shaft 114 of the hook drive 36 . Thus, pivoting the release lever 108 from a first, lock position outward to a second, unlock position, thereby unlocking the bobbin case from the hook drive 36 and permitting the bobbin case 38 to be removed therefrom.
Referring to FIGS. 2 and 3, when the carriage 42 has been moved to its upper, inward position, the carriage 42 is immediately adjacent the hook drive 36 . As illustrated in FIG. 4, the outer end 92 of the finger 86 is positioned immediately adjacent the movable end of the bobbin case release lever 108 located at its lock position. Referring to FIG. 6, actuating the finger cylinder 80 causes the finger cylinder rod 98 to extend, thereby pivoting the finger 86 in a generally counterclockwise direction as viewed in FIG. 6 . As the finger 86 begins to pivot, its outer end 92 engages a rear side 117 of the pivoting lever 108 of the bobbin case 38 . The pivoting finger 86 applies a force against the rear side of the lever 108 , thereby pivoting the release lever 108 outward to the unlock position. The finger 86 holds the release lever 108 in the unlock position by clamping the lever 108 against a stop surface 105 on the stop 106 . Further, the bobbin case 38 is pulled against the forward side 90 of the carriage 42 , thereby securing the bobbin case 38 to the carriage 42 . The release lever 108 is also supported between the upper and lower walls 116 , 118 , respectively, of the slot 88 shown in FIG. 5 . Thus, the bobbin case 38 is now being carried by the carriage 42 ; and by actuating the horizontal cylinder 56 , the bobbin case 38 is removed from the hook drive 36 and carried to another location, for example, to the used bobbin tray 44 (FIG. 1 ).
To release the bobbin case 38 from the carriage 42 , the finger cylinder 80 is actuated so that the finger cylinder rod 98 retracts back into the cylinder 80 , and the finger 86 rotates clockwise as viewed in FIG. 6, to the position illustrated in FIG. 4 . That motion of the finger 86 releases the lever 108 from the stop 106 which allows the lever 108 to return to its lock position as illustrated in FIG. 4; and the bobbin case 38 is released from, and no longer supported by, the carriage 42 .
Referring to FIG. 7, the bobbin staging station 46 has a staging rod 120 with one end rigidly connected to the mounting block 50 . The rod 120 has a distal end 122 with a circular, cross-sectional profile. Immediately behind the distal end 122 , the shaft 120 is relieved or cutaway, beginning at 124 , to form a noncircular, cross-sectional profile. The cutout 126 formed by the noncircular, cross-sectional profile has a flat surface that extends longitudinally along the rod to a location, at 128 , where the circular, cross-sectional profile begins again. A pair of guide rods 130 are rigidly secured at one end to the mounting block 50 . The guide rods 130 are spaced to extend through a cutaway portion 132 in the outer periphery of the bobbin case 38 , thereby maintaining the bobbin case 38 in the desired angular orientation on the staging shaft 120 .
As previously discussed with respect to FIGS. 4-6, with the release lever 108 of the bobbin case 38 pivoted outward to its unlock position, the bobbin case 38 can readily slide over the circular, distal end 122 of the staging shaft 120 . After the bobbin case is mounted on the staging shaft 120 , the lever 108 is released; and as the release lever 108 returns to its lock position, it moves a locking tab into the cutout 126 of the staging shaft 120 , thereby prohibiting the bobbin case 38 from being moved outward past the circular, distal end 122 . A biasing element, for example, a compression spring 134 , has one end mounted in a bore 136 of the mounting block 50 and an opposite end contacts a rear side 138 of the bobbin case 38 . Thus, the spring 134 applies a biasing force to maintain the bobbin case 38 as close as possible to the circular, distal end 122 of the staging shaft 120 .
In use, the quilting machine control 140 (FIG. 3) keeps track of the thread being used from the spool of thread in the bobbin case 38 . The controller 140 typically will be a programmed controller of the quilting machine that contains data of the shapes of the patterns to be quilted, and can contain other parameters for scheduling and operating the machine for different products to be quilted. The quilting machine control 140 is programmed with the length of stitch and keeps track of the relative position of the presser foot 28 with respect to the needle plate 22 representing the thickness of the layer of material 20 being sewn. Therefore, the control 140 is able to determine the amount of thread being used from the bobbin spool with each stitch. The number of stitches can be determined in one of several ways depending on the data available on the quilting machine. For example, each reciprocation of the needle 24 or rotation of the upper sewing motor can be detected and counted by the control 140 . Alternatively, each cycle of the hook drive 36 can be detected directly from the motion of the hook drive or by the operation of the lower sewing head motor 34 . Finally, the number of stitches in a pattern and the amount of thread on a full spool is known and programmed into the quilting machine control 140 . Given the above data or by other methods known in the art, the quilting machine control 140 is able to determine a bobbin stitch count, that is, the number of stitches that can be sewn starting with a full spool of thread on the bobbin before the spool of thread reaches a state at which it should be changed.
When the control 140 determines that a bobbin change is needed, the change may be implemented in one of a number of sequences. A bobbin change may be implemented by determining that the amount of thread left on a bobbin is less than that needed to complete the next scheduled product. When such a determination is made, a bobbin change can be caused to be executed between products, for example, after the pattern of one product has been completed, tack stitches are sewn, and the thread has been cut, but before the pattern is started on the next product. Such a bobbin change can be executed also when a determination that bobbin thread must be changed for another reason, such as a scheduled change in color or thread type for the next product.
A bobbin change may also be caused to be executed by the quilting machine controller 140 , during the quilting of a pattern upon the determination that the thread on the bobbin is running out. When this determination occurs, the control 140 may cause the pattern stitching to stop, the bottom thread from the bobbin to be cut, and the bobbin to be changed, whereupon the pattern stitching is resumed. The thread cutting may involve the cutting of both top and bottom threads just as they would be cut at the end of a pattern, or with only the bottom thread cut.
When all threads are cut, a standard procedure is to stop the machine with the top thread extending from the needle eye through the needle plate hole below the fabric, around the hook and back through the needle plate hole to the last stitch formed in the material. A cutter below the needle plate then typically moves against the threads, displaces the top thread extending from the needle and then cuts both the top thread that extends through the hole in the needle plate from the material and the bottom thread that extends through the hole from the material to the bobbin. Usually it will be desirable to sew a tack in the pattern before cutting the thread. Also, it may be desirable to sew another tack immediately after resuming the stitching of the pattern following a bobbin change.
A bobbin change may be implemented by cutting only the bottom thread. This may be done by stopping the machine, upon a determination by the controller that a bobbin change is necessary in the midst of quilting a pattern, with the needle in the raised position typically above the presser foot, opposite the needle plate from the material, with the top thread released from the hook and the top thread take-up having withdrawn the top thread slack from below the material. With only the bottom thread extending through the hole in the needle plate to the bobbin, the bottom thread can be cut. The sewing of tack stitches before or after the bottom thread is cut may be carried out, but is not always necessary.
During a stitching cycle, the carriage 42 is generally at its lower, inner position, as illustrated in FIG. 8A, to reduce any potential for interference with the hook drive 36 . In order to provide the most efficient bobbin change cycle, since the carriage must be moved from its starting, rest position adjacent the staging shaft 120 to a position adjacent the hook drive 36 , the quilting machine control 140 initiates a bobbin change cycle before it detects a bobbin change stitch count. So that the carriage 42 is ready to effect a bobbin change as soon as the sewing motors and the hook drive 36 stop, the bobbin change cycle is initiated before the detection of a bobbin change stitch count by a period of time substantially equal to the time required to move the carriage 42 from its rest position to a position opposite the hook drive 36 . At that time, the control 140 provides a signal on an output 142 to a horizontal solenoid valve 144 , thereby switching the state of the valve 144 . Pressurized fluid is appropriately ported through the valve 144 between a pressurized fluid source 146 and the horizontal cylinder 56 . The horizontal cylinder 56 is activated to move the horizontal slide 62 and carriage 42 to a lower, outward position as illustrated in FIG. 8 B.
Next, the control 140 provides a signal on an output 152 to a vertical solenoid valve 154 switching the state of the valve 154 . Pressurized fluid is appropriately ported through the valve 154 between a pressurized fluid source 146 and the vertical cylinder 74 . The vertical cylinder 74 is activated to move the carriage 42 to an upper, outward position as illustrated in FIG. 8 C. The control 140 then, again, provides a signal on an output 142 to the horizontal solenoid valve 144 causing the valve 144 to operate the horizontal cylinder 56 to move the horizontal slide 62 and carriage 42 to an upper, inward position immediately adjacent the end of the hook drive 36 as illustrated in FIGS. 4 and 8D.
Substantially simultaneously with the carriage arriving at the upper, inward position of FIG. 8D, the quilting machine control 140 detects the bobbin change stitch count and provides command signals to stop the sewing head motors. Next, the quilting machine control provides a signal on an output 148 to a finger solenoid valve 150 switching the state of that valve. Fluid is ported through the valve 150 to the finger cylinder 80 , thereby actuating the cylinder 80 , rotating the finger 86 and pivoting the release lever 108 outward to the unlock position as previously described. That action disengages the bobbin case 38 from the hook drive 36 (FIG. 6) and clamps the bobbin case with the used spool of thread to the carriage 42 . Next, the quilting machine control 140 provides a signal on the output 142 to the horizontal solenoid valve 144 changing the state of the solenoid valve 144 to reverse the operation of the horizontal cylinder 56 . Thus, the horizontal slide 62 , carriage 42 and bobbin case 38 are moved outward, thereby removing the bobbin case 38 from the shaft 114 of the hook drive 36 . The carriage 42 and bobbin case 38 are moved outward to the position illustrated in FIG. 8 E. Thereafter, the quilting machine control 140 provides an output control signal on the output 152 to a vertical solenoid valve 154 switching the state of the valve 154 and actuating the vertical cylinder 74 to lower the carriage 42 and bobbin case 38 with the used spool of thread to a position immediately over the used bobbin tray 44 as shown in FIG. 8 F.
The quilting machine control 140 then supplies a control signal over the output 148 to the finger solenoid valve 150 switching the state of that valve to reverse the operation of the finger cylinder 80 , thereby rotating the finger 86 back to its initial position (FIG. 4 ). As the finger 86 moves back to its initial position, it releases the lever 108 of the bobbin case 38 ; and the bobbin case 38 with the used spool of thread drops into the used bobbin tray 44 (FIG. 8 G). Next, the quilting machine control 140 provides a control signal over the output 142 to operate the horizontal solenoid valve 144 such that the horizontal cylinder 56 moves the horizontal slide 62 and carriage 42 inward to a position immediately adjacent the bobbin staging shaft station 46 (FIG. 8 H). The quilting machine control 140 then actuates the finger solenoid valve 150 to cause the finger solenoid 80 to again rotate the finger 86 to engage a release lever 108 of a bobbin case 38 having a full spool of thread. The pivoting motion of the finger 86 moves the release lever 108 to the unlock position which unlocks the bobbin 38 from the staging shaft 120 ; and simultaneously, the pivoting finger clamps the release lever 108 against the stop 106 to hold the bobbin case 38 on the carriage. Thereafter, the quilting machine control 140 operates the horizontal and vertical solenoid valves 144 , 154 to cause the respective horizontal and vertical cylinders 56 , 74 to move the carriage 42 carrying the bobbin case 38 with the full spool of thread first, outward to remove the bobbin case 38 from the staging shaft 120 and then, up and inward to a position adjacent the end of the hook drive 36 as shown in FIG. 81 .
As the horizontal slide 62 and carriage 42 carrying the bobbin case 38 with the full spool of thread move inward, the bobbin case 38 is slid over the center shaft 114 of the hook and drive 36 such that the locking tab 110 is placed in alignment with the slot 112 on the shaft 114 . Thereafter, the quilting machine control 140 operates the finger solenoid valve 150 to return the finger 86 back to its rest position, thereby releasing the lever 108 from its unlock position. The lever 108 is spring biased back to its lock position, thereby locking the bobbin case 38 with the full spool of thread on the center shaft 114 . The quilting machine control 140 then provides a command signal to the sewing head motors to initiate the sewing cycle; and substantially simultaneously, the quilting machine control 140 then operates the horizontal solenoid valve 144 to actuate the horizontal cylinder 56 in a manner to move the horizontal slide 62 and carriage 42 away from the hook drive 36 to its upper, outer position which was previously shown in FIG. 8 C. Immediately thereafter, the control 140 provides further signals to the vertical and horizontal solenoid valves 154 , 144 to operate the respective vertical and horizontal cylinders 74 , 56 to move the carriage 42 back to its starting rest position illustrated in FIG. 8 A.
While the present invention has been illustrated by a description of one embodiment and while that embodiment has been described in considerable detail, it is not intended to restrict or in any way limit the scope of the appended claims to such detail. Additional advantages and modifications within the spirit and scope of the invention will readily appear to those skilled in the art. For example, in the described embodiment, the cylinders 56 , 74 and 80 are fluid cylinders operated with pressurized air. As will be appreciated hydraulic cylinders could also be used. In addition, the commercial cylinders could be replaced by electric motor and rack and pinion drives or other known mechanisms that convert the rotary motion of the electric motor to the desired linear motion.
In the described embodiment, the stop is a resilient pad; however, as will be appreciated, a nonresilient pad may also be used if it is positioned to provide the desired clamping of the bobbin case release lever. Further, the described embodiment illustrates a single needle, however, as will be appreciated, the bobbin changer of the present invention may also be used on a quilting machine having multiple needles. Also, as will be recognized, while the bobbin changing apparatus is described herein with respect to a quilting machine, certain aspects of the bobbin changing apparatus may also have utility on nonquilting machines.
Therefore, the invention in its broadest aspects is not limited to the specific detail shown and described. Consequently, departures may be made from the details described herein without departing from the spirit and scope of the claims which follow.
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An apparatus for automatically changing a bobbin case on a quilting machine having a hook drive operatively supporting the bobbin case during a stitching operation. The apparatus includes a staging station adapted to support at least one bobbin case normally having a full spool of thread, and a carriage movable between the staging station and the hook drive. A finger is movably mounted on the carriage, and the finger moves a release lever on the bobbin to an unlock position and clamps the release lever at the unlock position. A method of using the above apparatus in an automatic bobbin changing operation is also provided. A controller determines the need for a bobbin change, for example, by counting stitches and calculating the thread remaining on the bobbin. The bobbin change can be carried out between patterns or during a pattern by cutting the bobbin thread or both the top and bottom threads. The sewing of tacking stitches may also be done in sequence with the thread cutting and bobbin changes.
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CROSS-REFERENCE TO RELATED APPLICATIONS
The present application is a continuation-in-part of co-pending application entitled LATCH AND LOCK ASSEMBLIES WITH SPRING-BIASED PIVOT BOLTS, Ser. No. 327,545 filed Mar. 23, 1989 by Lee S. Weinerman et al (referred to hereinafter either as the "Presently Pending Parent Case" or as "Utility Case III(b)") issued as U.S. Pat. No. 4,969,916, which application was filed as a continuation-in-part of a prior application entitled LATCH AND LOCK ASSEMBLIES WITH SPRING-BIASED PIVOT BOLTS, Ser. No. 072,174 filed July 10, 1987 by Lee S. Weinerman et al (referred to hereinafter either as the "Parent Case" or as "Utility Case III(a)") issued July 25, 1989 as U.S. Pat. No. 4,850,208, which prior application was filed as a continuation-in-part of an earlier application entitled CABINET LOCK WITH RECESSED HANDLE, Ser. No. 859,194 filed Apr. 28, 1986 by Lee S. Weinerman et al that issued Aug. 4, 1987 as U.S. Pat. No. 4,683,736, which earlier application was filed as a continuation-in-part of another earlier application Ser. No. 601,648 filed Apr. 18, 1984 (now abandoned), with said earlier applications being referred to hereinafter as the "Predecessor Cases," and with the disclosures of all of the Parent Cases and the Predecessor Cases being incorporated herein by reference.
REFERENCE TO OTHER RELEVANT APPLICATIONS AND PATENTS
At the time that the Parent Case (as identified above) was filed, several "companion" applications also were filed that relate to other concurrently developed aspects of a long term and continuing program of development that gave rise to the invention of the Parent Case. The list that follows identifies not only the "companion" applications that were filed and the patents that have issued therefrom, but also such divisional and continuation-in-part applications that have been filed together with such patents as have issued therefrom. The disclosures of the several patents and applications that are listed below are incorporated herein by reference, namely:
LATCH AND LOCK HOUSINGS, HANDLES AND MOUNTING BRACKETS, U.S. Pat. No. 4,850,209 Issued July 25, 1989 from application Ser. No. 072,176, filed July 10, 1987 by Lee S. Weinerman, Steven A. Mayo, Joel T. Vargus, Frank R. Albris, Richard H. Russell, Thomas V. McLinden, Richard M. O'Grady and Timothy H. Wentzell, hereinafter referred to as the "Utility Case I;"
LATCH AND LOCK ASSEMBLIES WITH SPRING-BIASED SLIDE BOLTS, U.S. Pat. No. 4,841,755 Issued June 27, 1989 from application Ser. No. 072,177, filed July 10, 1987 by Lee S. Weinerman, Steven A. Mayo, Joel T. Vargus, Frank R. Albris, Richard H. Russell, Thomas V. McLinden, Richard M. O'Grady and Timothy H. Wentzell, hereinafter referred to as the "Utility Case II;"
LATCH AND LOCK ASSEMBLIES WITH LIFT AND TURN HANDLES, U.S. Pat. No. 4,838,054 Issued June 13, 1989 from application Ser. No. 072,175, filed July 10, 1987 by Lee S. Weinerman, Frank R. Albris, Thomas V. McLinden and Timothy H. Wentzell, hereinafter referred to as the "Utility Case IV;"
LATCH AND LOCK ASSEMBLIES WITH EXPANSIBLE LATCH ELEMENTS, U.S. Pat. No. 4,838,056 Issued June 13, 1989 from application Ser. No. 072,250, filed July 10, 1987 by Lee S. Weinerman, Steven A. Mayo, Thomas V. McLinden and Timothy H. Wentzell, hereinafter referred to as the "Utility Case V;"
HOUSINGS FOR LATCHES AND LOCKS, U.S. Pat. No. Des. 303,922 Issued Oct. 10, 1989 from application Ser. No. 072,282 filed July 10, 1987 by Richard H. Russell David W. Kaiser and Richard M. O'Grady, hereinafter referred to as the "Design Case I(a)," a divisional application entitled HOUSING FOR LATCHES AND LOCKS, Ser. No. 383,983 having been filed July 24, 1989, hereinafter referred to as the "Design Case I(b);"
FLUSH MOUNTED LATCH ASSEMBLY, U.S. Pat. No. Des. 303,619 Issued Sept. 26, 1989 from application Ser. No. 072,283, filed July 10, 1987 by Richard H. Russell, David W. Kaiser and Richard M. O'Grady, hereinafter referred to as the "Design Case II;"
FLUSH MOUNTED LATCH ASSEMBLY, U.S. Pat. No. Des. 303,621 Issued Sept. 26, 1989 from application Ser. No. 072,285, filed July 10, 1987 by Richard H. Russell and David W. Kaiser, hereinafter referred to as the "Design Case III;"
FLUSH MOUNTED LATCH ASSEMBLY, U.S. Pat. No. Des. 303,620 Issued Sept. 26, 1989 from application Ser. No. 072,284, filed July 10, 1987 by Richard H. Russell and David W. Kaiser, hereinafter referred to as the "Design Case IV;"
FLUSH MOUNTED LATCH ASSEMBLY, U.S. Pat. No. Des. 304,155 Issued Oct. 24, 1989 from application Ser. No. 072,276, filed July 10, 1987 by Richard H. Russell and David W. Kaiser, hereinafter referred to as the "Design Case V;"
FLUSH MOUNTED LATCH ASSEMBLY, U.S. Pat. No. Des. 303,617 Issued Sept. 26, 1989, from application Ser. No 072,573, filed July 10, 1987 by Richard H. Russell and David W. Kaiser, hereinafter referred to as the "Design Case VI;"
COMBINED HOUSINGS AND HANDLES FOR LATCHES AND LOCKS, U.S. Pat. No. Des. 303,618 Issued Sept. 26, 1989 from application Ser. No. 072,277, filed July 10, 1987 by Richard H. Russell and David W. Kaiser, hereinafter referred to as the "Design Case VII;"
MOUNTING BRACKETS FOR LATCHES AND LOCKS, U.S. Pat. No. Des. 303,350 Issued Sept. 12, 1989 from application Ser. No. 072,278, filed July 10, 1987 by Richard H. Russell and Thomas V. McLinden, hereinafter referred to as the "Design Case VIII(a)" a division of which issued May 22, 1990 as U.S. Pat. No. Des. 308,010 from application Ser. No. 372,945 having been filed June 28, 1989, hereinafter referred to as the "Design Case VIII(b);"
MOUNTING BRACKETS FOR A FLUSH-MOUNTED LATCH ASSEMBLY, U.S. Pat. No. Des. 302,239 Issued July 18, 1989 from application Ser. No. 072,280, filed July 10, 1987 by Richard H. Russell and Thomas V. McLinden, hereinafter referred to as the "Design Case IX;"
STRIKE PLATE, U.S. Pat. No. Des. 303,351 Issued Sept. 12, 1989 from application Ser. No. 072,279, filed July 10, 1987 by Lee S. Weinerman and Steven A. Mayo, hereinafter referred to as the "Design Case X;" and,
STRIKE PLATE, U.S. Pat. No. Des. 303,754 Issued Oct. 3, 1989 from application Ser. No. 072,281, filed July 10, 1987 by Lee S. Weinerman and Steven A. Mayo, hereinafter referred to as the "Design Case XI."
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to flush mounted latches and locks of the type used with closures for industrial cabinets, tool carts, electrical equipment enclosures and the like. More particularly, the present invention relates to novel and improved latches and locks that utilize coaxially-pivoted sets of overlying latch bolt and operating arm components that are of novel form and that cooperate and co-act in a plurality of ways to provide desired types of latching and locking actions.
2. Prior Art
Flush mounted latches and locks that each include a body, a latch bolt movably carried on the body, and an operating handle that is nested by the body are well known. Normally the handle is in a flush or nested position when the bolt is in a latched position; and unlatching movement of the bolt is effected by moving the handle to an operating position. Latches and locks of this type are well suited for use on industrial cabinets, tool carts, electrical equipment enclosures and the like.
Flush-mounted latches and locks having pan-shaped housings that nest paddle-shaped operating handles, and that have spring-projected slide bolts are disclosed in such U.S. Pat. Nos. as 4,335,595, 4,321,812, 4,320,642, 4,312,205, 4,312,204, 4,312,203, 4,312,202, 4,309,884, 4,231,597, 4,138,869, 3,707,862, 3,668,907, 3,449,005, 3,389,932, 3,357,734, 3,209,564, 3,209,563, 3,055,204, 2,987,908, 2,900,204 and 2,642,300, all of which are assigned to the Eastern Company, a corporation of Connecticut.
Flush mounted latches and locks having latch bolts of other than the spring-projected, slide-mounted type are disclosed in such U.S. Pat. Nos. as 4,413,849, 4,320,642, 4,312,203, 4,134,281, 3,857,594, 3,338,610, 3,044,814, 3,044,287 and 2,735,706, all of which are assigned to the Eastern Company.
Latches having spring-biased pivotally-mounted latch bolts with hook-shaped arm portions projecting sidewardly from housings that enclose associated operating components, with the arm portions being "slammable" into latching engagement with suitably configured striker formations are disclosed in U.S. Pat. No. 4,511,166 assigned to the Eastern Company.
A cabinet latch having a housing that is usable with a variety of pivotally mounted latch bolts, and with a variety of latching mechanisms is disclosed in U.S. Pat. No. 4,177,656, also assigned to the Eastern Company.
3. Cross-Referenced & Referenced Patents & Applications
The present invention, taken together with the inventions that form the subjects matter of a select group of the cross-referenced and referenced utility and design patents and applications, require special comment inasmuch as these several inventions represent the work products of a long term and continuing development program. The group includes such cross-referenced and referenced cases as involve applications that either were put on file on July 10, 1987, or were filed as divisions or continuations of applications that were put on file on July 10, 1987. Thus the select group is comprised of cases that all relate back to cases that were filed July 10, 1987; and, the present case is appropriate to include within the select group inasmuch as it is a continuation-in-part of one of the cases of the select group, namely a case that was filed as a continuation-in-part of one of a total of sixteen applications that were put on file on July 10, 1987.
With respect to the cases of the select group, it should be understood that there are clear lines of demarcation among the subjects matter of each of these cases. The several functional features that form the subjects matter of the utility cases, and the several appearance features that form the subjects matter of the design cases, were developed by various co-workers, as is reflected in the listing of inventors in these cases. Many of the functional and appearance features that are claimed in separate ones of the utility and design cases developed substantially concurrently, especially as regards the subjects matter of the several companion cases that were put on file on July 10, 1987.
If an invention feature that is disclosed in one of the select group of utility and design cases constitutes a species of a development concept that is utilized in another of these related cases, it will be understood that care has been taken to present a generic claim in the case that describes the earliest development of a species that will support the generic claim. In this manner, a careful effort has been made to establish clear lines of demarcation among the claimed subjects matter of this and the several other utility and design cases of the select group. No two of these cases include claims of identical scope.
Referenced Utility Cases III(a) and III(b) disclose combinations of housing and handle assemblies that use spring-biased latch bolts that are pivotally mounted, with the latch bolts being configured and arranged so as to provide "slam-capable" latch and lock units--however, these units are not well suited for use on sliding doors, which is the principal application for latches and locks of the type that embody features of the present invention. Referenced Utility Case II, namely U.S. Pat. No. 4,841,755, discloses housing and handle combinations of the general type that preferably are utilized in latch and lock units that include features of the present invention. Design Cases I(a) and I(b), namely U.S. Pat. No. Des. 303,922 and co-pending divisional application Ser. No. 383,983, relate to appearance features of housings of said general type. Design Cases II, IV and VII, namely U.S. Pat. Nos. Des. 303,619, 303,618 and 303,620, respectively, relate to appearance features of housing and handle combinations that are of said general type. Design Cases VIII(a) and VIII(b), namely U.S. Pat. Nos. Des. 303,350 and 308,010, relate to appearance features of mounting brackets of the general type that can be used to mount latch and lock assemblies that embody the preferred practice of the present invention on closures of the type that are provided with openings that closely receive central body portions of said housings. Others of the cases of the select group disclose subjects matter that are believed to be of less relevance to features of the present invention.
SUMMARY OF THE INVENTION
The present invention provides novel and improved, flush mountable latches and locks for industrial cabinets, tool carts, electrical equipment enclosures and the like. More particularly, the present invention relates to novel and improved latches and locks that are particularly well suited to use handle and housing combinations of the general type that are disclosed in U.S. Pat. No. 4,841,755; that are intended to provide "slam-capable" latches and locks as by providing sidewardly-projecting, pivotally-mounted latch bolts that have hook-shaped latching formations of the general type that are disclosed in U.S. Pat. No. 4,511,166; and that include improvement features that reside in the utilization of sets of overlying operating arm and latch bolt components that are coaxially but independently pivoted, and that are drivingly connected 1) so that movement of each handle from its normal position to its operating position will cause corresponding pivotal movements both a) of the associated operating arm to its operating position, and b) of the associated latch bolt to its unlatched position, and 2) so as to permit each latch bolt to pivot relative to its associated operating arm so that a hook-shaped portion of the latch bolt can be "slammed" into latching engagement with a suitably configured figured keeper or striker (just as similarly configured hook-shaped latch bolt formations are described in U.S. Pat. No. 4,511,166 as being capable of functioning).
In accordance with features of the present invention, flush mountable latches and locks are provided for use in conjunction with industrial cabinets, tool carts, electrical equipment enclosures and the like. The latches and locks preferably utilize versatile housings that can nest and movably mount a variety of operating handles, with the most preferred forms of the handle and housing components being those that are described and illustrated in U.S. Pat. No. 4,841,755. The handles move relative to the housings to effect unlatching movements of spring-biased, pivotally mounted latch bolts, with pivotally mounted operating arms being provided to serve the primary function of drivingly interconnecting the handles with the latch bolts, but with the operating arms and their associated latch bolts being cooperatively configured so as to permit relative movement to take place between the latch bolts and their associated operating arms (to enable the latch bolts to be "slammed" into latching engagement with suitably configured keepers and striker formations).
A latch or lock that embodies features of the preferred practice of present invention typically is employed as by mounting its housing on a closure (typically as by inserting central body portions of the housing into a passage that is formed through an edge region of the closure, and by clamping other portions of the housing into engagement with portions of the closure that surround the passage), with the closure being of the type that is slidably mounted for movement (i.e., the closure is movable principally in side-to-side directions) relative to an access opening that is to be selectively "closed" by the closure; and, the latch or lock utilizes a paired set of interactive components that are mounted on its housing for independent pivotal movement about a common axis, namely an operating arm and a latch bolt that cooperate not only 1) to provide a driving connection between the operating handle and the latch bolt, but also 2) to assure that, regardless of whether the operating arm is being restrained from moving out of its normal non-operating position, the latch bolt is free to pivot as may be required to enable a hook-shaped portion of the latch bolt to latchingly engage a suitably configured keeper or striker formation as the closure (on which the latch or lock is mounted) is "slammed" closed.
In locking units of the type that embody the preferred practice of the present invention, a locking device is provided that is moveable selectively into and out of the path of movement that is followed by the operating arm in moving from its normal position to its operating position. By this arrangement, movement of the operating arm from its normal position to its operating position is controlled by "locking" and "unlocking" movements of a portion of the locking device selectively into and out of the path of movement of the operating arm (with these "locking" and "unlocking" movements being carried out when the operating arm is in its normal non-operated position). By selectively restraining the movement of the operating arm (while not restraining movement of the associated latch bolt), each such locking unit does nothing to impede such latch bolt movements as are required to permit the latch bolt to latchingly engage a suitably configured keeper or striker--whereby what is referred to in the art as a "slam capability" is imparted even to locking units that embody the preferred practice of the present invention.
Turning more specifically to novel features that are embodied in a set of latch bolt and operating arm components that are utilized in the most preferred practice of the present invention, the latch bolt is an elongate member that has portions that not only extend across the back wall of the recessed portion of the housing but also extend beyond opposite sides of the recessed portion of the housing. Carried on the portions of the latch bolt that extend beyond opposite sides of the recessed portions of the housing are a pair of stop formations, with one of these stop formations being engageable with one side of the recessed portion of the housing, and with the other of these stop formations being engageable with the other side of the recessed portion of the housing. By this arrangement, opposed sides of the recessed portion of the housing are engaged by latch-bolt-carried stops when the latch bolt has reached either of the extreme ranges of its movement, namely it is in its latched position or its unlatched positions. Further, the latch bolt has cut-out portions that define a recess for receiving portions of a torsion coil spring that is interposed between the housing and the latch bolt for biasing the latch bolt toward its latched position.
Still other features reside in the provision of the latch bolt with a relatively large diameter hole that is formed through one end region of the latch bolt. The hole receives and smoothly journals for relative rotation a mounting-sleeve portion of the operating arm so that a secure co-axial, pivotal mounting of these two key components is assured. The operating arm preferably is of generally L-shaped configuration and has one of its legs that closely overlies portions of the latch bolt. The "overlying leg" of the operating arm provides an enlarged formation of material that is interposed between a handle-carried operating formation and portions of the latch bolt to transmit operating force quite directly from the handle-carried operating formation through the enlarged formation of the operating arm to the latch bolt to effect movement of the latch bolt from its latched position to its unlatched position in response to movement of the handle from its normal non-operated position to its operated position. Moreover, the extent to which the operating arm has any "obstructing" portions that align with the path of movement that is followed by the latch bolt in moving between its latched and unlatched positions is limited; indeed, it is limited to the provision of the enlarged formation that is described in the foregoing sentence; and, to assure that the enlarged formation does not impede needed movement of the latch bolt, the enlarged formation normally is positioned by the operating arm so as to be situated at one end of said path of movement whereby it poses no obstacle to such relative movements of the latch bolt and the operating arm as are needed in order to provide latch and lock units of the present invention with a "slam capability."
BRIEF DESCRIPTION OF THE DRAWINGS
These and other features, and a fuller understanding of the invention may be had by referring to the description and claims that follow, taken in conjunction with the accompanying drawings, wherein:
FIG. 1 is an exploded perspective view of one form of lock assembly that embodies features of the preferred practice of the present invention, illustrating how the lock assembly is mounted on portions of a closure, with the view showing principally front portions thereof;
FIG. 2 is an exploded perspective view of components of the lock assembly of FIG. 1;
FIG. 3 is a right side elevational view thereof, with the handle in its normally nested position, with the latch bolt projected to its latched position, with locking components locked, but with selected portions removed therefrom to permit other portions to be seen;
FIG. 4 is a rear elevational view thereof;
FIG. 5 is a bottom plan view thereof;
FIG. 6 is a perspective view showing principally rear portions thereof, but with the locking components unlocked;
FIG. 7 is a rear elevational view similar to FIG. 4, but with the locking components unlocked;
FIG. 8 is a is a rear elevational view similar to FIG. 7, but with the handle operated and with the latch bolt retracted to its unlatched position;
FIG. 9 is a perspective view, on an enlarged scale, of selected interactive components of the lock assembly of FIG. 1;
FIG. 10 is an exploded perspective view of another form of lock that embodies features of the preferred practice of the present invention illustrating how the lock assembly is mounted on portions of a closure, and with the view showing principally front portions thereof;
FIG. 11 is an exploded perspective view of components of the lock assembly of FIG. 10;
FIG. 12 is a right side elevational view thereof, with the handle in its normally nested position, with the latch bolt projected to its latched position, and with locking components locked, but with selected portions removed therefrom to permit other portions to be seen;
FIG. 13 is a rear elevational view thereof;
FIG. 14 is a bottom plan view thereof;
FIG. 15 is a perspective view showing principally rear portions thereof, but with the locking components unlocked;
FIG. 16 is a rear elevational view similar to FIG. 13, but with the locking components unlocked;
FIG. 17 is a is a rear elevational view similar to FIG. 16, but with the handle operated and with the latch bolt retracted to its unlatched position;
FIG. 18 is an exploded perspective view of still another form of lock that embodies feature of the preferred practice of the present invention illustrating how the lock assembly is mounted on portions of a closure, with the view showing principally front portions thereof;
FIG. 19 is an exploded perspective view of components of the lock assembly of FIG. 18;
FIG. 20 is a right side elevational view thereof, with the handle in its normally nested position, with the latch bolt projected to its latched position, and with locking components locked, but with selected portions removed therefrom to permit other portions to be seen;
FIG. 21 is a rear elevational view thereof;
FIG. 22 is a bottom plan view thereof;
FIG. 23 is a perspective view showing principally rear portions thereof, but with the locking components unlocked;
FIG. 24 is a rear elevational view similar to FIG. 21, but with the locking components unlocked;
FIG. 25 is a is a rear elevational view similar to FIG. 24, but with the handle operated and with the latch bolt retracted to its unlatched position;
FIG. 26 is a perspective view of selected components of the lock assembly of FIGS. 1-8, with the handle operated;
FIG. 27 is a perspective view of selected components of the lock assembly of FIGS. 10-17, with the handle operated;
FIG. 28 is a perspective view of selected components of the lock assembly of FIGS. 18-25, with the handle operated;
FIG. 29 is an exploded perspective view of selected portions of the lock assembly of FIGS. 1-8, with the view showing alternate tool-operated plugs that can be installed in the housing, and with the view showing locked and unlocked positions of selected components of the lock assembly of FIGS. 1-8, it being understood that what is depicted in FIG. 29 is equally applicable to the lock assemblies of FIGS. 10-17 and 18-25; and,
FIG. 30 is a perspective view of rear portions of the housing that is shown in FIG. 29.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, one form of a lock assembly that embodies features of the preferred practice of the present invention is indicated generally by the numeral 100. The lock assembly 100 has a housing 200 that mounts a plurality of interactive components that provide latching and locking functions. In preferred practice, latch and lock components that are described below are formed either from a durable thermoplastics material that will be described, or from stainless steel, whereby the resulting latch and lock units can be utilized in most normal environments without concern about deterioration from causes such as corrosion.
In overview, and as will be explained in greater detail, the interactive components that are carried on the housing 200 principally include a handle 300 that is mounted on the housing 200 for movement between normal and operating positions; a spring-biased latch bolt 400 that is pivotally mounted on the housing 200 for movement between latched and unlatched positions; an operating arm 500 that is pivotally mounted on the housing 200 for movement between "normal" and "operating" positions (with these positions corresponding, respectively, to the "normal" and "operating" positions of the handle 300), with the operating arm 500 serving a principal function of drivingly interconnecting the handle 300 and the latch bolt 400 such that the latch bolt 400 will move to its "unlatched" position in response to movement of the handle 300 to its "operating" position; and, a locking mechanism 600 for selectively permitting and preventing movement of the latch bolt 400 by the handle 300 (as by selectively permitting and preventing movement of the operating arm 500 from its normal position to its operating position). If the locking mechanism 600 is omitted, the lock assembly 100 is thereby transformed into a latch assembly, i.e., a unit which has a handle 300 that always can be operated to effect pivotal unlatching movement of the spring-biased latch bolt 400. Additional explanation is provided later in this document concerning such features as these that are simply being introduced to the reader in this introductory portion of the detailed description.
Referring to FIG. 1, it will be seen that the latch bolt 400 projects relatively sidewardly with respect to the housing 200 and has a hook-shaped end region 450 for engaging a suitably configured keeper or striker formation (not shown). In preferred practice, the lock assembly 100 is mounted on a closure (portions of which are indicated in FIG. 1 by the numeral 110) that is slidable sidewardly relative to structure (not shown) that surrounds and defines an access opening (not shown) through which access is selectively permitted and prevented as by selectively "opening" and "closing" the closure 110.
In referenced U.S. Pat. No. 4,511,166, a door lock 10 is described and illustrated that is provided with a pair of "slam capable" latch bolts. Each of the latch bolts have a hook-shaped, sidewardly projecting arm portion that is "slammable" into a "hooked" type of releasable latching engagement with a suitably configured keeper or striker formation. In much the same fashion, the lock assembly 100 has a single latch bolt 400 that has a hook-shaped portion 452 that is "slammable" into engagement with a suitably configured keeper or striker formation (not shown). The hook-shaped formation 452 is defined, in part, by a tapered surface portion 454 that is intended to engage a portion of a keeper or striker formation so as to cause the latch bolt to pivot such that its hook-shaped formation 452 will ride "down and under" (or "up and over") a portion of the keeper or striker so that the hook-shaped formation 452 can "hook" behind a portion of the keeper or striker--and can thereby serve to releasably retain the closure 110 in its closed position.
In a typical application, the lock assembly 100 is mounted near a "leading edge" region of the closure 110 (i.e., a an edge region of the closure 110 that "leads" or "moves ahead of" the majority of the other portions of the closure 110 as the closure is moved from an "open" to a "closed" position), with the hook-shaped end region 452 being configured to be pivoted out of the way of, to move by, and thence to hook behind so as to latchingly engage a portion of a suitably configured keeper or striker formation that is provided on the structure that surrounds the access opening that is "closed" when the closure is moved to its closed position. Thus, the latch bolt 400 is intended to function in the manner of the hook-shaped arms (referred to by numerals 160 and 162) of the door lock that is described in U.S. Pat. No. 4,511,166, to releasably "latch" the closure 110 in its closed position.
To "unlatch" the hook-shaped end region 452 from engagement with the keeper or striker (so that the closure 110 can be opened), 1) the hook-shaped end region 452 is pivoted to disengage the portion of the keeper or striker that had been "hooked," and 2) the closure 110 is slided sidewardly (i.e., out of its "closed" position toward its "open" position) to withdraw the hook-shaped end region 452 from being received by a suitably configured keeper or striker formation.
Before turning to a more detailed description of the components of the lock assembly 100, the preferred manner in which the lock assembly 100 can be mounted on a closure 110 will be described. The portion of the closure 110 that is shown in FIG. 1 is a plate-like structure that has a mounting opening 112 formed therethrough. The closure portion 110 has a front surface 114 and a rear surface 116 that extend about the perimeter of the opening 112. The opening 112 has top and bottom boundaries 122, 124, and left and right side boundaries 126, 128.
Referring to FIG. 2 in conjunction with what is depicted in FIG. 1, in order to mount the lock assembly 100 on the closure 110, the lock assembly 100 has a pair of mounting posts 700 (only one of which is shown in FIG. 1) that project rearwardly for connection to a mounting bracket 750. The mounting bracket 750 is of generally U-shaped configuration, having a back wall 760 that connects at opposite ends with legs 762, 764. The legs 762, 764 extend forwardly from the plane of the back wall 760 toward a perimetrically extending mounting flange 202 that comprises a part of the housing 200. The legs 762, 764 of the U-shaped mounting bracket 750 cooperate with the mounting flange 202 of the housing 200 to clampingly mount the lock assembly 100 on the closure 110.
When the lock assembly 100 is to be installed on the closure 110, a gasket 270 is positioned behind the mounting flange 202 to engage the rearwardly-facing surface of the mounting flange 202, and portions of the lock assembly 100 are installed through the closure opening 112 to position the gasket 270 adjacent the opening 112 in clamped engagement between the rear face 206 of the mounting flange 202 and the front surface 114 of the closure 110. The mounting bracket 750 is positioned to overlie the lock assembly 100, with the legs 762, 764 of the mounting bracket 750 extending into engagement with the rear surface 116 of the closure 110. Threaded fasteners 702 are installed to extend through holes 752 that are formed through the back wall 760 of the bracket 750. The fasteners 702 are threaded into the mounting posts 700 of the lock assembly 100 to clamp the mounting flange 202 into engagement with the gasket 270, to clamp the gasket 270 into engagement with the front surface 114, and to clamp the legs 762, 764 into engagement with a rear surface 116 of the closure 110.
The gasket 270 has a central opening 275 that is configured to permit the gasket 270 to be slipped over such portions of the lock assembly 100 as extend rearwardly from the mounting flange 202, so that the gasket 270 takes up a position adjacent the mounting flange 202. The central opening 275 can be configured (as is shown in FIG. 1) relatively complexly so as to extend into relatively close proximity to portions of the lock assembly 100 that are surrounded by the gasket 270. Alternatively, the gasket 270 can take a simpler configuration, such as is depicted in FIG. 1 of U.S. Pat. No. 4,841,755, so as to more loosely surround portions of the lock assembly 100. While the gasket 270 is not essential in many applications where the lock assembly 100 can be used, the gasket 270 preferably is used in applications that present a possibility that moisture, dust or the like may penetrate the opening 112 as by passing between the back face 206 of the mounting flange 202 and the front face 114 of the closure 110.
To facilitate an understanding of the various relative positions of the principal relatively movable components of the lock assembly 100, reference is made to FIGS. 1-5 wherein the handle 300 is in its "normal" or "nested" position; the latch bolt 400 is in its "latched" position; the operating arm 500 is in its "normal" or "non-operating" position; and the lock mechanism 600 is "locked" so as to prevent movement of the operating arm 500 out of its "normal" position toward its "operating" position (i.e., to prevent unlatching movement of the latch bolt 400 in response to operation of the handle 300. In FIGS. 6-8, the locking mechanism 600 of the lock assembly 100 is shown "unlocked" so as to permit movement of the operating arm from its "normal" position (as shown in FIGS. 6 and 7 to its "operating" position (as shown in FIG. 8). In FIGS. 6 and 7, the latch bolt 400 is shown in its "latched" position; whereas, in FIG. 8, the latch bolt 400 is shown pivoted to its "unlatched" position in response to being acted upon by the operating arm 500 as the result of movement of the operating arm 500 in response to being acted upon by the handle 300 in moving from its "normal" or "nested" position to its "operating" position. The "operating" position of the handle 300 is shown in FIG. 26.
In the detailed description that follows, the lock assembly 100 and two alternate lock assembly embodiments 1100 and 2100 will be described. Features of the lock assembly 100 are depicted in FIGS. 1-8 and 26. Features of the lock assembly 1100 are depicted in FIGS. 10-17 and 27. Features of the lock assembly 2100 are depicted in FIGS. 18-25 and 28. The set of pivotal operating arm and latch bolt components that is depicted in FIG. 9 is described in conjunction with the discussion of the lock assembly 100, but is used in all of the embodiments 100, 1100 and 2100.
To the extent that the lock assemblies 100, 1100 and 2100 use identical parts, identical reference numerals are used to designate the identical parts. To the extent that the lock assemblies 100, 1100 and 2100 use differently configured parts that function substantially identically, reference numerals that differ by magnitudes of 1000 and 2000 are used to identify these components--whereby many of the features that are designated by four-digit reference numerals need not be described inasmuch as the character of these features will be apparent from the discussion that is presented of corresponding features that are designated by three digit reference numerals.
The lock assemblies 100, 1100 and 2100 share a general layout of operating components, with many of the operating components being interchangeable from lock to lock. Features shared by all three of these lock embodiments include the use of identically configured spring-biased, pivotally mounted latch bolts 400; the use of identically configured operating arms 500 that drivingly connect the latch bolts 400 with their associated operating handles 300, 1300 and 2300; and the use of identical arrangements of locking devices 600 to selectively restrict movement of the operating arms 500 so as to permit and prevent handle movement to effect unlatching movement of an associated one of the latch bolts 400, but with the locking devices 600 not interfering with the "slam capable" pivotally-movable nature of the latch bolts 400.
Principal areas of difference among the lock embodiments 100, 1100 and 2100 reside in the configuration of their handles 300, 1300 and 2300; the movements that are executed by the handles 300, 1300 and 2300 to effect pivot the operating arms 500 so as to pivot the operating arms 500 to effect "unlatching" movement of the latch bolts 400; the mountings of the handles 300, 1300 and 2300 on their associated housings 200, 1200 and 2200; and the character of such handles "extensions" as project through a back wall opening or through side wall opening(s) that are formed in the pan-shaped parts 220, 1220 and 2220 of the housings 200, 1200 and 2200 (as will be explained) for engaging the operating arms 500.
Turning now to a more detailed description of features of the components of the lock assembly 100, the housing 200 is preferably formed as a molded, one piece structure; thus it will be understood that the mounting flange 202 together with the walls that form an essentially pan-shaped housing portion 220 (i.e., the walls that define the width, length and depth of the recess 210) are integrally-formed parts of the same one-piece structure. The fabrication of the housing 200 as a one-piece member molded from thermoplastic, material such as a glass reinforced polycarbonate based polymer blend helps to provide a strong, rigid, impact resistant structure, whereby the housing 200 is capable of providing a versatile mounting platform for supporting the various relatively movable components of the lock assembly 100.
A preferred material from which the housing 200 is formed is a thermoplastic that is a glass reinforced polycarbonate based polymer blend, typically of the type sold by General Electric Company, Pittsfield, Mass. 01201 under the registered trademark XENOY. The most preferred resin blend is about 10 percent glass reinforced, and is selected from the "6000 Series" of the XENOY products sold by General Electric, with XENOY 6240 being preferred. While many other commercially available moldable plastics materials can be used to form the housing 200, as will be apparent to those skilled in the art, the preferred material helps to provide a high strength housing that is light in weight, resists crazing and hardening, is heat and chemical resistant, is resistant to impact, and can be machined as needed to provide suitable mounting holes and the like for movably mounting a wide variety of handles within the confines of the recess 210, as will be explained.
Referring to FIGS. 1 and 2, the mounting flange 202 has a front face 204 that defines the front of the housing 200. The mounting flange 202 has a rear face 206 that is substantially flat, i.e., all portions of the rear face 206 extend substantially in a single plane. The mounting flange 202 is bordered by a perimetrically extending edge surface 208 that joins the front and rear surfaces 204, 206 at their peripheries. While all portions of the mounting flange 202 are formed integrally and therefore serve to define elements of a one-piece structure, for purposes of reference, the mounting flange 202 can be thought of as having a top portion 212 that extends across the top of the recess 210, a bottom portion 214 that extends across the bottom of the recess 210, and opposed side portions 216, 218 that extend along left and right sides of the recess 210. Likewise, the edge surface 208 can be thought of as having a top portion 222, a bottom portion 224, and opposed side portions 226, 228. The flange portions 212, 214, 216, 218 and their associated edge portions 222, 224, 226, 228 cooperate to define a mounting flange 202 that has a generally rectangular configuration, with corner regions where adjacent ones of the edge portions 222, 224, 226, 228 join preferably being gently rounded to give an enhanced appearance.
Referring to FIGS. 3-5, the pan-shaped portion 220 of the housing 200 (i.e., the portion of the housing 200 that defines the forwardly facing recess 210) includes a top wall 232, a bottom wall 234, a pair of opposed side walls 236, 238, and a back wall 242. The back wall 242 is arranged so that it extends substantially parallel to the rear face 206 of the mounting flange 202. Stated in another way, the back wall 242 has a front face 244 (see FIG. 2) and a rear face 246 (see FIG. 4) that extend in planes that substantially parallel the plane of the rear surface 206 of the mounting flange 202.
For the purpose of providing an enhanced appearance, it is preferred that front face 204 of the housing 200 be of curved, slightly convex configuration. Stated in another way, the front face 204 is convexly curved such that the thicknesses of the mounting flange portions 212, 214, 216, 218 increase progressively the closer these formations extend toward an imaginary center point of the front face 204. Likewise, the thicknesses of the mounting flange portions 212, 214, 216, 218 decreases progressively as these formations extend toward the edge surface portions 222, 224, 226, 228. Preferably, the thicknesses of the mounting flange portions 212, 214, 216, 218 as measured at locations that are adjacent to the edge portions 222, 224, 226, 228, are substantially uniform all along the edge surface 208--which is to say that the edge surface 208 has a width that is substantially constant as the edge surface 208 extends about the housing 200.
For the purpose of providing an enhanced appearance, the positioning of the top and bottom walls 232, 234 of the pan-shaped housing portion 220 that defines the recess 210 preferably is asymmetrical relative to top and bottom edges 222, 224 of the mounting flange 202. Likewise, for purposes of enhanced appearance, the positioning of the left and right side walls 236, 238 of the pan-shaped housing portion 220 preferably is asymmetrical relative to the left and right opposed side edges 226, 228 of the mounting flange 202. This absence of symmetry in locating the recess 210 relative to opposed top and side edge portions 222, 224 and 226, 228 of the mounting flange 202 results in the top wall portion 212 being relatively short in height in comparison with the relatively tall height of the bottom wall portion 214 that depends beneath the recess 210, and results in the left sidewall portion 216 being relatively wide, while the right side wall portion 218 is relatively narrow.
A feature of latch and lock units that embody the preferred practice of the present invention is that each such unit not only includes a compact, concentrically pivoted arrangement of its latch bolt 400 and its operating arm 500, but also includes arrays of functional formations and operating components that extend substantially symmetrically about an imaginary, vertically extending center plane. Such a center plane for the lock assembly 100 is designated by the numeral 201 in FIG. 4, and has features that are arranged symmetrically with respect thereto, such as the side walls 236, 238 of the housing portion 220 (which are spaced substantially equally on opposite sides of the center plane 201), and a sleeve-like housing formation 280 (which has its center intersected by the center plane 201). Corresponding center planes for the lock assemblies 1100 and 2100 are indicated by numerals 1201 and 2201 in FIGS. 13 and 21, respectively.
With respect to the side-to-side positioning of the recess 210 relative to features of the mounting flange 202, however, it will be understood that this is feature dictated solely by appearance considerations, and not by functional considerations. Indeed, functional features of the lock assembly 100 would not be affected if the narrow flange portions 212, 218 were enlarged to give the flange portions 212, 218 widths that are equivalent to the relatively wider flange portions 214, 216, respectively. Likewise the styling of the front face 204 of the mounting flange 202 is dictated entirely by appearance considerations.
Referring to FIGS. 2 and 4, a pair of threaded studs 250 (only one appears in FIG. 2) project rearwardly from the rear face 246 of the back wall 242 for mounting various latch and lock components, as will be discussed. As is described and illustrated in the referenced Utility Cases I, II, III(a), III(b), IV and V, the studs 250 have enlarged head portions (not shown herein) that are embedded within the molded material of the back wall 242 of the housing 200 to provide threaded mounting formations that are anchored securely to the material of the plastic and will not rotate with respect thereto. The studs 250 have elongate threaded shank portions that project rearwardly from the rear wall 242 along spaced imaginary axes (designated by the numeral 251 in FIG. 2) that intersect the plane of the back wall 242 at right angles thereto. The axes 251 extend coaxially through the holes 752 that are formed in the back wall 760 of the mounting bracket 750. The axes 251 of the studs 250 are located equidistantly from the center plane 201, and are positioned on opposite sides of the center plane 201.
Locator projections 260 are provided at spaced locations along the side walls 236, 238 at junctures of the side walls 236, 238 with the rear face 206 of the mounting flange 202. As will be seen in FIG. 4, the locator projections 260 are arranged symmetrically in pairs on opposite sides of the center plane 201. The locator projections 260 are intended to directly engage opposite sides 126, 128 of the opening 112 to orient the lock assembly 100 properly on the closure 110; however, if the opening 112 has been formed so as to be slightly "oversized," the locator projections 260 may be utilized during installation of the lock assembly on the closure 110 as "guides" to visually aid in properly positioning the housing 200 with respect to the closure opening 112, preferably with the locator projections 260 being arranged to be spaced substantially equidistantly from opposite side portions 126, 128 of the opening 112.
The sleeve-like formation 280 of the housing 200 is located below the recess 210 and extends rearwardly from the rear face 206 of the mounting flange 202 along the bottom wall 234 of the housing portion 220. In preferred practice, the sleeve formation 280 is provided on the housing 200 regardless of whether the sleeve formation 280 is to be utilized to house operating components of a latch or lock.
If the sleeve formation 280 is to be utilized to house latch or lock components, an opening 282 is formed through the front wall 204 to communicate with a passage 284 that extends through the sleeve formation 280. The opening 282 and the passage 284 extend coaxially along an imaginary axis 281 (see FIG. 2) that lies within the imaginary center plane 201 and that extends substantially perpendicular to the planes of the rear face 206 and the back wall 246. If the sleeve formation 280 is not to be utilized to house latch or lock components, either no opening 282 is formed through the front wall 204, or a suitably configured plug (not shown) is installed in the opening 282 to close the opening 282.
Referring to FIG. 29, a shoulder 286 extends substantially radially with respect to the axis 281 to form a transition between the relatively large diameter of the opening 282 and the relatively smaller diameter of the passage 284 Axially extending top and bottom grooves 288 are formed in opposed upper and lower portions of the passage 284. Referring to FIG. 30, the grooves 288 extend axially rearwardly from the shoulder 286 and have bottom walls 289 that are curved and represent continuations of a cylindrical surface 290 of enlarged diameter that is formed in the rearward end region of the sleeve 280. A radially extending shoulder 292 forms a transition between the passage diameter that is designated by the numeral 284, and the enlarged diameter end region 290. A rounded groove 294 of shallower depth than the grooves 288 is formed in a side of the passage portion 284. The rounded groove 294 extends from the shoulder 286 to the shoulder 292.
Two opposed portions 296, 298 of the shoulder 292 extend radially outwardly and interrupt opposed side portions of the sleeve formation 280 to provide radially extending, rearwardly opening notches that are designated by the numerals 296, 298.
In preferred practice, the housing 200 is formed without any openings, holes, slots or the like extending through the walls that define the recess 210, i.e., the top, bottom, and side walls 232, 234, 236, 238, and the back wall 242 are smooth and have no openings formed therethrough. Depending on the type of handle that is to be used with the housing 200, and on the type of latch or lock operating mechanism that is to be mounted on the housing 200, one or more suitable passages through the housing 200 are machined in the form of openings, holes, slots and the like which formed as by drilling, milling or other conventional machining techniques.
The handles 300, 1300 and 2300 that are used in the housings 200, 1200 and 2200 are formed from molded plastics material, preferably of the same thermoplastics material from which the housings 200, 1200 and 2200 are formed. The handles 300, 1300 and 2300 have front surface portions 304, 1304 and 2304 that are of complexly curved, generally convex shape, and are configured to extend in a flush, substantially contiguous manner to smoothly continue the curvature of the complexly curved, convex front surfaces 204, 1204 and 2204 of the mounting flange 202, 1202 and 2202 when the handles 300, 1300 and 2300 are in their normal or nested position. The handle 300 is mounted on the housing 200 for movement between a normally nested position that is shown in FIGS. 1 and 3-7, and an operating position that is shown in FIG. 26 (also, rear portions of the handle 200 are shown in their operating positions in FIG. 8). The handle 1300 is mounted on the housing 1200 for movement between a normally nested position that is shown in FIGS. 10 and 12-16, and an operating position that is shown in FIG. 27 (also, rear portions of the handle 1200 are shown in their operating positions in FIG. 17). The handle 2300 is mounted on the housing 2200 for movement between a normally nested position that is, shown in FIGS. 18 and 20-24, and an operating position that is shown in FIG. 28 (also, rear portions of the handle 1200 are shown in their operating positions in FIG. 25).
The handles 300, 1300 and 2300 have shapes that let them nest and move with ease within the confines of their respective recesses 210, 1210 and 2210. Referring to FIGS. 2 and 11, the handles 300, 1300 have pivoted mounting portions that extend transversely across the recesses 210, 1210 and provide through passages 312, 1312 that are of square cross section for receiving handle mounting shafts 350, 1350 that also are of square cross section. The opposed end regions 314, 1314 of the mounting portions have cylindrical recesses 316, 1316 that surround the ends of the passages 312, 1312 for mounting O-rings 318.
Stop surfaces 320, 1320 are formed on depending portions of the handles 300, 1300 to engage the back walls 242, 1242 of the housings 200, 1200 when the handles 300, 1300 are nested in the recesses 210, 1210. Stop surface 322, 1322 are formed on the end regions of the handles 300 and 1300 for engaging the top walls 232, 1232 of the housing portions 220, 1220 when the handles 300, 1300 are in their operating positions.
The handles 300, 1300 and 2300 have operator engagement formations 310, 1310 and 2310 that can be engaged by an operator's hand (preferably by one or more fingers thereof) for moving the handles 300, 1300, 2300 between their normal or nested positions and their operating positions.
Referring to FIGS. 2 and 11, aligned handle mounting holes 336, 338 and 1336, 1338 are formed through the side walls 236, 238 and 1236, 1238 on opposite sides of the recesses 210 and 1210. The holes 336, 338 and 1336, 1338 are concentric about imaginary axes 331 and 1331 that extend substantially parallel to the back walls 242 and 1242, and that extend substantially perpendicular to the side walls 236, 238 and 1236, 1238, respectively.
The holes 336, 338 and 1336, 1338 are of equal diameters, and serve to journal reduced diameter end regions 346, 348 of a pair of bushings 356, 358. The bushings 356, 358 have relatively large diameter portions 366, 368 that extend alongside outer surfaces of the side walls 236, 238 and 1236, 1238. The O-rings 318 are positioned on the inside of the recess 316 and 1316 to surround the holes 336, 338 and 1236, 1238 to provide moisture seals that are compressed between opposite sides of the handle 300, 1300 and inner surfaces of the housing walls 236, 238 and 1236, 1238.
The bushings 356, 358 have square holes 376, 378 formed therethrough that extend along the imaginary axes 331 and 1331. The hole 378 that is formed in the bushing 358 has an end region 379 that is widened to receive a corner bend of a handle mounting shaft 350. The hole 376 that is formed in the bushing 356 can be "narrowed" on opposite sides as by providing opposed projections 377 that extend inwardly from opposite sides of portions of the hole 376--it being understood that the purpose of this exercise is to provide a means of retaining the bushing 356 on one of the handle mounting shafts 350, 1350 (i.e., grooves 380, 1380 preferably are provided in the handle shaft end regions, and the projections 377 can be inserted into these grooves; alternately, the grooves 380, 1380 can be engaged by a conventional, commercially available gripping type fastener (not shown) such as a conventional snap ring or the like.)
The handle mounting shafts 350, 1350 are formed from stainless steel stock of square cross section, and are provided with leg portions 352, 354 and 1352, 1354 that are connected by curved, right-angle bends 370 and 1370, respectively. The legs 354 and 1354 connect with U-shaped end regions 372 and 1372 that are referred to elsewhere in this document by the term "handle-connected members"--the intention being to denote that the U-shaped end regions 372 and 1372 are rigidly connected to their associated operating handles 300 and 1300 and therefore pivot with the handles 300, 1300 relative to the housings 200, 1200. The legs 352 and 1352 extend through the bushing holes 376, 378 and the handle passages 312 and 1312. In the embodiments depicted in the drawings, the grooves 380 and 1380 that are formed in opposite sides of end regions 382 and 1382 of the legs 352 and 1352 are used to receive the bushing projections 377.
With respect to each of the lock assemblies 100, 1100 and 2100, its associated latch bolt 400 is mounted on an associated one of the housings 200, 1200 and 2200 for pivotal movement between a latched position (wherein the latch bolts 400 extend sidewardly relative to their associated housings 200, 1200 and 2200 as is depicted, for example, in FIGS. 1, 10 and 18, respectively), and an unlatched position (that is depicted in FIGS. 8, 17 and 25, respectively).
For purposes of permitting portions of the latch bolt 400, the operating arm 500 and a torsion coil spring 575 (that is used to spring-bias the latch bolt 400, as will be explained) to be viewed, reference is made to the depiction of a set of these components that is presented in FIG. 9. The orientation of the components that is depicted in FIG. 9 is quite easily understood if the reader will simply compare what is depicted in FIG. 9 which such portions of these same components as appear in FIGS. 1, 10 and 18--for the component orientation that is shown in FIG. 9 corresponds exactly to the component orientation that is depicted in FIGS. 1, 10 and 18. Thus, what is shown in FIG. 9 includes a depiction of the latch bolt 400 in its "latched" position, and a depiction of the operating arm 500 in its "normal" or "non-operated" position.
The latch bolt 400 and the operating arm 500 are coaxially but independently mounted for pivotal movement about the axis of the post-like fastener 700. Referring to FIG. 2, the operating arm 500 has a sleeve-like formation 516 that defines a mounting hole 511. The hole 511 is sized to receive a generally cylindrical portion 703 of the post-like fastener 700 in a slip fit so as to pivotally mount the operating arm 500 for pivotal movement relative to the housing 200 about the axis 251 of the fastener 700. The outer diameter of the sleeve-like formation 516 is received in a slip fit in a relatively large diameter hole 416 that is formed through the latch bolt 400. By this arrangement, the latch bolt 400 is mounted for pivotal movement relative to the housing 200 about the axis 251 of the fastener 700 (with either of the latch bolt 400 and the operating arm 500 being free to pivot relative to each other).
The latch bolt 400 is an elongate member that has opposed first and second end regions 402, 404 that are connected by a central region 406. The inner end region 402 defines a mounting formation that takes the form of the relatively large diameter hole 416 that is described above. A part of the inner end region 402 that is designated in FIG. 9 by the numeral 426 is intended to extend beyond the side of the back wall 242 (i.e., beyond the confines of the side wall 236 of the recess-defining portion 220 of the housing 200 (as is shown in FIG. 6). A stop formation 436 is carried by the inner end region part 426. The stop formation 436 is configured to engage the side wall 236, as is best seen in FIG. 5, when the latch bolt 400 is in its latched position--whereby the "latching" movement of the latch bolt 400 is limited by the action of the stop formation 436.
The outer end region 404 of the latch bolt 400 defines what has previously been referred to as the hook-shaped end region 452. The "slam engagement surface" 454 is defined on outer portions of the end region 452, and is slanted so that, if this surface is engaged by a striker formation (not shown) that is moving relatively toward the housing 200, the latch bolt 400 will be caused to pivot briefly toward its unlatching position (i.e., to a sufficient extent to permit the striker formation to pass by the hook shaped end region 452 whereafter the latch bolt 400 typically would return to its latched position under the influence of the torsion coil spring 575 so as to latchingly engage the striker formation as by "hooking" it with the hook shaped end region 452).
The central region 406 extends across the back wall 242 and beyond the side wall 238 to a position where a stop formation 438 is defined. In FIG. 8, the stop formation 438 is shown in phantom to illustrate that, when the latch bolt 400 is pivoted to its unlatched position, the stop formation 438 engages the side wall 238 to stop further unlatching movement of the latch bolt 400. The central portion 406 has an edge portion 422 that serves as a drive engagement surface to drivingly engage a corresponding drive engagement formation 522 that is provided on the operating arm 500, as will be explained in greater detail.
Referring principally to FIG. 9, a hollowed out or cut out formation 432 is provided in the inner end portion 402 and extends to the central portion 406 to receive portions of the torsion coil spring 575. The cutout 432 includes a portion 418 that extends about the hole 416 (to receive a coiled central portion 577 of the torsion coil spring 575) and a portion 419 that extends along one edge of the central region 406 (to receive a leg portion 579 of the spring 575). A leg portion 578 of the spring 575 extends from the coil 577 across portions of the cutout 432, across portions of the backwall 242, and has an L-shaped end region 576 that extends along the bottom wall 234 of the recessed pan portion 220 at a location adjacent the sleeve formation 280, as is best seen in FIG. 8.
In the lock embodiments that are shown in the drawings hereof, the latch bolt 400 has an offset or "dogleg" portion 405 that functions to rearwardly position the hook-shaped end region 452. If a particular application does not require such an offset, or if a greater offset is needed, the configuration of the latch bolt 400 can be appropriately adjusted, as will be readily understood by those who are skilled in the art.
The operating arm 500 has a central region 506, with a pair of legs 508, 512 that cooperate with the central region to define a generally L-shaped member that is referred to elsewhere herein by the reference numeral 510. Referring to FIG. 2, a triangular drive formation 522 is carried on the leg 512 for engaging the drive formation 422 of the latch bolt 400 so as to transfer directly through the drive formation 522 such handle-operated force as is generated by moving the handle 300 from its nested position to its operated position--which, in turn, causes the U-shaped end region 372 of the handle-connected member 350 to apply force to the drive formation 522, which transmits that force to the drive formation 422 and thereby causes movement of the latch bolt 400 from its latched position to its unlatched position.
The leg 508 of the operating arm 500 defines a generally U-shaped slot or groove 530 that gives the end region of the leg 508 a hook-shaped appearance that is referred to elsewhere herein by the reference numeral 520. As will be explained, the groove 530 is provided to receive a movable portion of the locking device 600 that is selectively movable into and out of the path of movement that is followed by the leg 508 when the operating arm 500 is pivoted from its normal, non-operated position to its operated position. By this arrangement, the locking device 600 serves to selectively restrain the operating arm 500 from moving out of its normal, non-operated position, and thereby serves to "lock" the lock assembly 100.
In effect, the two legs 508, 512 of the L-shaped operating arm 500 perform separate functions. The leg 512 (which carries the operating formation 522) functions to transmit force between the operating handle 300 and the latch bolt 400 so as to effect "unlatching" movement of the latch bolt 400 in response to the operating handle's being moved out of its nested position to its operated position. The leg 508, on the other hand, cooperates with the locking device 600 to selectively prevent movement of the operating arm 500 in response to attempted movement of the operating handle 300; and, since the handle 300 cannot move out of its nested position if the operating arm 500 is not free to pivot about the post-like fastener 700, if the operating arm 500 is "locked" against moving from its normal, non-operated position, so is the handle 300.
The action of the torsion coil spring 575 serves to bias the latch bolt 400 in a direction away from its unlatched position (as shown in FIG. 8) toward its latched position (as shown in FIGS. 1 and 3-7). The spring end region 576 engages the housing 200; the end region 579 engages the latch bolt 400; and, the torsion coils 577 effect the described biasing action as by tending to cause relative movement of the spring end regions 576, 579 about the axis 251 of the fastener 700. A feature of the action of the torsion coil spring 575 is that its biasing action is so strong as to be transmitted from the latch bolt 400 through the operating arm 500 to the handle 300 so as to normally maintain both the operating arm 500 and the handle 300 in their normal, non-operated positions.
Just as the stop formations 436, 438 control the range of pivotal movement of the latch bolt 400, the fact that the torsion coil spring 575 tends to maintain engagement between the drive formations 422, 522 causes the action of the stop formations (as described above) to likewise define the range of pivotal movement that is executed by the operating arm 500.
Because the lock assembly 2100 has an operator graspable handle 2300 that slides within the recess 2210 rather than pivots relative to its associated housing 2200 (as is the case with the handles of the lock assemblies 100 and 1100), a brief discussion is in order concerning the unique character of this sliding handle embodiment.
Referring to FIGS. 18-25 and 28 wherein features of the lock assembly 2100 are depicted, two operator engageable structures 2900, 2910 are nested in the recess 2210. The structures 2900, 2910 are identical in many essential respects, with one principal difference residing in the fact that the structure 2900 is rigidly bonded to the housing formation that surround the recess 2210, while the structure 2910 is a handle that is movable relative to the housing 2200 along the length of the recess 2210. A slot 2912 (shown in FIG. 19 in a gap that is provided as by breaking away portions of the housing 2200) is formed through the housing back wall 2242 to receive a handle carried arm or projection 2350 that extends through the slot 2912 for engaging the operating arm 500 to move the " arm 500 to unlatch the lock or latch 2100.
As is best seen in FIG. 19, the handle operated arm or projection 2350 has a shoulder 2930 formed thereon at a location spaced slightly below the opening in the back wall 2242 so that, when a guide member 2940 is installed on the projection 2350 in a press-fit, the guide member 2940 will rest against the shoulder 2930 and not clamp against the back wall 2242 in away that will inhibit movement of the handle relative to the housing 2200. Preferably, the connection between the handle projection 2350 and the guide member 2940 is secured as by adhesive bonding, whereby the handle operated arm 2350 is every bit as suited as the handle operated arms 350, 1350 to pivot the arm 500 in response to handle movement.
The operating arms 500 that are utilized in the lock embodiments 100 and 1100 have leg portions 512 that are engaged by the handle-connected members 372, 1372. Likewise, the operating arm 500 that is utilized in the lock embodiment 2100 has a leg portion 512 that is engaged by a handle-connected formation 2350. Thus, the operating arms 500 all are caused to pivot about their associated mounting posts 700 as by movement of handle-connected members or formations 372, 1372 and 2350.
The lock mechanisms 600 serve to engage the hook shaped end regions 520 to selectively permit and prevent movement of the arms 500 in response to attempted operation of the handles 300, 1300 and 2300. Referring to FIG. 2, the lock mechanisms 600 include a ring-like insert 610 that is provided for positioning in the rear end region 292 of the sleeve portion 280 of the housing 200. The insert 610 serves the function of closing rear end regions of the top and bottom grooves 288 and of defining a rearwardly extending stop projection 620 for limiting the range of rotary movement of locking members 630.
In order to provide an extension of the rounded installation groove 294 through the ring-like insert 610, a rounded groove 624 is formed in the insert 610 and is aligned with the rounded groove 294 of the sleeve members 280. In order to properly position the ring-like insert 610 for mounting on the housings 200, 1200, 2200, a pair of radially extending formations 626, 628 are provided to engage the grooves 296, 298 that are formed at the rear end of the sleeve member 280. The groove 626 and the formation 296 is of relatively small size and is configured to mate in a close slip fit. The groove 628 and the formation 298 is of relatively larger size and is configured to mate in a close slip fit.
Referring to FIGS. 2, 11 and 19, a key receiving, tumbler-carrying plug assembly 650 is provided that has an enlarged diameter head portion 652 that has a circumferentially extending groove for carrying an O-ring 653, and a smaller diameter body 654 that are configured to be rotatably received in the openings and passages 282, 284. Radially extensible tumblers 656 form components of the plug 650 assembly and are extensible into the top and bottom groove 288 to selectively permit and prevent rotation of the key cylinder assembly 650 with respect to the housings 200, 1200, 2200.
The key cylinder assembly 650 has a rearwardly projecting square drive formation 678 that is engaged by a rotary locking member 680. The rotary locking member 680 is rigidly attached to the cylinder assembly by means of a threaded fastener 682 and a lock washer 684. The locking member 680 has a rearwardly extending projection 695 of curved shape that can be rotated by the key cylinder assembly 650 into and out of locking engagement with the hook shaped end region 520 of the arm 510. The rearwardly extending projection 620 of the insert ring 610 limits the range of rotary travel of the locking member 680 so as to prevent full 360 degree rotation thereof. The rearwardly extending projection 695 of the locking member 680 is rotatable 1) into locking engagement with the hook shaped end region 520 of the operating arm 510 out of locking engagement therewith to permit pivotal movement of the arm 510 by the handles 300, 1300, 2300 to retract (i.e., "unlatch") the latch bolt 400.
A locked orientation of the locking mechanism components as described above is presented in an exploded display in FIG. 29 and is designated by the numeral 790. An unlocked orientation of these components is designated by the numeral 792.
If desired, the key locking cylinder assembly 650 can be replaced by tool operated plugs, as designated by numerals 800, 810 in FIG. 29. Detent devices 802, 812 are preferably provided in the plugs 800, 810 as by forming radially extending bores 804, 814 that house springs 806, 816 and balls 808, 818 which cooperate with such interior sleeve formations as the grooves 788 that are shown in FIG. 29 to releasably retain the plugs 800, 810 in position to prevent undesired rotation thereof.
The plugs 800, 810 carry tool receiving formations, typically a hex 820 recess for receiving an Allen wrench, or a narrow, shallow slot 822 for receiving a screwdriver.
Operation of the locks 100, 1100, 2100 described herein to pivot the latch bolts 400 in "unlatching" movements will be understood by those skilled in the art to involve a simple movement of their operating handles 300, 1300, 2300 when their locking mechanisms 600 are unlocked, whereby their operating arm 510 will pivot to effect latch bolt "unlatching." And, because latch bolt "unlatching" movement is not directly tied to operating arm movement, the described locks and latches have a "slam" capability that enables the latch bolts 400 to be moved into latching engagement with strikers without causing corresponding handle movements.
To the extent that orientation terms such as "frontwardly," "rearwardly," "upwardly," "downwardly" and the like have been used in this document, it will be understood that such terms have been used simply for convenience and to facilitate understanding of the features that have been described, whereby the use of such orientation term should not be deemed to limit the scope of the claims that follow.
Although the invention has been described in its preferred form with a certain degree of particularity, it will be understood that the present disclosure of the preferred form has been made only by way of example, and that numerous changes in the details of construction and the combination and arrangements of parts and the like may be resorted to without departing from the spirit and scope of the invention as hereinafter claimed. It is intended that the patent shall cover, by suitable expression in the appended claims, whatever features of patentable novelty exist in the invention disclosed.
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Flush mountable latches and locks for industrial cabinets, tool carts, electrical equipment enclosures and the like utilize versatile housings together with a variety of types of handles that are movable relative to the housings to effect unlatching movements of spring-biased, pivotally mounted latch bolts, with pivotally mounted operating arms serving to drivingly interconnect the handles with the latch bolts. Lockable embodiments have locking mechanisms that prevent operating movements of the operating arms, but do not prevent pivotal movement of the latch bolts out of their latched positions, whereby even the lockable embodiments have latch bolts that can be "slammed" into latching engagement with suitably configured strike formations. Other improvement features reside in the provision of coaxially-pivoted overlying sets of latch bolt and operating arm components that cooperate in a plurality of ways, and in the provision of stop formations, torsion-spring-receiving formations, and co-acting drive formations, with such features enabling the resulting latch and lock assemblies to employ a small number of relatively movable parts that can be assembled, installed and serviced with ease.
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This application is based on Japanese patent application No. 2008-042984 filed on Feb. 25, 2008, the contents of which are hereby incorporated by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an image processing apparatus and an image processing method used in an image forming apparatus such as an MFP.
2. Description of the Related Art
Image processing apparatuses, which process image data, are conventionally provided in image forming apparatuses called MFPs, or Multi-Function Peripherals.
Such image processing apparatuses execute resolution conversion processing on image data and attribute data, thereby scaling (enlarging or reducing) that data, in order to adjust the image data and attribute data to the print size, resolution of the printer, and so on.
The nearest neighbor method, the bilinear method, and the bicubic method are known as examples of methods for executing scale processing on image data. The nearest neighbor method, also known as the nearest neighbor algorithm, uses the image data (luminance data) of a pre-scaling pixel nearest in distance to the pixel that is to be interpolated (a pixel of interest).
The bilinear and bicubic methods are linear interpolation methods, which interpolate image data having taken the pixels surrounding a pixel of interest into consideration.
While the nearest neighbor method can be applied to both binary image data and multivalued image data, the bilinear and bicubic methods cannot interpolate binary image data (that is, the meaning of the data is altered, and thus the methods cannot be applied).
Generally speaking, image data is multivalued data, and therefore the bicubic method, which can attractively interpolate the image data, is often used for scaling. However, attribute data is typically binary data, as illustrated in FIG. 5 and described later, and therefore the nearest neighbor method is used for the scaling thereof.
FIG. 7 illustrates resolution conversion processing that performs 4× enlargement on attribute data a 0 and image data b 0 using the nearest neighbor method. In this example, an image interpolation processing circuit 200 converts the resolution of the image data b 0 , resulting in image data b 01 , b 02 , b 03 , and b 04 . Meanwhile, the attribute data a 0 is simply duplicated into four instances of attribute data a 0 .
FIG. 8 illustrates resolution conversion processing using the nearest neighbor method on a pixel-by-pixel basis, where the attribute data of pixels of interest P 1 , P 2 , P 3 , and P 4 are taken as a 0 , a 1 , a 2 , and a 3 , respectively. As a result of this processing, the attribute data of the pixel P 1 , a pixel P 11 adjacent to the pixel P 1 , a pixel P 12 adjacent to the pixel P 11 , and a pixel P 13 adjacent to the pixel P 12 each take on attribute data a 0 ; the attribute data of the pixel P 2 , a pixel P 21 adjacent to the pixel P 2 , a pixel P 22 adjacent to the pixel P 21 , and a pixel P 23 adjacent to the pixel P 22 each become attribute data a 1 ; the attribute data of the pixel P 3 , a pixel P 31 adjacent to the pixel P 3 , a pixel P 32 adjacent to the pixel P 31 , and a pixel P 33 adjacent to the pixel P 32 each become attribute data a 2 ; and the attribute data of the pixel P 4 , a pixel P 41 adjacent to the pixel P 4 , a pixel P 42 adjacent to the pixel P 41 , and a pixel P 43 adjacent to the pixel P 42 each take on attribute data a 3 . In this manner, attribute data ZD is simply duplicated when the resolution conversion processing is carried out.
Region determination processing, for determining which region each pixel of inputted image data belongs to, is typically carried out prior to the image data being outputted (see Patent Document 1, JP H11-213152A). According to the image processing apparatus disclosed in Patent Document 1, the absolute value of the difference in pixel values between a neighboring pixel and either an adjacent pixel, a neighboring pixel located at a predetermined distance from the pixel of interest within a predetermined range, or both is found. The attributes of the predetermined pixel are then identified based on that absolute value.
In addition, in order to obtain a high-quality image for reproduction, determining the image attributes of an image signal, generating an attribute determination signal that indicates the image attributes, and carrying out image processing using a signal in which the attribute determination signal is embedded into the image signal in a predetermined format are disclosed in Patent Document 2, JP 2004-228811A.
However, the following problems arise when resolution conversion processing is performed on attribute data using the nearest neighbor method.
Assuming that, as illustrated in FIG. 9 , the image data (luminance data) of pixels P 1 to P 6 , which are pixels of interest, is, in order, b 0 (white data), b 0 , b 1 (black data), b 1 , b 0 , and b 0 , the data becomes as follows when enlarged 4× through a predetermined resolution conversion processing (the bicubic method): the image data of pixels P 1 , P 11 , P 12 , and P 13 becomes b 0 ; the image data of pixels P 2 , P 21 , P 22 , and P 23 becomes, in order, b 0 , b 01 , b 02 , and b 03 ; the image data of pixels P 3 , P 31 , P 32 , and P 33 becomes b 1 ; the image data of pixels P 4 , P 41 , P 42 , and P 43 becomes, in order, b 1 , b 03 , b 02 , and b 01 ; the image data of pixels P 5 , P 51 , P 52 , and P 53 becomes b 0 ; and the image data of pixels P 6 , P 61 , P 62 , and P 63 becomes b 0 .
The stated image data b 0 , b 01 , b 02 , b 03 , and b 1 indicates a gradation, where the tone changes from white to black in that order. For example, the image data b 01 is light gray data, the image data b 02 is gray data, and the image data b 03 is dark gray data.
As opposed to this, assuming that the attribute data of the pixels P 1 to P 6 is, in order, a 0 (a white character), a 0 , a 1 (a black character), a 1 , a 0 , and a 0 , the data becomes as follows when enlarged 4× through the nearest neighbor method: the attribute data of pixels P 1 , P 1 , P 12 , and P 13 becomes a 0 ; the attribute data of pixels P 2 , P 21 , P 22 , and P 23 becomes a 0 ; the attribute data of pixels P 3 , P 31 , P 32 , and P 33 becomes a 1 ; the attribute data of pixels P 4 , P 41 , P 42 , and P 43 becomes a 1 ; the attribute data of pixels P 5 , P 51 , P 52 , and P 53 becomes a 0 ; and the attribute data of pixels P 6 , P 61 , P 62 , and P 63 becomes a 0 .
When image data is processed using a predetermined resolution conversion method and attribute data is processed using the nearest neighbor method in this manner, the colors indicated by the image data b 01 (light gray data), b 02 (gray data), and b 03 (dark gray data) for the pixels P 21 , P 22 , and P 23 are clearly different from the colors indicated by the attribute data a 0 (white characters) of the same pixels. As a result, post-processing such as edge enhancement cannot be executed properly, which in turn leads to a degradation in image quality. This degradation is particularly apparent when compressing image data into a compact PDF format.
The methods disclosed in Patent Documents 1 and 2 do not carry out resolution conversion processing on image data and attribute data without causing a degradation in image quality.
SUMMARY
Having been conceived in light of such problems, it is an object of the present invention to enable resolution conversion processing to be carried out on image data and attribute data without causing a degradation in image quality, a drop in scale ratio, and the like.
An image processing apparatus according to one aspect of the present invention is an image processing apparatus that scales image data, the image data generated by reading a document using a reading unit, by performing resolution conversion processing on the image data. The apparatus includes a detector that detects attributes of the image data generated by the reading unit, an attribute data generator that generates attribute data based on a result of detection performed by the detector, an image resolution converter that performs image resolution conversion processing on the image data of a pixel of interest, and an attribute resolution converter that performs attribute resolution conversion processing on the attribute data of the pixel of interest. The attribute resolution converter employs attribute data identical to the attribute data before being subjected to the attribute resolution conversion processing as the attribute data for the pixel of interest following the attribute resolution conversion processing, and employs the attribute data after being subjected to the attribute resolution conversion processing as the attribute data for neighboring pixels to the right and left of the pixel of interest following the attribute resolution conversion processing.
Preferably, the attributes of the image data may include halftone information indicating whether or not the image data is halftone data, edge information indicating whether or not the image data is of an edge, and character information indicating whether or not the image data is of characters and a character type. The attribute data generator may generate the attribute data based on the halftone information, the edge information, and the character information.
Further, the attribute resolution converter may employ, as the attribute data after being subjected to the attribute resolution conversion processing for the neighboring pixels, either the attribute data of the pixel of interest before being subjected to the attribute resolution conversion processing or the attribute data of adjacent pixels that are adjacent to the pixel of interest before being subjected to the attribute resolution conversion processing, or new attribute data generated based on the attribute data of the pixel of interest and the attribute data of the adjacent pixels.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram illustrating an overall configuration of an image processing apparatus according to an embodiment of the present invention.
FIG. 2 is a block diagram illustrating the configuration of an output resolution conversion unit shown in FIG. 1 .
FIG. 3 is a diagram illustrating resolution conversion processing performed on attribute data.
FIGS. 4A and 4B are diagrams illustrating image data and attribute data on which resolution conversion has been executed.
FIGS. 5A through 5C are diagrams illustrating a method for generating attribute data for pixels in an interpolated pixel generation region.
FIG. 6 is a diagram illustrating another example of a method for generating attribute data using the image processing apparatus.
FIG. 7 is a block diagram illustrating a conventional configuration for performing resolution conversion on image data and attribute data.
FIG. 8 is a diagram illustrating resolution conversion according to the nearest neighbor method.
FIG. 9 is a diagram illustrating a problem with resolution conversion according to the nearest neighbor method.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
An image processing apparatus 1 according to the present embodiment is used in an image forming apparatus such as an MFP (multi-function peripheral), in which a scanner unit and a printer unit are integrated into a single unit.
As illustrated in FIG. 1 , the image processing apparatus 1 according to the present embodiment is configured of a scanner control unit 2 , an input resolution conversion unit 3 , a first image adjustment unit 4 , a color conversion unit 5 , an image modification unit 6 , an output resolution conversion unit 7 , an AE/ACS processing unit 8 , a second image adjustment unit 9 , and a region determination unit 10 .
CPUs, memories, other types of circuit elements, and so on are used for the constituent elements of the image processing apparatus 1 described above. These may be entirely or partially integrated as ICs and used as, for example, microprocessors, ASICs (Application-Specific Integrated Circuits), or the like.
A document is read by a reading unit (not shown) configured of a CCD (charge-coupled device), a mirror, document glass, and so on, and image data GD is generated as a result.
The scanner control unit 2 performs shading modification, inter-line modification, and chromatic aberration modification on the image data GD.
“Shading modification” refers to modifying what is known as “scanner irregularities” in the image data GD (e.g. variations in the sensitivities of the pixels in the CCD, irregularities in the light distribution, and so on). “Inter-line modification” refers to modifying phase shift in R, G, and B color signals (data) arising due to positional shift between the R, G, and B lines in the CCD. This modification is performed by delaying the R and G components of the image data GD using a filed memory. Finally, “chromatic aberration modification” refers to modifying phase shift in the image data GD arising due to chromatic aberration in a lens system.
The input resolution conversion unit 3 performs conversion processing on the resolution of the image data GD in the main scanning direction and in the sub-scanning direction. The first image adjustment unit 4 adjusts the color of the image data GD. The color conversion unit 5 performs color conversion processing and γ correction on the image data GD. “Color conversion processing” refers to a process for substituting a color for another color, or a process for expressing the color data as a pure color using only one or two coloring materials. “γ correction”, meanwhile, refers to correcting gradation characteristics in the image processing apparatus 1 when gradation is expressed using a dither pattern.
The image modification unit 6 adjusts the color balance of the image data GD, and generates attribute data ZD based on the image data GD that has undergone processing by the region determination unit 10 , which shall be discussed later.
The attribute data ZD is data indicating attributes of the image data GD, such as: whether or not the image data GD is made up of halftone dots (whether or not the image is continuous tone); whether or not the data indicates an edge; whether or not the data indicates characters; if the data does indicate characters, whether those characters are white characters, color characters, or black characters; and so on.
The output resolution conversion unit 7 performs conversion processing on the resolution of the image data GD and the attribute data ZD generated by the image modification unit 6 , in the main scanning direction and in the sub-scanning direction. Through this, the image data GD and attribute data ZD are scaled (enlarged or reduced) in the main scanning direction and the sub-scanning direction.
The AE/ACS processing unit 8 performs AE detection processing (photometric processing) and color/monochrome determination processing. The second image adjustment unit 9 adjusts the color of the image data GD.
The region determination unit 10 divides the image data GD into regions according to attributes such as characters, photographs, halftone, and so on. In other words, the region determination unit 10 performs character determination processing, halftone determination processing, and edge determination processing. In the character determination processing, it is determined whether or not the image consists of characters. In the halftone determination processing, it is determined whether or not the image is a halftone image. Finally, in the edge determination processing, it is determined whether or not the image is an edge. Note that the region determination performed by the region determination unit 10 is carried out on image data GD of, for example, 600 dpi or 400 dpi.
As illustrated in FIG. 2 , the output resolution conversion unit 7 is configured of an attribute conversion processing circuit 7 a and an image conversion processing circuit 7 b .
CPUs, memories, other types of circuit elements, and so on are used for the output resolution conversion unit 7 . A computer program for realizing the functions of the output resolution conversion unit 7 is stored in such a memory. This type of program can be installed from a portable recording medium BT, which includes a recording medium BT 1 , such as a CD-ROM, DVD-ROM, or the like, or a recording medium BT 2 , such as a semiconductor memory or the like, the recording medium having the program recorded therein. The program may also be downloaded from a server via a network.
When the image data and attribute data are scaled 4× through resolution conversion processing, the attribute conversion processing circuit 7 a converts the attribute data a 0 to, for example, attribute data a 01 , a 02 , a 03 , and a 04 , whereas the image conversion processing circuit 7 b converts the image data b 0 to, for example, image data b 01 , b 02 , b 03 , and b 04 . In such a manner, rather than simply being duplicated, resolution conversion is also carried out on the attribute data, as well as the image data, in the present embodiment.
Descriptions shall now be provided regarding the resolution conversion carried out on the attribute data by the image processing apparatus 1 according to the present embodiment.
In FIG. 3 , the attribute data of an inputted pixel P 1 is a 0 , the attribute data of an inputted pixel P 2 is a 1 , the attribute data of an inputted pixel P 3 is a 2 , and the attribute data of an inputted pixel P 4 is a 3 ; resolution conversion processing is executed thereon so as to enlarge this data 4×.
In the present embodiment, a region RC (called an “input data replacement region” hereinafter), where the inputted attribute data is used as-is, and a region RH (called an “interpolated pixel generation region” hereinafter), where new attribute data is generated from the attribute data of two adjacent inputted pixels, are set as regions of the pixels P on the output side. The output resolution conversion unit 7 switches between allocating attribute data to the pixels P belonging to the input data replacement region RC and allocating attribute data to the pixels P belonging to the interpolated pixel generation region RH.
In the example shown in FIG. 3 , pixels P 1 , P 11 , and so on belong to an input data replacement region RC 1 ; a pixel P 12 belongs to an interpolated pixel generation region RH 1 ; pixels P 13 , P 2 , and P 21 belong to an input data replacement region RC 2 ; and a pixel P 22 belongs to an interpolated pixel generation region RH 2 .
Furthermore, pixels P 23 , P 3 , and P 31 belong to an input data replacement region RC 3 ; a pixel P 32 belongs to an interpolated pixel generation region RH 3 ; pixels P 33 , P 4 , and P 41 belong to an input data replacement region RC 4 ; a pixel P 42 belongs to an interpolated pixel generation region RH 4 ; and a pixel P 43 belongs to an input data replacement region RC 5 .
As described above, in the present embodiment, the inputted attribute data is employed as-is for the attribute data of pixels present in the input data replacement region RC. Therefore, a 0 is employed for the attribute data of pixels P 1 and P 11 , a 1 is employed for the attribute data of pixels P 13 , P 2 , and P 21 , a 2 is employed for the attribute data of pixels P 23 , P 3 , and P 31 , and a 3 is employed for the attribute data of pixels P 33 , P 4 , and P 41 .
However, new attribute data generated from the attribute data of two adjacent inputted pixels is employed for the attribute data of pixels present in the interpolated pixel generation region RH. Therefore, a 01 is employed for the attribute data of pixel P 12 , a 12 is employed for the attribute data of pixel P 22 , and a 23 is employed for the attribute data of pixel P 32 .
The attribute data a 01 is new attribute data generated from the attribute data a 0 and a 1 of two adjacent inputted pixels P 1 and P 2 ; the attribute data a 12 is new attribute data generated from the attribute data a 1 and a 2 of pixels P 2 and P 3 ; and attribute data a 23 is new attribute data generated from the attribute data a 2 and a 3 of pixels P 3 and P 4 .
FIGS. 4A and 4B are diagrams illustrating image data and attribute data on which resolution conversion has been executed, and FIGS. 5A through 5C are diagrams illustrating a method for generating attribute data for pixels in the interpolated pixel generation region RH.
Assuming that, as illustrated in FIG. 4A , the image data of pixels P 1 to P 6 , which are pixels of interest, is, in order, b 0 (white data), b 0 , b 1 (black data), b 1 , b 0 , and b 0 , the data becomes as follows when enlarged 4× through a resolution conversion processing using the bicubic method: the image data of pixels P 1 , P 11 , P 12 , and P 13 becomes b 0 ; the image data of pixels P 2 , P 21 , P 22 , and P 23 becomes, in order, b 0 , b 01 , b 02 , and b 03 ; the image data of pixels P 3 , P 31 , P 32 , and P 33 becomes b 1 ; the image data of pixels P 4 , P 41 , P 42 , and P 43 becomes, in order, b 1 , b 03 , b 02 , and b 01 ; the image data of pixels P 5 , P 51 , P 52 , and P 53 becomes b 0 ; and the image data of pixels P 6 , P 61 , P 62 , and P 63 becomes b 0 . Note that the bicubic method is an interpolation method that uses cubic polynomials, and is a method that obtains the image data of a pixel of interest from cubic polynomials based on the values of 16 pixels (4 vertical and 4 horizontal) in the vicinity of the pixel of interest for which the image data is to be found.
The aforementioned image data b 0 , b 01 , b 02 , b 03 , and b 1 indicate a gradation, where the tone changes from white to black in that order. For example, the image data b 01 is light gray data, the image data b 02 is gray data, and the image data b 03 is dark gray data.
However, in the present embodiment, the details of the attribute data is expressed using code realized by bits, and the details of the attribute data of pixels in the interpolated pixel generation region RH is also expressed by code. In FIG. 4A , the code that expresses the attribute data of the pixels P 1 through P 6 is, in order, 0000, 0100, 0111, 0011, 0100, and 0000. The details of the attribute data expressed by the code shall be mentioned later.
When illustrating such 4-digit code within the pixels P shown in FIG. 4A , and assuming that the four digits in the code are represented by D 1 , D 2 , D 3 , and D 4 in order from the most significant digit, D 1 is located at the upper left, D 2 at the upper right, D 3 at the lower left, and D 4 at the lower right of each pixel P, as indicated in FIG. 4B .
The following are provided as regions for the post-resolution conversion pixels P: an input data replacement region RC 1 , including an input data replacement region RC 11 to which pixels P employing the attribute data of the pixel P 1 as-is belong, and an input data replacement region RC 12 to which pixels P employing the attribute data of the pixel P 2 as-is belong; an interpolated pixel generation region RH 1 in which attribute data is generated from the pixels P 2 and P 3 and employed; an input data replacement region RC 2 , including an input data replacement region RC 23 to which pixels P employing the attribute data of the pixel P 3 as-is belong, and an input data replacement region RC 24 to which pixels P employing the attribute data of the pixel P 4 as-is belong; an interpolated pixel generation region RH 2 in which attribute data is generated from the pixels P 4 and P 5 and employed; and an input data replacement region RC 3 , including an input data replacement region RC 35 to which pixels P employing the attribute data of the pixel P 5 as-is belong, and an input data replacement region RC 36 to which pixels P employing the attribute data of the pixel P 6 as-is belong.
Next, the details of the attribute data, as well as a method for generating the attribute data of the pixels P within the interpolated pixel generation regions RH, shall be described with reference to FIGS. 5A through 5C .
As shown in FIG. 5A , the attribute data code used in the present embodiment indicates whether or not the pixel P is in a halftone dot; whether or not the pixel P is on an edge; whether or not the pixel P is in a character; and if the pixel P is in a character, whether the character is a white character, a color character, or a black character.
In the present embodiment, the attribute data is 4-digit attribute information expressed in 4 bits. If the most significant digit is 0, the pixel P is not in a halftone dot, whereas if the most significant digit is 1, the pixel P is in a halftone dot. Meanwhile, if the next digit down from the most significant digit is 0, the pixel P is not on an edge, whereas if that digit is 1, the pixel P is on an edge.
Furthermore, if the next digit up from the least significant digit and the least significant digit together are 00, there is no character, whereas the pixel P is in a white character if these digits are 01, the pixel P is in a color character if these digits are 10, and the pixel P is in a black character if these digits are 11.
Such 4-bit attribute data is decoded into 6-digit attribute data expressed by 6 bits in order to obtain a logical sum during the process of generating the attribute data (interpolation processing), described later. In other words, up to the fourth digit from the least significant digit is used, and thus 0001 indicates that no characters are present, 0010 indicates that the pixel P is in a white character, 0100 indicates that the pixel P is in a color character, and 1000 indicates that the pixel P is in a black character. Note, however, that the details indicated by the most significant digit and the next digit up from the most significant digit are the same as described above in this case as well.
Next, the attribute data of the pixels P in the interpolated pixel generation region RH is generated using the attribute data made up of the 6 digits of two adjacent pixels.
In the present embodiment, a logical sum of the attribute data made up of the 6 digits of two pixels is obtained. To describe in more detail, the logical sum of the attribute data 011000 and 000001 of two adjacent pixels, or 011001, is obtained, and that logical sum is taken as the attribute data of the pixels P in the interpolated pixel generation region RH.
Next, the 6-bit attribute data obtained from the logical sum is re-encoded into 4-bit attribute data. In this case, the lowest 4 digits of the attribute data obtained through the logical sum are re-encoded into 2 digits.
To be more specific, if the lowest 4 digits of the attribute data are 0001, it is assumed that there is no character, and thus the digits are re-encoded into 00; if the lowest 4 digits of the attribute data are 001x (where x is arbitrary), it is assumed that the pixel P is in a white character, and thus the digits are re-encoded into 01; if the lowest 4 digits of the attribute data are 01xx, it is assumed that the pixel P is in a color character, and thus the digits are re-encoded into 10; and if the lowest 4 digits of the attribute data are 1xxx, it is assumed that the pixel P is in a black character, and thus the digits are re-encoded into 11.
Accordingly, by setting 1xxx as a standard for determination of the lowest 4 digits of the attribute data, a higher level of priority can be set for when the pixel P is in a black character than as for when the pixel P is in a white character, and so on. This in turn makes it possible to sufficiently enhance black characters during the edge enhancement process, which is an example of post-processing.
As described above, if the attribute data obtained through the logical sum is 011001, the lowest 4 digits thereof are equivalent to 1xxx, and thus the re-encoded attribute data is 0111. In this case, the re-encoded attribute data 0111 indicates a pixel P in an interpolated pixel generation region RH that is part of a continuous tone, is on an edge, and is in a black character.
A case where such a method for generating the attribute data of pixels P in an interpolated pixel generation region RH is applied to the example shown in FIG. 4A shall be described next.
The attribute data of the pixel P 22 in the interpolated pixel generation region RH 1 is obtained from the attribute data 0101 of the pixel P 2 and the attribute data 0111 of the pixel P 3 .
First, the attribute data 0101 of the pixel P 2 and the attribute data 0111 of the pixel P 3 are decoded into 6-digit attribute data, resulting in 010010 and 011000, respectively. Obtaining the logical sum of these results in 011010.
Next, re-encoding 011010, obtained through the logical sum, makes it possible to obtain 0111 for the attribute data of the pixel P 22 in the interpolated pixel generation region RH 1 . The attribute data of the pixel P 42 in the interpolated pixel generation region RH 2 can be obtained in the same manner.
As described thus far, in the present embodiment, an interpolated pixel generation region RH is provided in the region of outputted pixels P; employing attribute data obtained through a logical sum of the attribute data of a pixel of interest and the attribute data of pixels adjacent to the pixel of interest (adjacent pixels) and expressed in bits as the attribute data of pixels P belonging to the interpolated pixel generation region RH makes it possible to reduce the difference between the details of the image data and the attribute data of the pixels P.
According to the conventional nearest neighbor method, the attribute data of the pixel P 22 in the interpolated pixel generation region RH 1 is a 0 (a white character), which is, as shown in FIG. 9 , clearly different from the details (i.e., a gray color) indicated by the image data b 02 of the pixel P 22 .
However, according to the image processing apparatus 1 of the present embodiment, the details of the attribute data of the pixel P 22 indicate a black character on an edge, as shown in FIG. 4A , and thus the difference between the details indicated by the image data b 02 of the pixel 22 and the details indicated by the attribute data is reduced.
This makes it possible to suppress a degradation in image quality caused by problems with post-processing such as edge enhancement, where, for example, the processing for enhancing black characters cannot be carried out because the attribute data indicates white characters.
(Other Embodiments)
Generation of the attribute data by the image processing apparatus 1 according to the present embodiment may alternatively be executed in the following manner.
FIG. 6 is a diagram illustrating another example of a method for generating attribute data using the image processing apparatus 1 . As illustrated in FIG. 6 , if the attribute data of pixels P 1 to P 5 , which are pixels of interest, is, for example, a 0 , a 1 , a 2 , a 3 , and a 4 , respectively, the attribute data of the pixels of interest is employed as the attribute data of the adjacent pixels on both sides of each of the pixels of interest when viewed in the main scanning direction.
In FIG. 6 , for example, the attribute data a 0 of the inputted pixel P 1 is employed as-is as the attribute data of the outputted pixel P 1 , and a 0 is also employed as the attribute data of the pixels P 11 and P 12 , which are adjacent to and on either side of the pixel P 1 .
Generating the attribute data using such a method makes it possible to reduce the amount of attribute data stored in a memory (not shown) provided in the image processing apparatus 1 .
Furthermore, the span of the interpolated pixel generation region RH, or in other words, the number of pixels in the interpolated pixel generation region RH, can be set as desired. For example, although the number of pixels in the interpolated pixel generation regions RH 1 and RH 2 is 1 in FIG. 4A , this number may be set to 2 or more.
Finally, the configuration, processing content, processing order, and so on of the image processing apparatus 1 in its entirety or the various constituent elements included therein may be altered as appropriate within the spirit of the present invention. The abovementioned unique and distinguished effects can be attained in such a case as well.
While example embodiments of the present invention have been shown and described, it will be understood that the present invention is not limited thereto, and that various changes and modifications may be made by those skilled in the art without departing from the scope of the invention as set forth in the appended claims and their equivalents.
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An image processing apparatus includes a region determination unit detecting attributes of image data generated by a reading unit; an image modification unit generating attribute data based on the results of the determination performed by the region determination unit; an image conversion processing circuit performing resolution conversion processing on the image data of a pixel of interest; and an attribute conversion processing circuit performing resolution conversion processing on the attribute data of the pixel of interest. The attribute resolution converter employs attribute data identical to the attribute data before being subjected to the attribute resolution conversion processing as the attribute data for the pixel of interest following the attribute resolution conversion processing, and employs the attribute data after being subjected to the attribute resolution conversion processing as the attribute data for neighboring pixels to the right and left of the pixel of interest following the attribute resolution conversion processing.
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BACKGROUND OF THE INVENTION
The present invention relates to apparatus for effecting the fine-adjustment of the position of a scraper blade and particularly of a lip of the head-box of a paper-making or cardboard-making machine. It also relates to a method of adjusting a property of material produced on a continuous basis on a machine having a scraper blade, for example a machine for making paper or cardboard, by effecting fine adjustment of the position of the scraper blade.
The description that follows relates to the fine adjustment of the position of the lip of a head-box or starting box of a paper-making or cardboard-making machine, but it should be pointed out that it has other applications in fields in which the adjustment of a scraper blade is called for.
The head-box of a paper-making machine converts the flow of fibrous suspension, forming the paper slurry, from a cylindrical stream into a layer corresponding to the width of the sheet to be formed. This head-box takes the form of a reservoir of variable shape, the front face of which has, towards the bottom, a slot provided with lips, between which the liquid slurry is projected onto a production wire. The purpose of the head-box is to ensure a constant delivery and to adjust the fibrous suspension over the entire width of the machine, which may be as much as nine meters in the case of modern installations.
The layer containing fibres in suspension as well as mineral filler is forced under a pressure of between approximately 0.03 and 2 bars between the lips in modern high-speed machines. The evenness of the rate of discharge of the layer containing fibres in suspension and the uniformity in thickness, together with the uniformity of the concentration determine the uniformity of the weight per unit area of the manufactured product. In modern paper-making machines, flow takes place between two metallic lips, one of which is fixed whereas the other is movable as a whole so that it adjusts the thickness. Furthermore, the movable lip, which is usually the upper lip, is deformable lengthwise under the action of rods controlled by manually-operated screw-jacks. A modern head-box comprises several dozens of such manually-operated screw-jacks.
The correction of the thickness of the layer of material containing fibres in suspension as it passes the lip, as a function of the changes in weight per unit of area of the product obtained at the end of the machine, is not very conveniently carried out with the aid of such manually-operated screw-jacks, the adjustment of which is a delicate matter and which gives good results only on a trail-and-error basis.
To eliminate this disadvantage, head-boxes have been designed wherein the manually-operated regulating screw-jacks are each controlled by a motor-reducer unit which is itself controlled in dependence upon continuous measurements of mass, by way of a computer which receives the results of the measurements of mass and calculates the corrections to be made by acting on the machine elements and particularly on the movable lip.
These control systems using motor-reducers are not sufficiently satisfactory. In fact, relatively great mechanical back-lash always occurs, and precision in adjustment is not very great. However, the greatest drawback is the very high cost of these mechanisms, since the head-box of a modern machine may comprise up to sixty or more of them.
U.S. Pat. No. 2,779,253 describes a purely mechanical means for adjusting the movable lip of a head-box of a paper-making machine. According to that Patent, adjustment is carried out on a purely mechanical basis with the aid of screw-jacks, and variations are detected by means of a mechanical comparator. French Pat. No. 1,192,516 describes apparatus for adjusting the orifice through which the paper slurry passes from a head-box, the adjustment being achieved by inflating and deflating rubber-bellows devices which form the edges of the lips. Thus, the device is pneumatically or hydraulically operated.
On the other hand, U.S. Pat. Nos. 2,938,231 and 3,940,221 describe dies for the extrusion of plastics material wherein the position of part of a first side of the die is adjusted with the aid of a heat-expansible device; in particular, the above-mentioned U.S. Pat. No. 3,940,221 describes a guide for the extrusion of plastics material that comprises a block, one part of which, designed to delimit the outlet orifice, is separated from the body of the block by a part of reduced thickness so that it acquires a certain resilience. A heat-expansible rod applies varying degrees of thrust to this flexible end so as to determine its position in a precise manner.
Dies for extruding plastics material are devices that are totally different from the lips of the head-boxes of paper-making machines. In fact, the plastics material passing through an extursion die is moved under a very high pressure. The die must comprise, at least over a certain distance, a duct having substantially parallel walls so that they continually guide the material which, in effect, is aligned when it flows into the die orifice. In contrast to this, the lip of a head-box of a paper-machine is formed by a scraper blade which is set, relative to the surface of the formed layer, at a relatively large angle, generally at least 30° and sometimes as much as 90°. A lip of this kind must not, in any event, cause orientation of the fibres suspended in the material that passes below it. In fact, such orientation of the fibres would be disastrous in the finished paper (producing a direction of preferential tearing). It is therefore essential not only that the lip be considerably inclined in relation to the formed layer of product material, but also that the pressure on the material containing fibres in suspension be slight.
It is therefore obvious that the lip of a head-box of a paper-making machine is a device that is totally different from a die for extruding plastics material.
In view of the fact that there are at present in existence means for continuously measuring mass and that these means can be connected to computers which are able to recognise the need for corrections and to calculate their amounts, it is very desirable to provide simple and inexpensive devices for continuously effecting fine adjustment of the position of the moving lip of a head-box of a paper-making machine at different points along this lip.
SUMMARY OF THE INVENTION
The invention concerns such an apparatus having a positioning member, mounted between the frame of the machine and the lip, and a means for heating the positioning member so as to vary the length of this member and to ensure that the lip is held in the required position. This position is determined from the results of the continuous measurements, for example the measurement of mass, by means of a computer which makes it possible to control the heating means for a large number of positioning members positioned along the head-box. The positioning means is thus a stationary mechanism requiring no maintenance and no lubrication, and it is extremely reliable.
More precisely, the invention relates to a means for effecting fine-adjustment of the positioning, relative to a support, of an inclined blade for scraping a fluid on a surface by displacing the blade in a pre-determined direction, said means comprising:
a positioning member which co-operates at a first point with the support and at a second point with the scraper blade,
a means for heating at least one part of the positioning member, which part lies between the two co-operation points, and
a member for controlling the heating means in dependence upon the required position of the scraper blade in relation to the support.
Advantageously, the system also comprises a coarse-adjustment means, for example, a manually operated screw-jack designed to alter the distance between the two co-operation points. In an advantageous embodiment, the positioning member comprises at least one mounting part and a heat-expansible part intended to be heated, and the mounting part is cooled, in particular by convection or the circulalation of a cooling fluid.
In a further embodiment, the mounting part for the positioning member is arranged parallel with the heat-expansible part and on the same side as the latter of the point at which they are connected, and an additional heating means is provided for heating the mounting part and is located between the points at which it is connected to the heat-expansible part and to the support. In this case, thermal-insulation means is advantageously placed between the mounting part and the heat-expasible part.
The positioning member advantageously also comprises a force-transmission element designed to bring about displacement of the lip in the said pre-determined direction when the heat-expansible part becomes longer or shorter in one or other direction. Furthermore, this force-transmission element or some other element may constitute a multiplier element which causes a displacement of the scraper blade that is substantially equal to a multiple of the distance travelled by that end of the heat-expansible part that is disposed opposite the mounting part.
It is advantageous that the means for heating the heat-expansible part and, where necessary, the means for heating the mounting part are of a type selected from the following: an element producing heat by the Joule effect and in thermal contact with the positioning member; means heating the positioning member directly by the Joule effect by the circulation of electric current therein; flame-heating means; and means for applying heat by contact with a heat-carrying fluid.
In an advantageous embodiment, the heat-expansible part is flexible, and the system also comprises a spring designed to push the scraper blade in a direction substantially parallel with said pre-determined direction.
A particularly advantageous application of the invention is of course that in which the support is a part of a head-box of a paper-making machine, and the scraper blade is a lip for regulating the thickness of the layer of material containing fibres in suspension that is intended to form a paper.
The invention also concerns a method of adjusting a property of a material produced on a continuous basis in a machine, the latter being of a type which comprises a scraper blade that is movable relatively to a support and is connected at a first location to a positioning member which in turn is connected to a support at a second location, the position of the scraper blade relative to the support influencing said property of the continuously produced material; according to the invention, this method comprises:
the direct or indirect measurement of said property of the material and the generation of a signal representing this measurement;
the comparison of the measurement signal with a reference signal and the generation of a comparison signal; and
regulation, as a function of the comparison signal, of the heating of at least one part of the positioning member between the two points at which it co-operates with the moving part and with the support.
In an advantageous embodiment wherein the positioning members may be differentially heated, that is to say, when use is made of a positioning member having a mounting part and a heat-expansible part loacted at the same side of the point of co-operation, the method comprises the regulation of the heat applied either to the heat-expansible part or to the mounting part depending upon the direction in which the lip has to be moved.
Other features and advantages of the invention will emerge more clearly from the following description which refers to the attached drawings.
BREIF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows diagrammatically a section through a portion of a head-box of a paper-making machine and illustrates a means, in accordance with the invention, for positioning the movable lip of the box;
FIG. 2 shows, on a larger scale than FIG. 1, a detailed section of a part of the positioning means of FIG. 1;
FIG. 3 is similar to FIG. 1 but illustrates a modified form of the positioning means in accordance with the invention;
FIG. 4 is a diagrammatic section similar to part of FIG. 3 and illustrating a different form of the positioning means in accordance with the invention;
FIG. 5 is a diagrammatic section similar to FIG. 1 and illustrates a modified form of the positioning means in accordance with the invention;
FIG. 6 is a plan view of the positioning member of the apparatus shown in FIG. 5;
FIGS. 7 and 8 show, in front elevation and side elevation respectively, a modified form of the positioning member intended for use in the FIG. 5 arrangement; and
FIG. 9 is a sketch illustrating the use of the invention in the fine adjustment of a blade of a coating machine.
DETAILED DESCRIPTION OF THE INVENTION
FIGS. 1 and 2 illustrate an example of the positioning means in accordance with the invention. FIG. 1 shows the mounting of the positioning means in a head-box of a known type; only a part of the box is illustrated and it has a frame 10. The layer of material containing fibres in suspension that is formed by the box passes between a substantially horizontal fixed lip 12 and a movable lip 14. The layer of material is formed on the breast roll 16 of a production wire comprising a porous screen or mesh formed of metal or plastic 18 mounted on forming board 20 just beyond the breast roll 16. That end of the movable lip 14 that is nearer the production bench is secured to a tube 22 by way of a hinge 24. The tube 22 passes through openings 26 and 28 in members of the frame 10 of the box. The other end of the tube 22 is secured to a screw-jack 30, which is manually operated by means of a knurled knob 32. The fixed part of the screw-jack is mounted on a support tube 34 secured to the frame. This tube 34 has small orifices 36 formed in its upper portion.
The positioning means in accordance with the invention comprises the tube 22, the screw-jack 30 and the tube 34.
FIG. 2 illustrates in greater detail the upper portion of the tube 22. The interior of the tube houses an electric heating element 38 having connecting wires 40 which pass through an opening 42 in the wall of the tube 22. Packing 44, consisting of a material having good thermal conductivity, is advantageously used for holding the heating element 38 in the tube 22. In one form of construction, the length of the resistor 38 introduced into the tube 22 is one meter. The tube 22 itself is made of brass, and when the resistor, the rating of which is 70 W and which is supplied with electricity at a voltage of 20 V, is operating at maximum power, the tube reaches a maximum temperature of 90° C. In these conditions, the change in length of the tube 22 between these two extreme temperatures is in the order of magnitude of 1.2 mm. Since the thickness of the layer of material with fibres in suspension that is formed on the production wire is generally between 5 and 40 mm, this adjustment range is quite satisfactory for correcting the variations observed during the course of manufacture when coarse adjustment has been carried out manually by operating the screw-jacks 30.
In a head-box of a modern machine, sixty or so positioning means of the type illustrated in FIG. 1 can be actuated simultaneously on the basis of signals transmitted by a computer.
Control of the heating elements for the various positioning means can be carried out using numerous known techniques, for example by varying the voltage applied, by varying the period during which a fixed voltage is applied, by varying the frequency of the impulses that are applied, or by any other method or combination of methods of control that are well known to the expert in the field.
In the form of construction shown in FIG. 1, it is obviously desirable that only the tube 22 should heat up and that the tube 34 should remain at ambient temperature. Since the heat released in the tube 22 must be discharged, the holes 36, formed in the upper portion of the tube 34, permit the circulation of a current of air which passes through the frame 10 and rises in the tube 34 which only acts as a support.
In view of the relatively great inertia of the tube 22 when it heats up, several minutes have to elapse before a fault is effectively corrected. Taking into account the speed of continuous measurement of the mass in the paper-making machines, a time-constant of this kind is quite satisfactory. If, however, it appears to be too great in certain applications, it could be reduced by the use of greater heating and of artificial cooling of the tube 22, for example, this tube may have fins which increase the rate at which it is cooled. In a modified arrangement, the tube 22 may be of double-walled type with a cooling liquid, for example water, circulating between the walls.
Upon start-up of a paper-making machine having a head-box equipped with positioning means in accordance with the invention, the movable lip is initially adjusted with the aid of the screw-jacks 30 so that its edge is parallel with the fixed lip. The production run of the machine then starts. A sheet profile is then established dependent upon the results of the measurement of weight per square meter that is carried out continuously at the end of the machine. Since the positioning means are initially cold, the portions of the sheets that are too heavy can be corrected by heating the positioning means that correspond to these thick areas so that they are elongated.
FIG. 3 is similar to FIG. 1 and illustrates a modified form of the positioning means in accordance with the invention. In this modification, the length of the positioning means is less than that of the means shown in FIG. 1. In FIG. 3 reference numerals identical to those used in FIG. 1 designated similar elements. Thus, the frame 10 of a head-box, having a fixed lip 12 and a movable lip 14 and forming a layer of material containing fibres in suspension on the end cylinder 16 of a production wire, supports a positioning means which comprises a tube 46, similar to the tube 22 but considerably shorter, a screw-jack 48 which may be identical to the jack 30 in the FIG. 1 embodiment, and a support tube 50 similar to the tube 34.
In the FIG. 3 embodiment, the changes in length of the tube are not transmitted directly to the movable blade 14, but by way of a connecting rod 54. The latter is hinged at 52 to the end of the tube 46. One end of the connecting rod is hinged at 56 on the frame 10, whereas the other end is hinged at 58 on the rod 60 which is itself hinged at 62 to the movable lip 14. As shown in FIG. 3, the distance between the hinge 52 for the heat-expansible tube 46 and the hinge 56 on the frame 10 is much less than the distance separating the hinge 58 for the rod 60, which controls displacement of the lip 14, from the hinge 56. In this way, the displacement of the rod 46 is increased by means of the connecting rod 54. Since the force that has to be applied to the movable lip 14 by a positioning device is of the order of 200 N at most, the force applied by the tube 46 to the hinge 52 is only of the order of 600 N since the multiplication factor is only three. Such force can readily be applied by a tube of small diameter and wall-thickness.
The main advantage of the FIG. 3 embodiment over that shown in FIG. 1 lies in a considerable reduction of the total length of the positioning means. However, the FIG. 3 arrangement suffers from the disadvantage of the need for incorporating movable elements which can only reduce the reliability of the system, despite the fact that very simple and very robust mechanisms are used.
FIG. 4 illustrates a further modified form of the equipment in accordance with the invention for effecting differential positioning. This differential adjustment is shown in its application to the FIG. 3 construction, but it should be pointed out that it can also be applied in a general way to all the other forms of construction.
More precisely, as indicated in FIG. 4, the rod 76, corresponding to the rod 46 in the FIG. 3 arrangement, is mounted on the screw-jack 48 and it passes through the opening 26 in the frame 10. The support tube 50 is replaced by a tube 78 which performs the same function as the tube 50 but which, in addition, advantageously has a relatively great co-efficient of thermal expansion. A heating element 80 in the form of a resistance-heating sleeve surrounds the support tube 78. It is supplied with electric energy from a source, not illustrated, by way of wires, likewise not illustrated. In one advantageous arrangement, a heat-insulating sleeve 82 is held between rod 76 and the support tube 78.
The arrangement shown in FIG. 4 functions in the following manner. When the movable lip is to be brought closer to the production wire, the rod 76 is heated in the manner described by reference to FIGS. 1 to 3. However, if the lip is to be moved rapidly away from the production wire, the thermal inertia of the tube 76 prevents a rapid return. In these conditions, the heating element 80 is then supplied with current and it rapidly heats up the support tube 78. This expands and moves the lip away from the production wire. The insulating sleeve 82 facilitates the thermal uncoupling of the tubes 76 and 78.
This arrangement is considerably more sensitive than those illustrated in FIGS. 1 to 3, since it it known that heating can occur much more rapidly than does natural cooling. This arrangement therefore constitutes an interesting variant which can be used instead of artificial cooling of the tube 76.
FIG. 5 illustrates a modified form of the means shown in FIG. 1. The reference numerals 10, 14 and 30 indicate the same elements as in FIG. 1, namely the frame, regulating lip and the screw-jack respectively.
This form of construction comprises a positioning member 84 of a flexible type, illustrated in greater detail in FIG. 6; this member is placed in a support tube 86, exactly similar to the tube 34 or 50. The positioning member 84 comprises four flexible strips made from a suitable metallic alloy, for example "Kanthal" or Chromium (20%)-Nickel (80°), which is used for producing electrical resistors but which nevertheless has good mechanical strength. The ends of the strips 86 are clamped in two supports 88 and 90. The support 90 has an extension 92 designed to be secured to the screw-jack 30, whereas the support 88 has a tab 94, in which is pierced a hole for affording passage to a screw-threaded rod extending from a lever 96. The latter is hinged on arms 100 secured to the frame and to a control rod 98 for the lip 14. Furthermore, a spring 102 is advantageously fitted between the frame 10 and the lver 96 so that it pushes this lever in the direction that causes the application of a tension force to the positioning member 84.
The advantage associated with the positioning member 84 is that is can be directly heated by the Joule effect and it can therefore be very sensitive to heat. Furthermore, since it is constituted by flat strips which have a small thickness but a large area, it cools down rapidly. The lever 96 constitutes an example of a force-transmission element, but the assembly may instead be as illustrated in FIG. 3, the spring 102 being suitably repositioned. The arm 100 may be arranged at any suitable place so that it provides the required multiplication ratio of, for example, 1.
FIGS. 7 and 8 illustrate a modified form of flexible positioning member, similar to the member 84 shown in FIG. 6. In this variant, the member 104 comprises a first end support 106 provided with a tab 108 similar to the tab 94 associated with the member 84, and a further end support 110 provided with a means 112 for mounting on a screw-jack. The resistance-heating wires 114, which have a high mechanical resistance to tension, pass over insulating sleeves carried by screws 116 extending into the support 106, and over other insulating sleeves carried by screws 118 and 120 positioned on the other support 110. The wires are held on the support 110 in such a way that they are able to transmit tension forces between the two supports 106 and 110. This flexible positioning member 104 may be used instead of the member 84 in the FIG. 5 construction, and it has the same advantages as this latter member.
FIG. 9 illustrates a further example of the application of the invention. This Figure is a very simple sketch of a coating machine comprising a blade. A sheet of paper 64 is moved on a cylinder 68, and a coating roller 66 applies a surface layer of an aqueous dispersion containing, for example, mainly particles of kaolin and a suitable adhesive. A blade 70 is pressed against the paper 64 carried by the cylinder 66, and a certain force has to be applied to the blade 70 so as to obtain an even coating. The positioning means are perfectly suitable for this purpose, in view of the range over which they can be adjusted. FIG. 9 illustrates diagrammatically the end of a tube 72 of a positioning means which may be of the same type as those illustrated in FIGS. 1 to 4. A hinge 74 transmits to the blade 70 the force applied by the tube 72.
The invention is not of course limited to the particular forms of construction described above. Thus, although only a horizontal-type paper-making machine has been considered, the invention can be applied just as well in the adjustment of the moving lip in vertical machines. Furthermore, the fine-adjustment means of the invention has been described in a form associated with a coarse-adjustment means constituted by a screw-jack 30 or 48. It should be pointed out that the invention is also suitable for modern head-boxes, wherein each rod is actuated by a motor-reducer unit. In this case, the motor-reducer unit ensures only coarse adjustment, and the heating of the positioning devices in accordance with the invention leads to fine adjustment.
In particular, it should be pointed out that the fine-adjustment means in accordace with the invention are very reliable in view of their substantially stationary nature, and they require no maintenance or lubrication and they are particularly inexpensive. In addition, the technology necessary for carrying out the invention has been known to experts in the field for several dozen years.
While preferred embodiments of the present invention have been described, it should be understood that the invention is not limited thereto and is determined solely by the scope of the appended claims.
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A method and apparatus for adjustment of a movable lip of a head-box of a paper-making machine. Tubes mounted on screw-jacks each contain an electrical heating resistor which enables them to increase in length by thermal expansion as a function of the current passed to the electrical resistor. This current is regulated by a computer as a function of continuous measurements of the mass of the sheet of paper produced by the machine.
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FIELD OF THE INVENTION
This invention relates generally to cable laying apparatuses, and more particularly to underground cable laying apparatuses, trenchers, and the like.
BACKGROUND OF THE INVENTION
Aesthetics have always played an important role in home design and landscaping. Indeed, most homeowners take pride in the appearance of their yards and landscaping, often devoting many hours each weekend to ensuring that their lawn and garden look attractive and uncluttered.
Unfortunately, the necessities of day-to-day living often result in the use and installation of unsightly equipment. For example, the use of a garden hose and sprinkler to water the lawn and garden, the use of a fence to contain a pet, the running of cables and wires for lighting, cable TV, internet services, etc. all are visibly unappealing to many homeowners. The solution of choice for many homeowners is to run such cables, wires, pet containment systems, sprinkler systems, etc., underground so as to be hidden from view while still allowing the homeowner to reap the benefits provided thereby.
To run each of these varied systems underground, trenchers are used to dig a small trench in the yard into which is laid the cable, wire, pipe, etc., for the particular system being installed. The soil removed from the trench is then put back in over the wire, cable, pipe, etc. In this way, each of these systems, wires, cable, etc., are hidden from view.
Unfortunately, this solution to the aesthetic problem has resulted in an underground maze of wires, cable, pipes, etc., for which no coordinated mapping is typically provided. Further, utility marking services such as JULIE do not provide marking of such consumer-installed underground cables, wires, pipes, etc., instead only marking the main utilities of gas, electric, water, etc. As a result, the attempted installation of subsequent underground systems using a trencher often results in damage or breakage of the underground lines, cables, wires, pipes, etc., of previously installed underground systems. This not only results in frustration of the homeowner as the affected system may no longer be used until it is repaired, but also additional expense for the installers of the subsequent underground systems who have caused the damage and now must bear the expense of repair. Additionally, the type of damage resulting from the use of current methods for underground cable laying often results in multiple breaks in the underground system. That is, oftentimes the underground line, cable, wire, pipe, etc., is snagged by these trenching apparatus and pulled along until a failure occurs in the affected system. Such failures may be at locations other than the point at which the system was snagged by the trencher, often requiring a large portion of the damaged underground system to be dug up to effectuate the repair at the locations of the break.
A further disadvantage with current methods for laying underground cable, wire, flexible tubing, etc., is that the current methods leave a visible scar in the yard. This scar typically requires the planting of additional grass or other ground cover seed, which further increases the expense, detracts from the aesthetics which it was meant to protect, and requires additional lawn care to properly water the newly planted seed to ensure germination and full growth to fully hide the trenched scar.
There exists, therefore, a need in the art for a new and improved underground cable, wire, line, tubing, etc., laying apparatus and method that substantially reduces or eliminates the risk of breaking other underground systems, and which does not leave a visible scar in the yard that requires additional care and expense to correct.
BRIEF SUMMARY OF THE INVENTION
The present invention provides a new and improved underground cable and the like laying apparatus. More particularly, the present invention provides a new and improved underground cable laying apparatus that is capable of crossing without damaging other underground cables and the like. Further, the present invention provides a new and improved underground cable laying apparatus that does not leave a visibly obvious scar in the lawn under which the cable has been laid.
In accordance with one embodiment of the present invention, the underground cable laying apparatus includes a pair of angularly displaced turf slicing wheels that slice and separate the turf under which the underground cable is to be laid. A cable feed tube is positioned between the turf slicing wheels to guide the underground cable between the turf slicing wheels. A cable feed guide wheel is positioned rearward of the opening of the cable feed tube to aid in the positioning and proper laying of the underground cable in a smooth fashion. In a preferred embodiment, the leading edge of the cable feed tube includes a feed tube support extension member to provide additional rigidity and stabilization of the cable feed tube placement while laying the underground cable. A cable guide wheel cleaning mechanism can be applied to prevent the build up of soil on the guide wheel. A cable guide may also be employed at an insertion end of the cable feed tube.
In a preferred embodiment of the present invention, the underground cable laying apparatus also includes turf closing wheels operative to close the slit in the turf into which the cable has been laid. These turf closing wheels are carried by a turf closure housing that is pivotably coupled to the mounting yoke of the cable laying apparatus. Preferably, the turf closing wheels are spring loaded by a turf follower spring within the turf closure housing. This turf follower spring is preferably adjustable to vary the spring load tension on the closing wheels based upon the type of lawn under which the cable is to be laid. Positioning detents or blocks limit the downward travel of the turf closure housing under action of the turf follower spring.
In a preferred method of laying underground cable and the like in accordance with the teachings of the present invention, a thin slice in the turf is opened by the turf slicing wheels. Preferably, the soil is moist, either from natural sources or from a step of watering. Cable or the like is then positioned within the open slice in the turf. Preferably, this step is accomplished by guiding the cable to be laid into the slice in the turf. This step of guiding may be accomplished in a preferred embodiment through the use of a cable feed tube having at an aft end thereof a cable guide, which may take the form of a wheel, roller, guide bar, etc. This structure performs the function of maintaining the cable to be laid in the proper position within the slice in the turf.
Preferably, the method of laying underground cable in accordance with the present invention also includes the step of closing the slice in the turf once the cable has been laid therein. This step may be performed by providing a closing force in a direction to close the slit. Preferably, this closing force is applied to either side of the slit to preclude damage to the turf under which the cable has been laid.
Through the method of the present invention, damage to other underground systems, such as invisible fencing, other cables or wires, or sprinkler systems is precluded or the likelihood of such is significantly reduced. This is so because the rolling action of the turf slicing wheels does not snag or otherwise cut the other underground wires as occurs within the prior art methods of laying cable. As such, a significant advantage is realized through the use of the present invention for laying underground cable and the like. Similarly, by opening a thin slice in the turf which is then closed by applying a force to either side of the slice, the unsightly scarring of the turf that commonly results with prior art methods is also precluded.
Other aspects, objectives and advantages of the invention will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings incorporated in and forming a part of the specification illustrate several aspects of the present invention, and together with the description serve to explain the principles of the invention. In the drawings:
FIG. 1 is a side view illustration of an embodiment of an underground cable laying apparatus constructed in accordance with the teachings of the present invention;
FIG. 2 is a cross-sectional illustration of the cable laying apparatus of FIG. 1 ;
FIG. 3 is a frontal isometric view of the cable laying apparatus of FIG. 1 ;
FIG. 4 is a rear isometric illustration of the cable laying apparatus of FIG. 1 ;
FIG. 5 is a cross-sectional illustration of the cable laying apparatus of FIG. 1 shown in operation laying an underground cable; and
FIG. 6 is a partial isometric illustration of a cable feed guide wheel assembly of the cable laying apparatus of FIG. 1 .
While the invention will be described in connection with certain preferred embodiments, there is no intent to limit it to those embodiments. On the contrary, the intent is to cover all alternatives, modifications and equivalents as included within the spirit and scope of the invention as defined by the appended claims.
DETAILED DESCRIPTION OF THE INVENTION
Turning now to the drawings, there is illustrated in FIG. 1 an exemplary embodiment of an underground cable laying apparatus 10 constructed in accordance with the teachings of the present invention. In the interests of brevity, the term cable will be used throughout this description to include cable, line, wire, hose, fiber optic cable, tubing, etc., that one may desire to bury under the surface of the ground. As may be seen from this FIG. 1 , the underground cable laying apparatus 10 includes a mounting yoke 12 on which is mounted a pair of turf slicing wheels 14 , 16 (see FIG. 2 ). The mounting yoke 12 includes mounting receptacles, for example receptacles 18 , 20 that are positioned and configured to allow the apparatus 10 to be mounted to a truck or other vehicle that will be used in the cable laying process. As such, the particular configuration and placement of the mounting receptacles may vary in particular embodiments based upon the type of vehicle used in the cable laying process. Indeed, the position and configuration of the mounting receptacles may accommodate the usage of an intermediate mounting or other equipment, for example a shaker unit, that may be directly mounted to the vehicle.
In addition to the turf slicing wheels 14 , 16 , a turf closing mechanism, for example turf closing wheels 22 , 24 carried on a turf closure housing 26 , is pivotably mounted to the yoke 12 by the closure assembly mounting arms 28 , 30 . The turf closure housing 26 may include positioning detents 32 , 34 , blocks, shoulders, or other movement limiting structure to prevent the turf closure wheels 22 , 24 and their associated housing 26 from pivoting downward beyond a desired location. However, as will be discussed more fully below, the upward pivoting of the housing 26 is preferably unimpeded within a range to allow the turf closing wheels 22 , 24 to follow the contours of the soil into which the cable has been laid.
The underground cable laying apparatus also includes a cable feed tube 36 used to guide the cable to be laid through the apparatus 10 . To facilitate this operation, the cable feed tube 36 includes a cable inlet 38 at a forward location of the apparatus 10 that receives the cable from the spool or other holding device. If desired, the cable feed tube 36 may also include a cable guide 40 positioned above inlet 38 . This cable guide 40 may have a diameter larger than the inlet 38 to allow for some play in the cable before it enters inlet 38 . The cable feed tube 36 leads down between the turf slicing wheels 14 to a position rearward of the leading edges thereof. At this position the cable feed tube outlet 42 dispenses the cable to be laid in the slice in the turf which has been created by the turf slicing wheels 14 , 16 . At this outlet 42 a feed tube support extension member 44 may be provided to add additional stability and support for the end of the cable feed tube 36 .
FIG. 2 provides a cross-sectional illustration of the underground cable laying apparatus 10 illustrated in FIG. 1 . As may be seen from this cross-sectional illustration, the positioning of the cable feed tube 36 preferably provides a curved path through which the cable may be directed through the apparatus. In this way, the possibility of snagging or chafing the exterior of the cable to be laid is greatly reduced over prior systems that terminated in an outlet perpendicular to the trench into which the cable was to be laid. To further aid in the smooth and proper positioning of the cable within the slice in the turf created by the turf slicing wheels 14 , 16 , the apparatus 10 of the present invention may also include a cable feed guide, such as wheel 46 . This cable feed guide wheel 46 is positioned in proximity to the outlet 42 to further place the cable in the proper position in the slice in the turf without scraping or otherwise damaging the exterior surface of the cable. Indeed, in embodiments that utilize this cable feed guide the cable feed tube may be straight with an outlet perpendicular to the slit as the cable feed guide will ensure a smooth directional change in the cable without damage thereto. To prevent the buildup of soil within the groove 48 of the cable feed guide wheel 46 , a groove cleaning rod 50 may be provided. This groove cleaning rod 50 is positioned within the groove 48 of the cable feed guide wheel 46 in such a manner so as to prevent or reduce the amount of buildup of soil within the groove so that the cable being dispensed may be gently guided within the groove 48 to its proper position within the slit in the turf.
As may also be seen from this cross-sectional illustration of FIG. 2 , the turf closure housing 26 is spring-biased to its downward position by a turf follower spring 52 . Preferably, this turf follower spring 52 is coupled between the mounting yoke 12 via a spring mount 56 and the rearward wall 54 of the turf closure housing 26 , rearward of the pivot point 58 . The amount of force that the turf closure wheels 22 , 24 apply to the turf may be adjusted by varying the spring tension. In the embodiment illustrated in FIG. 2 , this spring tension variation may be accomplished by adjusting spring tension nut 60 . The adjustment of this spring tension is facilitated by the positioning detents 32 , 34 as they prevent further downward pivoting of the turf closure housing 26 through their engagement with the closure assembly mounting arms 28 , 30 .
As may be seen from the frontal isometric illustration of FIG. 3 , the turf slicing wheels 14 , 16 are angularly positioned relative to one another. Preferably, they are angularly positioned relative to both the horizontal and vertical axis of the mounting yoke 12 . That is, the turf slicing wheels 14 , 16 are positioned such that they contact each other along an area 62 , and are elsewhere displaced from one another. This displacement between the turf slicing wheels 14 , 16 preferably increases both along a horizontal and vertical axis such that a small slice is initiated in the turf by the forward contact area 62 , and is widened along both the horizontal and vertical axes as the apparatus 10 is moved through the turf. In this way, the turf defining the slit is displaced both outwardly and upwardly to accept the cable to be laid therein. With such a displacement of the turf defining the slit, the turf closure wheels 22 , which provide an angular closing force on either side thereof, may then fully close the slit without damage to the turf. Indeed, in most situations the closure of the slit is complete without leaving a residual scar in the turf whatsoever. As may be seen from this frontal view of FIG. 3 , the angular displacement of the turf closure wheels 22 , 24 is preferably greater than the angular displacement along the same axis of the turf slicing wheels 14 , 16 .
As may be seen from the rear isometric view of FIG. 4 , the cable feed guide wheel 46 is positioned to dispense the cable to be laid in the center of the slit in the turf created by turf slicing wheels 14 , 16 , prior to the application of the closing force on the slit by turf closing wheels 22 , 24 .
In operation, the apparatus 10 is lowered by the vehicle so that the contact area 62 of the turf slicing wheels contacts the upper surface 64 of the turf. As the vehicle travels across the turf, rotation of the turf slicing wheels 14 , 16 creates the slit in the turf that preferably opens both horizontally and vertically to receive the cable to be laid therein. Since the turf closure wheels 22 , 24 are displaced horizontally from one another by an amount greater than the maximum slit width, the wheels 22 , 24 ride on the outside of the slit and provide a downward and inward closure force to effectuate a closure of the slit once the cable has been laid therein. The amount of force applied on the sides of the slit is dependent upon the setting of the spring force of the turf follower spring 52 as discussed above. Also, due to the close proximity of the turf closure wheels 22 , 24 to the rearward edge of the turf slicing wheels 14 , 16 , closure of the slit into which the cable has been laid occurs in very close proximity to the point where the cable leaves the cable feed guide wheel. In this way, the proper positioning of the cable within the slit is ensured. With prior trencher systems, coils in the cable may allow the cable to rise above the bottom of the trench before the soil is placed back in the trench, resulting in areas where the cable is shallower than in others, which may result in uncovering of the cable and forming a hazardous condition.
As discussed briefly above, to ensure that the cable is properly positioned within the slit in the turf, a cable feed guide wheel 46 is used. However, one skilled in the art will recognize that a roller or other guide mechanism may be used at this location to provide proper placement and smooth transitioning of the cable from the cable feed tube to its position in the bottom of the slit. In an embodiment that utilizes a cable feed guide wheel 26 , such as that illustrated in FIG. 6 , the provision of a guide wheel cleaning mechanism may be desired. As introduced above, this cleaning mechanism may include a cable groove cleaning rod 50 that rides in the groove 48 of the cable feed guide wheel 46 . As the wheel rotates while dispensing the cable 68 any dirt or other debris that may accumulate within groove 48 will be displaced by the cleaning rod 50 . Similarly, the cable feed guide wheel housing 70 may include wheel edge scrapers 72 , 74 that clean the sides of the wheel 46 and prevent the accumulation of soil or other debris, which may affect the ability of the wheel 46 to rotate.
The underground cable laying apparatus of the present invention provides significant advantage through the use of the turf slicing wheels, particularly in installation locations where other installed underground systems may be in place, and where a visible scar in the turf resulting from the cable laying operation is not desired. In the first instance, the apparatus of the present invention provides a significant advantage through the use of the rotating turf slicing wheels for providing the slit in the turf into which the cable is to be laid. Since the turf slicing wheels rotate, there is a significantly reduced likelihood of damage to other installed underground systems as results from typical trenchers. Specifically, the rotating turf slicing wheels will not snag and pull the other underground systems which it encounters, and instead merely rolls over them while leaving them in place. This non-damaging contact with previously installed underground systems is aided by the angular relationship between the two turf slicing wheels. That is, the relative angular displacement of the turf slicing wheels forms a contact portion 62 that slices the top layer of the turf, but then separate from one another at all other locations. As a result, contact with previously installed underground systems often occurs at a position where the turf slicing wheels 14 , 16 are separated from one another, but are still in close proximity. As a result, the contact force is dispersed at the two contact points with each of the individual turf slicing wheels. Since these wheels are most likely still in close proximity, the contact force is not sufficient to damage the exterior surface of the previously installed underground system.
In the second instance, unlike blade type systems that gouge a slit into the turf, and trencher systems that completely remove the soil to form a trench, the underground cable laying apparatus of the present invention merely opens a slit in the turf, which is quickly reclosed once the cable has been placed therein. The angular placement of the turf slicing wheels ensures a narrow slit is initiated in the turf, is slightly widened to allow placement of the cable therein, and then is immediately reclosed by providing angular downward and inward force on the sides of the slit opened by the turf slicing wheels. As a result, it is nearly impossible to observe where the slit was opened in the turf once the cable has been laid therein. This is especially true when the turf is moist, or has been recently watered.
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.
The use of the terms “a” and “an” and “the” 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 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.
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.
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Presented is an underground cable laying apparatus that leaves virtually no visible scar in the turf under which cable, wire, line, hose, etc. is laid. The apparatus utilizes a pair of angularly displaced turf slicing wheels to slice and separate the turf forming a slit into which cable may be laid. A cable guide tube and roller properly place the cable within the slit. A pair of turf closure wheels close the slit in close proximity to the release point of the cable to ensure proper placement of the cable. The slit in the turf is gently and completely closed over the cable, leaving virtually no visible scar within the turf to upset the aesthetic beauty of a lawn. Further, the configuration and rolling action of the turf slicing wheels ensures that other underground cables will not be damaged if inadvertently encountered.
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BACKGROUND OF INVENTION
PRIOR ART
This invention relates to the manufacture of 8-methoxypsoralen and is directed to improvements in a process in which pyrogallol is converted to 8-methoxypsoralen in six unit process steps.
Lagercrantz, Acta Chemica Scandinavica Vol. 10, (1956) pp. 647-654 reports the preparation of 8-methoxypsoralen in the following six unit process steps beginning with pyrogallol:
(1) Pyrogallol is reacted with chloracetic acid in the presence of phosphorus oxychloride to form ω-chloro-2,3,4-trihydroxyacetophenone,
(2) which product is cyclized by the splitting off hydrochloric acid to form 6,7-dihydroxycoumaranone,
(3) which product is hydrogenated with hydrogen over a palladium catalyst in acetic acid at 1 atmosphere and 65° C.,
(4) which product is reacted with malic acid in the presence of concentrated sulphuric acid to form 2,3-dihydroxanthotoxol,
(5) which product is methylated using diazomethane to form 2,3-dihydroxanthotoxin,
(6) which product is dehydrogenated with palladium catalyst in boiling diphenyl ether to form the desired 8-methoxypsoralen (xanthotoxin).
Davies et al., J. Chem. Soc., (1950), 3202-6 reports the first two of these unit process steps and Spath et al., Ber. 69, (1936), 767-770, reports the last four of these steps.
The overall yield in these prior art processes is less than about 3 percent. This is due to the relatively low yield in some or most of the unit process steps. The problem steps apparently are the hydrogenation step (3) and the dehydrogenation step (6). In regard to the former, Spath obtained 33 percent yield and Lagercrantz, 50 percent yield. However, Lagercrantz points out that this unit process is highly critical, that the hydrogenation also involves enolization of the oxo group and that the starting 6,7-dihydroxycoumaran-3-one (hereinafter referred to as 6,7-dihydroxycoumaranone) must be "very pure" in order to avoid poisoning of the catalyst. He suggests recrystallization several times with active carbon. In regard to the dehydrogenation, the best yield reported is 37 percent. This, coupled with the relatively low yields reported for steps 1, 3, and 4, makes the overall yield of the prior art process less than about 3 percent.
OBJECT OF THE INVENTION
It is an object of the invention to provide an improved process for making 8-methoxypsoralen. A further object of the invention is to provide a process which avoids the disadvantages of the prior art. A further object of the invention is to provide an improved process for the hydrogenation of 6,7-dihydroxycoumaranone. A further object of the invention is to provide an improved process for dehydrogenation of 2,3-dihydroxanthotoxin. A further object of the invention is to provide an improved overall process. Further objects will appear as the description proceeds.
SUMMARY OF THE INVENTION
The invention relates to improvements in a process for making 8-methoxypsoralen from pyrogallol in the following steps:
(1) reacting pyrogallol with chloracetic acid to form ω-chloro-2,3,4-trihydroxyacetophenone,
(2) heating ω-chloro-2,3,4-trihydroxyacetophenone in the presence of a hydrogen chloride acceptor to form 6,7-dihydroxycoumaranone,
(3) hydrogenating 6,7-dihydroxycoumaranone to form 6,7-dihydroxy-2,3,-dihydrobenzofuran,
(4) reacting 6,7-dihydroxy-2,3,-dihydrobenzofuran with malic acid to form 2,3-dihydroxanthotoxol,
(5-6) methylating and dehydrogenating to convert 2,3-dihydroxanthotoxol to 8-methoxypsoralen,
which improvements comprise a novel procedure for effecting the hydrogenation, a novel procedure for effecting the dehydrogenation, and a general overall combination of particular unit process steps leading to improved overall yield.
In steps 5-6, the methylation can be done first and then the dehydrogenation, or the dehydrogenation first and then the methylation. The latter is of advantage where a tagged or labeled product is desired. Thus, if 2,3-dihydroxanthotoxol is first converted to xanthotoxol, the xanthotoxol can be methylated with a tagged or labeled methylating agent to form the desired tagged or labeled 8-methoxypsoralen.
Steps 1 and 2 are carried out as described in Lagercrantz and Davies and comparable yields are obtained. Step 3, however, has been modified to give substantially greater yields and to make it possible to avoid the necessity for repeated recrystallization of the starting 6,7-dihydroxycoumaranone. In Step 4, a low reaction temperature and a simplified work-up gives better yields. In Step 5-6, the methylation, the expensive and highly explosive and dangerous diazomethane is replaced by dimethyl sulphate without sacrificing yield and in the dehydrogenation, Step 5-6, use of 2,3-dichloro-5,6-dicyano-1,4-benzoquinone as a dehydrogenation agent results in a two-fold increase in the unit yield of 8-methoxypsoralen. Still higher unit yields are obtained if chlorobenzene is used as the solvent. With these improvements, overall yields greater than 10 percent are obtainable.
The hydrogenation of 6,7-dihydroxycoumaranone in accordance with the invention is effected in a low pressure hydrogenation unit under an absolute pressure of hydrogen of about 2 atmospheres and a temperature of about 100° C. in a mixture of acetic acid and ethyl acetate, advantageously, in the proportions of about five percent to about thirty percent acetic acid. Higher percentages of acetic acid can be used, but only with sacrifice in yields. Also the ethyl acetate can be substituted by other solvents like methanol and ethanol but only with a sacrifice in yields. Higher or lower pressures, say, from about 1 to about 10 atmospheres absolute pressure, and higher or lower temperature, say, from about 65° C. to about 150° C., can be used in accordance with practices already well known for low pressure hydrogenation.
The reaction mixture is cooled and the catalyst is filtered off. The solvent is distilled under reduced pressure leaving an oil which can be used as the starting material in the next step. If desired residual acetic acid can be removed by azeotropic distillation with benzene. Finally, the product is crystallized from an inert solvent, such as benzene, to yield a crude product which can be used directly in the next step. If desired, however, the crude material can be further recrystallized. For this crystallization and recrystallization, any inert solvent for the produced 6,7-dihydroxy-2,3-benzofuran, can be used but those like benzene, toluene, chlorobenzene, petroleum ether, ethylene chloride, cyclohexane, and the like, in which the product has limited solubility are preferred.
The starting material for Step 3, 6,7-dihydroxycoumaranone, is obtained by refluxing ω-chloro-2,3,4-trihydroxyacetophenone in ethanol in the presence of sodium acetate, distilling off the ethanol and crystallizing the product from water.
The crude product resulting from this crystallization is used directly in the hydrogen step but if desired, can be recrystallized from acetone or other suitable inert solvent in which the 6,7-dihydroxycoumaranone has limited solubility.
Alternatively, the cyclization can be effected by heating in the presence of a hydrogen chloride acceptor in a suitable solvent or vehicle. Suitable such hydrogen chloride acceptors include potassium carbonate and exchange resins such as Dow-X 1, Imac A-21, Permutic ES, Amberlite IRA-410, and the like. Ordinarily these ion exchange resins comprise a cross-linked polystyrene base or like cross-linked resin base, substituted by a trimethylbenzylammonium group or like quaternary ammonium groups. Such hydrogen acceptors have the advantage that they are easily separated from the reaction mixture by filtration.
The 6,7-dihydroxy-2,3-dihydrobenzofuran from Step 3 is reacted with malic acid in concentrated sulpuric acid at a temperature of about 80° C. to not more than about 100° C. This temperature, which is substantially lower than that used in the prior art, makes it easier to control foaming and this, coupled with slightly different work-ups, results in higher yields.
The low temperature is determined by that at which the reaction proceeds as evidenced by the evolution of gas, presumably carbon monoxide, and the higher temperature by that at which excessive tar does not form. The action is continued until substantial evolution of gas ceases. Ten minutes or so will ordinarily suffice at temperatures about 100° C., but longer periods may be required at lower temperatures. The desideratum is as low a temperature and as short a time as possible since longer times and higher temperatures result in the formation of more tar and lower yields.
Advantageously, the sulphuric acid is preheated to or near the desired reaction temperature, say to between about 70° C. and about 100° C. To the hot sulphuric acid, a mixture of 6,7-dihydroxy-2,3-dihydrobenzofuran and malic acid is added with stirring while maintaining the temperature between about 80° C. and about 100° C. The proportions are the stoichiometric, advantageously with a slight excess, say up to 10 or 20 percent excess, of malic acid. As the sulfuric acid acts primarily as a dehydrating agent, the amount is not critical as long as sufficient is present for this purpose and to give an easily workable and handleable reaction mixture. The reaction mixture, however obtained, is cooled and poured into ice water and extracted with chloroform. Advantageously, the ice water and the chloroform are pre-mixed so that the product, 2,3-dihydroxanthotoxol, is extracted into the chloroform before it becomes contaminated with or occluded in any tar that is precipitated.
The chloroform extract is dried with sodium sulphate, concentrated to or near dryness, and washed with a relatively large volume of an inert non-solvent, for example, hexane, filtered and dried. Any inert nonsolvent for the product can be used in place of the hexane, for example, any aliphatic or cycloaliphatic hydrocarbon, since it is used here primarily for its physical effect. The resulting crude product is used directly in the following step but, if desired, can be recrystallized from water.
The resulting 2,3-dihydroxanthotoxol is now methylated with dimethyl sulphate in an inert solvent such as acetone in the presence of an acid acceptor, for example, potassium carbonate. The reaction mixture is drowned in a dilute sodium hydroxide solution and the product recovered by filtration. The crude product thus obtained can be used directly in the next step but, if desired, can be recrystallized from benzene, or like inert-solvent in which 2,3-dihydroxanthotoxin has limited solubility.
The 2,3-dihydroxanthotoxin thus obtained is then dehydrogenated. This advantageously is effected by heating the 2,3-dihydroxanthotoxin with 2,3-dichloro-5,6-dicyano-1,4-benzoquinone in a substantially inert solvent, for example, toluene or chlorobenzene, advantageously at reflux, until substantial dehydrogenation is obtained. The 2,3-dichloro-5,6-dicyano-hydroquinone formed and any residual 2,3-dichloro-5,6-dicyano-1,4-benzoquinone are removed and the product taken up in chloroform and recovered therefrom. If substantial amounts of the residual 2,3-dichloro-5,6-dicyano-1,4-benzoquinone are present, it is desirable to convert this to the corresponding hydroquinone with sodium dithionite, dissolve the hydroquinone in aqueous sodium bicarbonate, and extract the sodium bicarbonate solution with chloroform to recover the 8-methoxypsoralen which can be recovered by drying over sodium sulphate and concentrating to dryness. The resulting product can then be recrystallized from benzene or any suitable inert solvent in which 8-methoxypsoralen has limited solubility. If there is little residual 2,3-dichloro-5,6-dicyano-1,4-benzoquinone, the reaction mixture can be cooled and the precipitated hydroquinone filtered off and the reaction mixture, i.e., the filtrate, then extracted with chloroform. If desired, the filter cake can be extracted with benzene or like solvents such as chlorobenzene, toluene, and the like, for example, by refluxing the filter cake in the solvent and then adding the extract to the reaction mixture filtrate prior to the chloroform extraction. The chloroform solution is then washed successively with dilute sodium bisulfite solution, dilute sodium bicarbonate solution, and water and dried over sodium sulfate. The resulting chloroform solution is then concentrated by distillation until the product precipitates and an inert non-solvent such as hexane or like aliphatic or cycloaliphatic hydrocarbon is added to cause further precipitation of the product and the product is filtered. If desired, the product can be further purified by redissolving it in chloroform, or chloroform containing a minor amount of ethyl acetate, passing the solution over an alumina column concentrating the effluent until crystallization takes place, adding hexane or like solvent further to cause precipitation of the product, and filtering the solution.
If desired, the last two steps, namely, the methylation and the dehydrogentaion can be inverted. In other words, the 2,3-dihydroxanthotoxol, instead of being methylated, is dehydrogenated to form xanthotoxol and the resulting xanthotoxol methylated to form 8-methoxypsoralen. The same reaction conditions and work-ups can be used as given above for the methylation and dehydrogenation.
DETAILED DESCRIPTION OF THE INVENTION
The following examples are given by way of illustration only. Parts and percentages are by weight unless otherwise specificed.
EXAMPLE 1
8-Methoxypsoralen
Part A:
ω-Chloro-2,3,4-trihydroxyacetophenone
A flask equipped with a stirrer and protected from atmospheric moisture was charged with 126.1 g of pyrogallol, 101.1 g chloracetic acid and 101.2 g of phosphorus oxychloride.
The contents were stirred and heated at 60° C. until stirring became quite difficult (approximately 4 hours), hydrogen chloride was evolved during the reaction. The reaction mixture was then cautiously hydrolyzed with ice water (750 ml/mole), and the resulting mixture was heated to 70° C. for 30 minutes and then cooled to 0° C. After stirring at 0° C. for 12 hours, the mixture was filtered to collect the product. The cooled product was washed with a small amount of ice water and dried. Dark tan crystals of ω-chloro-2,3,4-trihydroxyacetophenone melting at 166°-8° C. were obtained in a yield of 55 percent (111 g/mole). This crude product was used directly in the next step without further purification.
On successive replications, the yield varied from 45 to 55 percent.
The crude product on recrystallization from water gave light tan crystals melting at 168°-170° C.
Part B:
6,7-Dihydroxycumaranone
A mixture of 1.5 l of ethanol (2B alcohol), 249.1 g sodium acetate and 202.6 g ω-chloro-2,3,4-trihydroxyacetophenone from Part A was refluxed for six hours. The ethanol was distilled off and the residue was treated with 1.5 l of water and was cooled with stirring to -5° to -0° C., filtered, and the product washed with a small amount of ice water and air dried. There was obtained 141 g (85 percent yield), of crude 6,7-dihydroxycoumaranone melting at 230°-2° C. This crude product was used in Step C.
On successive replications, the yield varied from 76 to 85 percent.
On recrystallization from acetone there were obtained light tan crystals melting at 232°-4° C.
Part C:
6,7-Dihydroxy-2,3-dihydrobenzofuran
A low pressure hydrogenation unit was charged with 4 l of a 20 percent acetic acid solution in ethyl acetate, 55 g of 10 percent palladium on carbon and 166.1 g of the crude 6,7-dihydroxycoumaranone of Part B. Hydrogen was admitted under 30 psi guage pressure and at a temperature of 100° C. until the theoretical amount (1 mole) of hydrogen was absorbed and further take-up had stopped. This took approximately 12 hours. The reaction mixture was then cooled and filtered to remove the catalyst. The filtrate was distilled under reduced pressure leaving an oil. This oil was taken up in 1 liter of benzene and the benzene distilled off to remove residual acetic acid as a benzene-acetic acid azeotrope. This was repeated two times. Finally the residue was taken up in 500 ml of benzene and the resultant cooled to precipitate out the product. On filtering and washing with a little cold benzene, there was obtained 126 g (83 percent yield), of crude 6,7-dihydroxy-2,3-dihydrobenzofuran melting at 97°-9° C., which was transferred directly as the starting material as Step D.
On successive replications, the yield varied from 74 to 83 percent.
On recrystallization from benzene, there were obtained off-white crystals melting at 104°-6° C.
If all the acetic acid is not removed in the azeotropic distillation, an oily residue may remain which is not taken up by the benzene. This oily residue is high in product and can be used successfully in the next step.
Part D:
2,3-Dihydroxanthotoxol
A flask equipped with a stirrer and port thermometer was charged with 460 ml of concentrated sulphuric acid and the temperature was brought to 70° C. A mixture of 152 g of 6,7-dihydroxy-2,3-dihydrobenzofuran from Part C and 154 g of malic acid was cautiously added to the sulphuric acid with stirring while the temperature was brought to 100° C. Carbon monoxide was evolved during the reaction and caused some foaming of the reaction mixture. The reaction mixture was maintained at 100° C. for 10 minutes at which time the bulk of the gas evolution had ceased. The mixture was then cooled to room temperature and poured into a stirred mixture of 6 liters of water and 12 liters of chloroform. Sometimes material separates which generally remains suspended in the aqueous layer. The chloroform layer was separated and the aqueous re-extracted two more times with chloroform, first with 6 liters and second with 2 liters. To the combined chloroform extract after drying with sodium sulphate and concentrating the combined chloroform extracts to near dryness, was added 1 liter of hexane and the product filtered and dried. There was obtained 1.2 g (55 percent yield), of crude 2,3-dihydroxanthotoxol melting at 190°-3° C. This crude product was used in Step E.
On successive replications, the yield varied from 45 to 55 percent.
Upon recrystallization from water, there was obtained off-white crystals melting at 191°-3° C.
Part E:
2,3-Dihydroxanthotoxin
A reaction mixture of 204 g of 2,3-dihydroxanthotoxol of Part D, 136 g of dimethyl sulphate, 828 g of potassium carbonate, and 9 liters of acetone was refluxed with stirring for 16 hours. The reaction mixture was then cooled and filtered and the filter cake washed with acetone. The acetone solution was concentrated to approximately 2 liters and poured into 4 liters of 1 percent sodium hydroxide solution with good stirring. The product was filtered and washed with water until the pH was neutral. It was then washed with a little cold acetone and finally air dried. There was obtained 185 g (85 percent yield), of crude 2,3-dihydroxanthotoxin melting at 158°-160° C. This crude product was used directly in Step F.
On successive replications, the yield varied from 80 to 85 percent.
On recrystallization from benzene, there was obtained a white solid melting at 159°-160° C.
Part F-1:
8-Methoxypsoralen
A reaction mixture of 218 g of 2,3-dihydroxanthotoxin of Part E, 281 g of 2,3-dichloro-5,6-dicyano-1,4-benzoquinone, and 3 liters of toluene was stirred and heated at reflux for 20 hours. The mixture was cooled and poured into 10 liters of 10 percent sodium hydroxide solution containing 5 percent sodium dithionite. The solution was then extracted twice with about 2 liters of chloroform. The combined chloroform extracts were washed with water and dried over sodium sulphate and concentrated to dryness. There was obtained 150 g (70 percent yield), of crude 8-methoxypsoralen which on crystallization from benzene was obtained as white crystals melting at 138°-140° C.
On successive replications, the yield varied from 65 to 70 percent. The overall yield was 13%.
Part F-2:
8-Methoxypsoralen
A reaction mixture of 218 g of 2,3-dihydroxxanthotoxin of Part E, 250 g of 2,3-dichloro-5,6-dicyano-1,4-benzoquinone, and 2 l of chlorobenzene was stirred at reflux for 12 hours. The reaction mixture was cooled and the precipitated hydroquinone filtered off, the filter cake was extracted with 2 l of benzene at reflux, filtered hot and the extract added to the filtrate. Three l of chloroform was then added and the mixture washed, first, with 2 l of 2 percent sodium bisulfite, second, 2 l of 1 percent sodium bicarbonate, and third, 2 l of water, and then dried over sodium sulphate. The dried solution was then concentrated by distillation until the product precipitated, whereupon 500 ml of hexane was added and the product filtered. The product was then dissolved in 4:1 (v/v) chloroform/ethyl acetate and passed over an alumina column (Neutral Alumina, Brockman Activity 1). The effluent was concentrated until crystallization took place. There was then added 500 ml of hexane and the product was recovered by filtration. White crystals of 8-methoxypsoralen melting at 143.5°-145° C. were obtained in 85 percent yield.
On successive replications, yields of 80 to 85 percent were obtained. The overall yield was 15%.
EXAMPLE 2
8-Methoxypsoralen
Part A:
Following the procedure of Part F-2 of Example 1, substituting the 2,3-dihydroxanthotoxin by the equivalent amount of 2,3-dihydroxanthotoxol of Part E of Example 1, there is obtained xanthotoxol.
Part B:
Following the procedure of Part E of Example 1, substituting the 2,3-dihydroxanthotoxol by the equivalent amount of xanthotoxol from Part A above, there is obtained 8-methoxypsoralen.
Part C:
Following the procedure of Part B above, substituting the dimethylsulfate by tagged or labeled dimethylsulfate, there is obtained tagged or labeled 8-methoxypsoralen.
It is to be understood that the invention is not to be limited to the exact details of operation or structure shown as obvious modifications and equivalents will be apparent to one skilled in the art.
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8-Methoxypsoralen is prepared in six steps from pyrogallol including hydrogenation of 6,7-dihydroxy-2,3-dihydrobenzofuran and dehydrogenation of 2,3-dihydroxanthotoxin. Improvements in these two steps lead to a marked overall increase in yield.
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This is a continuation of application Ser. No. 07/677,591, filed Mar. 26, 1991, which was abandoned upon the filing hereof, and which was a continuation of application Ser. No. 07/480,549, filed Feb. 15, 1990, which was abandoned upon the filing of application Ser. No. 07/677,591.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a rearview mirror assembly for a motor vehicle, and more particularly to an attachment structure for a mirror support of an automotive rearview mirror assembly.
2. Description of the Relevant Art
Rearview mirror assemblies for use on motor vehicles include a mirror holder supported by a mirror holder support unit which is attached to a bracket connected to a motor vehicle body. When the mirror held by the mirror holder is damaged, the rearview mirror is not replaced in its entirety since it would be time-consuming and costly to replace the entire rearview mirror assembly with a new rearview mirror assembly. Instead, the mirror holder is detached from the bracket, then the mirror holder is removed from the mirror holder support unit, and replaced with a mirror holder on which a new mirror is mounted. To allow such a mirror replacement, the mirror holder support unit is detachably mounted on the bracket.
Japanese Laid-Open Utility Model Publication No. 62(1987)-170346 discloses a rearview mirror assembly for a motor vehicle, which includes a mirror holder support member and a metal plate disposed behind the mirror holder support member. The metal plate and the mirror holder support member are fastened to each other by a plurality of screws. The metal plate has fingers on its upper end which engage a bracket, with the lower end of the metal plate being fixed to the bracket by screws from below. The mirror holder support member is thus attached to the bracket. With such an attachment structure, however, since the lower end of the metal plate is attached to the bracket by the screws from below, the lower end tends to wobble in the horizontal direction.
A rearview mirror assembly disclosed in Japanese Utility Model Publication No. 63(1988)-37321 has a mirror holder support member having engagement holes defined in its upper end and screw threading portions in its lower end. The engagement holes receive fingers on a bracket, and the screw threading portions and a lower end of the bracket are fastened to each other by screws, thereby attaching the mirror holder support member to the bracket. The upper and lower ends of the mirror holder support member are fixed to the bracket by the fingers and screws, respectively. Consequently, the bracket cannot absorb the thermal expansion of the mirror holder support member due to the heat thereof.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a rearview mirror assembly for use on a motor vehicle, which includes a mirror support that is securely attached to a bracket without wobbling movement and whose thermal expansion and shrinkage can be absorbed.
A rearview mirror assembly according to the present invention comprises a mirror, a mirror support means on which the mirror is tiltably supported, and a bracket having a holding means for holding the mirror support means. The holding means comprises a biasing means for resiliently biasing a portion of the mirror support means, and an engaging means having at least one engaging portion on the bracket. The mirror support means is pressed against the engaging portion under the force of the biasing means.
The above and further objects, details and advantages of the present invention will become apparent from the following detailed description of preferred embodiments thereof, when read in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front elevational view of a rearview mirror assembly for a mirror vehicle according to the present invention;
FIG. 2 is a plan view, partly cut away, of the rearview mirror assembly shown in FIG. 1;
FIG. 3 is a cross-sectional view taken along line III--III of FIG. 1;
FIG. 4 is an enlarged cross-sectional view, partly cut away, showing a mirror holder support member which is attached to a bracket;
FIG. 5 is an enlarged perspective view of the bracket shown in FIG. 1;
FIG. 6 is an enlarged perspective view of the bracket, as viewed from behind, shown in FIG. 5;
FIG. 7 is an enlarged plan view of a resilient plate;
FIG. 8 is a cross-sectional view taken along line VIII--VIII of FIG. 7; and
FIG. 9 is a view similar to FIG. 4, but showing a modified resilient plate.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
As shown in FIG. 1, a base 1 is fixed to a motor vehicle body (not shown), and a bracket 2 of metal has its proximal end angularly movably mounted on the base 1. The bracket 2 supports a mirror holder support member 3 which is made of synthetic resin. The mirror holder support member 3 supports a mirror holder 4 which holds a mirror M. The bracket 2, the mirror holder support member 3, and the mirror holder 4 are housed in a housing H.
As shown in FIGS. 5 and 6, the bracket 2 has on its proximal end a cylindrical member 2a which is rotatably fitted over a fixed shaft (not shown) fixed to the base 1, so that the bracket 2 is angularly movable with respect to the base 1. The bracket 2 also has a frame 2b extending from the cylindrical member 2a. The frame 2b comprises an upper portion 201, a pair of left and right side portions 202, 203, and a slanted portion 204 extending between the upper portion 201 and the right side portion 203. The upper portion 201 has a first integral engaging edge 5, and the side portions 202, 203 and the slanted portion 204 have second integral engaging edges 6 on their inner surfaces.
The frame 2b has an integral support surface portion 8 on its back. The frame 2b and the support surface portion 8 jointly define a space S in which the mirror holder support member 3 is to be disposed. The support surface portion 8 has an integral flange 8a projecting forwardly from a lower edge thereof. A resilient plate 10 (FIGS. 1, 3, and 4) serving as a biasing means is attached to the flange 8a.
As shown in FIGS. 1 through 3, the mirror holder support member 3 has, on its front side, a support 3a which supports the mirror holder 4, and a pair of operating rods 3b engaging the mirror holder 4 and movable back and forth by a motor (not shown). The mirror holder support member 3 is disposed in the space S, and has an upper portion 3c whose front edge engages the first engaging edge 5, a rear portion 3d engaging the second engaging edges 6, and a lower portion 3e engaging the resilient plate 10.
As shown in FIGS. 7 and 8, the resilient plate 10 comprises a main body 10a, a pair of finger members 10b projecting obliquely upwardly from side edges of the main body 10a, and a biasing or engaging portion 10c extending curvilinearly from a distal end of the main body 10a.
The resilient plate 10 is fastened to the flange 8a by a screw b which is threaded through a hole 10d defined in the main body 10a into a hole 8b defined in the flange 8a. With the resilient plate 10 thus fastened, the engaging portion 10c abuts resiliently against a lower front edge of the mirror holder support member 3. Therefore, the resilient force of the engaging portion 10c acts in the direction indicated by the arrow A in FIG. 4, thus reliably supporting the mirror holder support member 3 against the frame 2b.
As described above, the upper portion 3c of the mirror holder support member 3 engages the first engaging edge 5, and the rear portion of the mirror holder support member 3 engages the second engaging edges 6. Consequently, the mirror holder support member 3 is reliably held in place. The mirror holder support member 3 is pushed by the engaging portion 10c obliquely upwardly in the direction indicated by the arrow A, as described above. Therefore, the mirror holder support member 3 is prevented from wobbling vertically and back and forth. The resilient plate 10, which is resiliently deformable in the vertical direction, can absorb thermal expansion and shrinkage of the mirror holder support member 3.
As shown in FIG. 4, the distance l1 between the upper end of the screw b and the lower end of the mirror holder support member 3 is smaller than the height l2 of the first engaging edge 5 (l1<l2). This dimensional relationship is effective to prevent the upper end of the mirror holder support member 3 from disengaging from the engaging edge 5. Before the screw b is tightened, the erected members 10b abut against the lower surface of the flange 8a, lowering the resilient plate 10, as indicated by the imaginary lines in FIG. 4. Therefore, the mirror holder support member 3 can easily be inserted into the space S, and the resilient plate 10 is prevented from wobbling at the time of assembly.
When the mirror M is damaged, the mirror holder support member 3 is removed from the bracket 2, and then the mirror holder 4 is detached from the mirror holder support member 3. Thereafter, a mirror holder with a new mirror installed is attached to the mirror holder support member 3. When the mirror holder support member 3 itself is damaged, the mirror holder support member 3 is detached from the bracket 2 for replacement.
As shown in FIG. 1, a coupler 30 is mounted on a harness 20 connected to the mirror holder support member 3. The mirror holder support member 3 can easily be detached when the coupler 30 is disconnected.
FIG. 9 shows a modification of the present invention. A resilient plate 10 shown in FIG. 9 differs from the resilient plate 10 of the previous embodiment in that it has a V-shaped engaging portion 10c which resiliently engages the mirror holder support member 3. The other structural details of the resilient plate 10 shown in FIG. 9 are the same as those of the resilient plate 10 of the previous embodiment.
In the above preferred embodiment, the mirror holder support member 3 serves as an actuator for actuating the mirror holder 4. However, the mirror holder support member 3 may simply be a support which only supports the mirror holder 4.
Although there have been described what are at present considered to be the preferred embodiments of the present invention, it will be understood that the invention may be embodied in other specific forms without departing from the essential characteristics thereof. The present embodiments are therefore to be considered in all aspects as illustrative, and not restrictive. The scope of the invention is indicated by the appended claims rather than by the foregoing description.
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A rearview mirror assembly for use on a motor vehicle includes a bracket swingably mounted on a base connected to a motor vehicle body and a mirror holder support member housed in a frame of the bracket. The frame of the bracket has a plurality of projecting engaging edges which engage the mirror holder support member. The mirror holder support member is biased into abutment against the engaging edges of the bracket frame under the bias of a resilient plate fastened to the bracket.
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BACKGROUND OF THE INVENTION
The present invention relates to an opening and closing device for a vehicle sliding door.
RELATED ART
In general, for moving a sliding door slidably attached to a vehicle body a stronger force is required than for a swinging door attached to a vehicle body through the intermediary of hinges since the moving resistance of the sliding door is larger. Accordingly, over the years motor driven devices for opening and closing a sliding door have been attached to the sliding door to facilitate openings. There have proposed several devices for opening and closing a sliding door as disclosed, for example, in U.S. Pat. No. 5,239,779 and U.S. Pat. No. 5,203,112.
The above-mentioned opening and closing device, for moving a sliding door from a full-open position to a full-close position under power of a motor, is incorporated therein with a safety device for stopping the movement of the sliding door due to an obstruction. Such a safety device is adapted to be manually or automatically operated if a hand or a finger is caught between the sliding door and the vehicle body, for example. The conventional safety device is adapted to cut off power transmission between the motor and the sliding door, and simultaneously, a latch of the door is released so as to freely move the sliding door. However, even with this precaution, the hand and the finger can still be caught between the sliding door and the vehicle body. That is, a relative large force is required for opening the sliding door and accordingly, it requires manually movement of the sliding door to remove a hand or a finger is still caught between the sliding door and vehicle body even though the sliding door is free.
SUMMARY OF THE INVENTION
Accordingly, the object of the present invention is to provide a device for opening and closing a vehicle sliding door, which slides the sliding door toward its open position under power of a motor when a safety device is manually or automatically actuated.
BRIEF DESCRIPTION OF THE INVENTION
The above and other objects, features and advantages of the present invention will become apparent from the detailed description of the preferred embodiments found below with reference to the accompanying drawings in which:
FIG. 1 is an developed view illustrating a rear outer side panel, a sliding door and a power sliding unit;
FIG. 2 is a longitudinally sectioned front view illustrating a latch unit;
FIG. 3 is a front view illustrating a powered closing unit;
FIG. 4 is an enlarged view illustrating a winch lever and a connecting lever in the powered closing unit;
FIG. 5 is a sectional view illustrating the winch lever, the connecting lever and a sector gear;
FIG. 6 is an enlarged view illustrating the sector gear; and
FIG. 7 is an explanatory view for a safety mechanism.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
An embodiment of the present invention will be described with reference to the accompanying drawings. FIG. 1 shows a rear outer side panel or a quarter panel 80 of a vehicle body 44 and a sliding door 43 which is slidably attached to the vehicle body 44. A guide rail 46 extending in the longitudinal or front-and-rear direction of the vehicle body 44 is secured to the side panel 80. A coupling bracket 47 rotatably attached to the sliding door 43 is slidably engaged the guide rail 46. The sliding door 43 is slid between a full-open position where it faces the side panel 80 and a full-close position or a full-latch position where it closes a door opening 45 of the vehicle body 44.
FIG. 1 also shows a powered sliding unit 51 for sliding the door 43. The sliding unit 51 and the coupling bracket 47 of the slide door 43 are connected with each other by a wire cable 50. When the wire cable 50 is pulled by the slide unit 51, the coupling bracket 47 is moved along the guide rail 46, and accordingly, the sliding door 43 is slid back and forth.
Front side pulleys 62, 63 for the cable 50 are arranged in the vicinity of the front end part of the guide rail 46, and rear side pulleys 60, 61 for the cable 50 are arranged in the vicinity of the rear end part of the guide rail 46.
The powered sliding unit 51 has a base plate 81 fixed to the vehicle body 44, a reversible motor 52, a wire drum 54 journalled to the base plate 81 and wound thereon with the wire cable 50 by several turns, a speed reduction mechanism 53 provided between the reversible motor 52 and the wire drum 54, a pair of first tension rollers 55, 56 attached to the base plate 81, a pair of guide pulleys 58, 59 journalled to the base plate 81, and a second tension roller 57 attached to the base plate 81.
The sliding door 43 is attached thereto with a latch unit 1 which is adapted to be engaged with a striker 2 secured to the vehicle body 44 so as to hold the sliding door 43 in its closed position. The latch unit 1 comprises a latch 4 engaged with the striker 2, and a ratchet 5 engaged with the latch 4 for holding the engagement between the latch 4 and the striker 2. The latch 4 and the ratchet 5 are rotatably attached to a latch body 82 of the latch unit 1. Referring to FIG. 2, the latch 4 is urged clockwise by a resilient force of a spring (not shown), and the ratchet 5 is urged counterclockwise by a resilient force of a spring (not shown)
When the sliding door 43 is slid toward the closed position, the striker 2 is engaged in an U-like groove 83 of the latch 4 so as to turn the latch 4 counterclockwise, then the ratchet 5 is engaged with the latch 4 so as to prevent the latch 4 from reversing. The engagement between the latch 4 and the ratchet 5 includes two kinds of engagement, that is, a half-latch engagement as an initial engagement in which a pawl portion 84 of the ratchet 5 is engaged with a half-latch step part 15 of the latch 4, and a full-latch engagement as a complete engagement in which the pawl portion 84 is engaged with a full-latch step part 16 of the latch 4. The sliding of the door 43 toward the closed position by the powered sliding unit 51 is carried out until the half-latch engagement is attained. When the half-latch engagement is completed, the operation of the powered sliding unit 51 is stopped.
FIGS. 3 to 7 show a powered closing unit 3 for displacing the sliding door 43 from a half-latch position where the half-latch engagement is attained to a full-latch position where the full-latch engagement is attained. A wire cable 6 is laid between the powered closing unit 3 and the latch unit 1, for transmitting a power from the powered closing unit 3 to the latch unit 1, and accordingly, the latch 4 of the latch unit 1 can be turned toward the full-latch position under the power of the powered closing unit 3.
The powered closing unit 3 comprises a base plate 17 secured to the sliding door 43, and a motor 13 attached to the base plate 17. A gear part 19 of a sector gear 18 is meshed with an output gear 21 of the motor 13. The sector gear 18 is journalled to the base plate 17 through the intermediary of a shaft 20. A winch lever 22 is rotatably journalled to the shaft 20 and is engaged thereto with one end 65 of the wire cable 6. A connecting lever 23 is provided between the winch lever 22 and the sector gear 18, as shown in FIG. 5. The connecting lever 23 is formed therein with an elongated hole 24 through which the shaft 20 pierces. The connecting lever 23 is slidable by a distance equivalent to a length of a play obtained between the elongated hole 24 and the shaft 20.
The connecting lever 23 is provided at one end thereof with a pin 25 (see FIG. 5) which is projected from the opposite sides of the connecting lever 23. An upper roller 26 slidably engaged in an elongated hole 29 in the winch lever 22, and a lower roller slidably engaged in a U-like groove 28 of the sector gear 18 are rotatably fitted on an upper portion and a lower portion of the pin 25, respectively (see FIG. 5). A spring 32 is stretched between a bent piece 30 of the connecting lever 23 and a protrusion 31 of the winch lever 22 so as to urge the connecting lever 23 in a direction of the arrow W. The engagement between the lower roller 27 and the U-like groove 28 of the sector gear 18 is held by the resilient force of the spring 32.
The motor 13 of the powered closing unit 3 is rotated when the latch unit 1 falls into the half-latch condition, and accordingly, the sector gear 18 is rotated clockwise as viewed in FIG. 3. Then, since the lower roller 27 of the connecting lever 23 is engaged with the groove 28 of the sector gear 18, the connecting lever 23 is rotated clockwise and the upper roller 26 of the connecting lever 23 turns the winch lever 22 clockwise so as to pull the wire cable 26. Thus, power is transmitted from the motor 13 to the latch unit 1.
A cable lever 7 is journalled to the rear side of the latch body 82 through the intermediary of a shaft 8. The cable lever 7 is clockwise urged by the resilient force of a spring 33. The cable lever 7 is coupled thereto with the other end 86 of the wire cable 6. The shaft 8 is secured thereto with a rotary arm 9 (see FIG. 2) which is rotated integrally with the cable lever 7. The rotary arm 9 is connected thereto with a link 11 to which a roller 85 is attached. When the rotary arm 9 is rotated, the roller 85 is moved along a guide groove 12 formed in the latch body 82. The latch is provided with a leg part 14 which overlaps with the guide groove 12 when the latch 4 turns to the half-latch position.
When the latch unit 1 falls into the half-latch condition, the wire cable 6 is pulled under the power of the motor 13 of the powered closing unit 3 so as to turn the cable lever 7 and the rotary arm 9. Then, the roller 85 moves along the guide groove 12 and makes contact with the leg part 14 of the latch 4. Thereby the latch 4 is turned to the full-latch position from the half-latch position. Then, the pawl portion 84 of the ratchet 5 is engaged with the full-latch step part 16 of the latch 4.
The powered closing unit 3 is provided therein with a safety lever 35 for cutting off the power transmission between the motor 13 and the latch unit 1. The safety lever 35 is journalled to the base plate 17 through the intermediary of a shaft 34. The safety lever 35 is connected by a rod 37 to an open lever 36 which is adapted to be turned by means of an outer open handle or an inner open handle 42 of the sliding door 43. The open lever 35 shown in FIG. 3 is separated from the latch unit 1, but it is usually provided on the rear side of the latch unit 5 and is operatively connected to the ratchet 5 so as to release the ratchet 5 from the latch 4 when the open handle 42 is turned.
The safety lever 35 is formed therein with a contact surface 39 which is an arcuate shape which is substantially coincident with the moving locus of a cancelling roller 41 of the connecting lever 23, as shown in FIG. 7. The cancelling roller 41 is held at a standby position as indicated by X shown in FIG. 7, under the resilient force of the spring 33 in the latch unit 1 when the motor 13 is deenergized. When the connecting lever 23 is turned clockwise and the cancelling roller 41 moves to a position Y, the roller 85 abuts against the leg part 14 of the latch 4 at the half-latch position. When the cancelling roller 41 has been moved to a position Z, the roller 85 moves the latch 4 counterclockwise to the full-latch position.
When the cancelling roller 41 of the connecting lever 23 is on the way between the position Y and the position Z, if the open lever 36 is turned by means of the open handle 42, the safety lever 35 is turned counterclockwise about the shaft 34 as a center so that the contact surface 39 of the safety lever 35 abuts against the cancelling roller 41 of the connecting lever 23. Thereby the connecting lever 23 is slid in the direction opposite to the arrow W against the resilient force of the spring 32. Then, the lower roller 27 of the connecting lever 23 is separated from the groove 28 of the sector gear 18, and the connecting lever 23 and the sector gear 18 are disengaged from each other. That is, the power transmission between the motor 13 and the latch unit 1 is cut off. As a result, even though a hand or a finger is caught between the sliding door 43 and the vehicle body 44 during movement of the sliding door 43 by the powered closing unit 3 from the half-latch position to the full-latch position, the hand and the finger can be prevented from being seriously injured, by manipulating the open handle 42 of the sliding door 43 with no flurry.
In general, the sliding door has a moving resistance which is greater than that of a swinging door attached to a vehicle body by means of hinges, and accordingly, a larger force is required for moving the sliding door. Therefore, the swinging door can be displaced toward its open position by a certain degree by an impact resilient force of a seal member provided between the swinging door and the vehicle body when a latch of the swinging door is released by manipulating the open handle. However the sliding door does not appreciably move unless it is purposely moved even though the latch is released by manipulating the open handle. Thus, as mentioned above, in such a case that a hand or a finger would be caught between the sliding door 43 and the vehicle body 44, even though the power transmission between the motor 13 and the latch unit 1 is cut off by the safety lever 35, the hand or the finger would be still caught between the sliding door 43 and the vehicle body 44. Thus, according to the present invention, the sliding door 43 is moved to the full-open position by the powered sliding unit 51 when the power transmission between the motor 13 and the latch unit 1 is cut off by the safety lever 35. A switch or a sensor 64 for detecting the operation of the safety lever 35 is provided at a position in the vicinity of the safety lever 35, the open lever 36, the open handle 42 or the connecting lever 23. A signal is transmitted from the switch 64 to a controller 66 for the powered sliding unit 51. When the signal is delivered to the controller 66, the motor 52 is reversed, and accordingly, the sliding door 43 is moved to the full-open position.
According to the present invention, if a hand or a finger is caught between the sliding door 43 and the vehicle body 44, the power transmission of the powered closing unit 3 can be cut off. However, an assumption would be made such that a person whose hand or finger is caught therebetween falls into a panic, and accordingly, he cannot manipulates the open handle 42. Accordingly, in the present invention, when an abnormal affair occurs, the sliding door 43 can be automatically moved to the full-open position. Such abnormal closing of the sliding door 43 can be detected by an amperemeter 87 connected to the motor 13 of the powered closing unit 3. When a current value detected by the amperemeter 87 exceeds a predetermined value, it is regarded that an abnormal closing of the sliding door 43 occurs. A powered releasing means 88 having a motor or solenoid is operatively connected to the ratchet 5 of the latch unit 1. When the amperemter 87 detects an abnormal current value, the controller 66 energizes the powered releasing means 88 so as to release the ratchet 5 from the latch 4, and then, it reverse the motor 52 so as to move the sliding door 43 toward the full-open position. Abnormal closing of the sliding door 43 can also be detected by monitoring the rotational speed of the motor 13.
The foregoing discussion discloses and describes merely exemplary embodiment of the present invention only. One skilled in the art will readily recognize from such discussion, and from the accompanying drawings and claims, that various changes, modifications and variations can be made therein without departing from the spirit and scope of the invention as defined in the following claims.
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An opening and closing device for a vehicle sliding door slidably attached to a vehicle body. The device has a latch engageable with a striker, a ratchet engageable with the latch for maintaining the engagement between the latch and the striker, a first motor, a second motor, a wire drum rotated by the first motor, a wire cable provided between the sliding door and the wire drum for pulling the sliding door toward an open position or close position thereof when the wire drum is rotated, a power transmission provided between the second motor and the latch for turning the latch from a half-latch position to a full-latch position under power of the second motor, a safety lever operatively connected to the open handle for cutting off the power transmission when the open handle is manipulated, detecting apparatus for detecting actuation of the safety lever, and a control for operating the first motor to move the sliding door toward the open position when the detecting apparatus senses activation of the safety lever.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of application Ser. No. 11/000,920, filed on Dec. 2, 2004 now abandoned, in the name of Mark Martens, which is a continuation-in-part of application Ser. No. 09/933,576, filed on Aug. 21, 2001, now abandoned, in the name of Mark Martens, both of which are incorporated herein by reference in their entirety.
BACKGROUND OF THE INVENTION
This present invention relates generally to exercise equipment and more particularly to a cardiovascular exercise machine having a display system to provide a visual gauge of fitness progress and a method for gauging fitness progress.
Cardiovascular exercise machines, as used herein, include fitness bikes, treadmills, step machines, stair machines, rowing machines, cross country skiing machines and/or the like. These exercise machines have been equipped with a device comprising a combination of a visual display and a controller. For example, an exercise machine is known to have attached thereto a media system. The media system may provide capability to play compact discs and cassette tapes, as well as providing small television screens on which to view television programming, movies, and/or the like. In such machines, there is no electronic connection between the media system and the exercise machine. The media system merely provides the capability to watch TV and play music during workouts.
In another known exercise machine, monitors are attached in order to vary and monitor parameters of the workout such as resistance, target heart rate, time elapsed, distance covered, current pulse rate, caloric burn ‘rate’, and total calories consumed during the workout. The monitors may typically display numeric variables in pre-formatted areas, and grids of dots that are either lit, to produce bars of various heights. Once a user finishes the workout, summary information may be briefly displayed in numeric format, and then may disappear.
In yet another example of known exercise equipment, exercise machines are provided with Internet connectivity for use while exercising. This particular system may also provide for individual user identification, recording of total or cumulative miles of ‘exercise’ achieved for each identified user, and permit a user to view his or her own summary of historical totals while in the system. However, this display may be in the form of numerical data, possibly in a spreadsheet format.
There may have been products or services where a computer projects a paced competitor that proceeds at a specific pre-selected speed. In other systems a user may compete against other users. Although these systems may harness the competitive spirit, or alleviate exercise boredom for some, these systems suffer from several limitations.
For example, conventional exercise displays may not allow a user to determine whether the user is performing better, or worse, than in the past. For example, a user may want to determine if he or she can cycle (or run) faster, further, or easier today as compared with yesterday, or last week. Further, conventional exercise displays may not allow a user to determine how much energy was expended during their present workout as compared with a previous workout, except in total, and after they complete the workout.
A common concern of exercise machine users is whether they are improving their fitness. Conventional exercise machine displays may not allow a user to determine if the user is improving his/her fitness, and, if so, by how much, and in what way.
Another common concern of exercise equipment users is whether they are more fit currently than they were in the past. Conventional exercise displays may not allow a user to determine, for example, whether the user is more fit today than the user was yesterday, last week, or last month, and, if so, by how much and in what way.
Yet another concern of users of exercise machines may be about what needs to be done immediately in order to reach a desired performance level. Conventional exercise machine displays may not allow a user to determine how much harder the user has to exercise in order to reach a desired performance goal. Further, conventional exercise machine displays may not allow a user to determine how much harder the user should exercise immediately in order to improve performance.
A still further concern of exercise machine users may be determining average performance during exercise sessions and what the trend of the average is.
Conventional exercise displays may not allow a user to determine how tired the user was at a similar point in a previous workout. Further, conventional exercise machine displays may not allow a user to determine if a user is capable of beating the user's fastest, or best, time because conventional exercise displays may not allow a user to determine the user's best performance achievement to date for specific distances, or durations.
A major concern of exercise machine users is determining whether there has been any measurable progress made toward the user's goal of improving their fitness.
A difficulty in exercise programs may be that regular rigorous exercise is hard to maintain. For example, many people may start exercise programs with great enthusiasm, but may quickly lose motivation after a few weeks. According to research, approximately 60% of new members joining gyms to start an exercise program may give up after 3 months. At the beginning of a new year, consumers may spend thousands of dollars on exercise machines, and, within a few months, the exercise machines may be gathering dust in a basement. For many people, it may be difficult enough to get motivated to start exercising in the first place, and may be even more difficult to maintain high exercise intensity for a full 20-30 minute workout. Although many people may be highly motivated to exercise for self-improvement, for most, aerobic activities, particularly using exercise machines, may be hard work, tedious, repetitive, uncomfortable, and/or boring.
Conventional visual systems on or around exercise equipment attempt to address these concerns. While some visual display systems may alleviate the tedium felt during repetitive motion exercise, they may also be distracting to the workout itself.
Although conventional systems may make the user less bored during exercise, they may not make the user less bored by exercise. For example, watching a great basketball game on a television display system while exercising may be entertaining, but it may not help a user get a better workout. In fact, quite the opposite may result. Such systems may entertain the user, but at the cost of further disconnecting the user from the exercise activity. They may also impair a connection to the exercise activity and an ability to engage in intense workouts.
Activities like television or surfing the net, available on exercise equipment, may make one more likely to come to the gym, but because they may distract the user from the workout, they may reduce the intensity of the exercise program. Yet for fitness improvement, it may be critical for a user to push beyond his limitations, and for this reason, an increase in workout intensity may be necessary. In other words, it may not be enough to be ‘less bored’ during exercise activity for fitness improvement. Rather, a user may need to feel more invested in the activity itself.
Exercise frequency is important, but without workout intensity improvements may be very limited. For intense workouts, motivation and concentration may be critical. Because conventional systems may actually make it more difficult to concentrate and work out hard, users may experience limited fitness improvements even after using such exercise machines for long periods of time. As a result, they may get both bored and disappointed, leading to a possible discontinuation of the exercise activity.
Conventional exercise machine display systems may periodically display limited variables such as the user's current heart rate in numerical format. In contrast, the present invention allows the user to view graphs and charts showing continuously changing variables (such as pulse rate) in real-time from the initiation of the workout. This real-time graphical representation allows a user to continuously monitor and adjust relative effort, intensity, and duration, as well as progress and self-improvement.
A further deficiency in conventional exercise equipment is that they isolate users from each other. Conventional exercise machine display systems do not provide for communication, competition, or interaction among users because, at best, said conventional systems are only connected to the same brand and/or ‘types’ of exercise equipment. In contrast, the current invention allows users of different models or even different types of equipment, from different vendors, in different places, and at different times, to mutually identify workout partners, to permit others to use their stored workouts as pacers, or even to compete against others in real-time. The Fitclub system can allow users to use different types of machines from different vendors by maintaining the relevant distance calibration for each model in the database as shown in the machinemodeldistance table ( 718 ) in the drawing in FIG. 7 . The present invention also allows a user to send and receive messages to and from other users while working out, and to make those messages accessible to other users both in real-time, or later during the receiver's workout. The current invention also allows individual users to cooperate with others in their workouts as members of teams or leagues, in real-time or with previously saved workouts. The current invention provides these capabilities for users exercising on equipment directly next to each other, in the same exercise facility, or in exercise facilities or homes across the world.
With some known exercise machines, users are able to choose a variety of pre-programmed workout environments, in which the user's virtual figure “exercises.” These various environments are generic and often involve a “country” landscape or a “mountain” landscape. The present invention, by contrast, allows users to choose from a variety of true-to-life routes on which to exercise by cycling, running, or other cardio activity, and to do so in real-time with others in the same ‘virtual place’. These real-time, real-life landscapes include Washington, D.C., New York City, and the Tour de France, as well as many other virtual location scenes, either actual or fictional.
SUMMARY OF THE INVENTION
An exemplary embodiment of the present invention provides a solution to the problem and limitations of conventional display system discussed above by creating a real-time visual feedback environment in which the user may exercise in a virtual competition. In the virtual competition, a user exercises against his/her own previous workouts as “shadow competitors”, while continuously receiving updated graphical presentations of relevant performance and physiological parameters, based on the current workout and in relation to those of previous workouts. An exemplary embodiment of the present invention comprises a local computer, or processor attached to an exercise machine, a visual display device, processes, software, drivers, graphical animation methods, and a remote server(s) and database. This embodiment uses a separate local computer for each client, but the system may work in an equivalent fashion with a single local server providing the processing. This embodiment of the present invention provides a method and system for measuring, recording, and providing graphical and/or visual feedback to users of the relevant parameters of their current workouts, juxtaposed with those of their own previous workouts, or with those of other user(s), who have permitted them to do so, on exercise machines. The system may work in an equivalent fashion, in real-time competitions, and with minor adjustments, for many different cardiovascular exercise machines.
In an exemplary embodiment of the present invention, the display system of the invention may be attached to an exercise bicycle. In this embodiment, the local system visual display mechanism (for example, a monitor attached to an exercise bike) presents a small cyclist figure representing the current workout of the user. The figure may move along a “virtual track” on the display screen, varying in relation to the rate at which the user is pedaling. The invention may also produce several other “shadow competitor” cyclist figures. The other shadow competitors may represent actual and/or theoretical workouts previously recorded, which may be averages, or the user's best performance results or may be other users who have given permission for their results to be used in a competition, either as an individual, or a member of a team or a league. Each of the shadow competitors may move along the virtual track at a rate in accordance with the speed at which the user pedaled during an actual workout. In addition to reproducing into the current virtual environment actual workouts previously recorded, the invention also generates mathematical or even theoretical shadow competitors to represent, for example, a weekly, monthly, team, or any other average, or for such things as the personal best time.
In addition to creating the ‘virtual competition’, an exemplary embodiment of the present invention may provide a continuous record of all workout variables from the beginning of the workout to the present time in graphical format. For example, the user may see not only what his current pulse rate is, but the user may see a line graph of exactly what it is at each point in the workout and how the user's pulse rate has been changing throughout the workout. To allow for comparisons with previous workouts, an exemplary embodiment may also provide the user with an input device, such as, for example, a touch screen, to bring up the same graphical representations for each and any of the “shadow competitors.” These graphs may be juxtaposed, or overlaid, with the current graph for that variable to provide the user with immediate up to date visual comparisons. This allows the user to readily see, for example, how his current pulse rate has changed compared to his/her pulse rate on a previous workout, up to this same point in the workout.
The visual juxtaposition, or overlay, of workout shadows allows the user to easily and immediately see whether the user is ahead or behind a particular shadow(s), and by how much. The graphical juxtaposition, or overlay, of workout variables such as pulse rate also allows the user to readily ascertain the relative intensity and relative fitness compared to specific previous workouts, at each point throughout the workout. This feedback may keep a user involved in a workout and provide an incentive to work harder.
The invention, in an exemplary embodiment, thus provides visual representations in real-time, of ‘up-to-date’ workout intensity and progress or change over time, as the user is achieving it. The present invention may be designed to make the workout more personal, more interesting, more compelling, and/or provide the greater motivation. Visually, the system may mimic watching oneself compete on television in a representation of an actual place, without ever actually being there. Although previously exercise may have been a solitary and boring activity, the visual feedback system of the present invention on relative workout performance, in real time, may provide for an interesting competition, and also provide immediate visual feedback on many aspects of the workout as well as improvement over time. The present invention may overcome the limitations of conventional systems by combining physical and/or physiological feedback relative to previous workouts, which may provide psychological reinforcement for increasing intensity and self-improvement.
In an exemplary embodiment of the present invention, each user may choose to compete against himself. This may be important for psychological reasons. Unlike competing against others, this is a competition that all users can win most of the time, providing more encouragement and therefore incentive to try harder. In fact, on any given day, each user may have a chance to win their race. However, each time they do, it raises the performance bar for next time. The more often one beats a shadow competitor, the better performance it takes to beat the shadow competitor the next time, but also the more the user pushes his/her body to improve it's capabilities. Conversely, after a few slower weeks, a user may be temporarily discouraged, but the performance bar is being lowered, which gives the user a better chance of doing well the next time period. It is this finely tuned ‘automatic adjusting of the performance bar’ that an exemplary embodiment of the present invention provides, which constructs an appropriate schedule of positive psychological reinforcement and therefore encouragement. To maximize motivation, an exemplary embodiment of the present invention may make each workout challenging, but not discouragingly so, for each user based on their abilities and past performance.
Another exemplary embodiment of the present invention shows measurable progress towards a fitness goal in a way that may also provide an incentive and reward for effort. By providing feedback in a current workout, the system may encourage a user in real-time, when the user's motivation is most vulnerable.
In other words, the system and method of the present invention may make a computer game out of workouts. Millions of people play computer games long and often, and, perhaps, even obsessively. Although this may sound like unproductive or frivolous behavior on a computer game, it is exactly the behavior to encourage for exercise activities. Therefore, the system and method of the present invention may be designed to take advantage of the same psychological forces by creating the same environment. Only in this game the “joystick” is an exercise machine, the “skill” is workout effort, and the only way to win the game is to workout harder. Normally obsessive gaming leads to “sore thumbs”, but by attaching a different game console and joystick, this invention actually harnesses obsessive behavior to get “sore muscles”, and fitness improvements.
Further, in this exemplary embodiment, a user may, with the permission of other users, choose to exercise or race against their workout partner's already completed and stored workouts as a ‘shadow competitor’. In the exemplary embodiment, the user will be permitted to add or remove the userIDs of their designated partners on a form on the website at any time. The users choice of designated workout partners will be kept on the remote database in a table like 902 in FIG. 9 of the drawings. In the exemplary embodiment, when the user logs on, they will then be allowed to choose from a list of their own saved workouts and those of users who have designated them as workout partners.
In the exemplary embodiment, a user may also choose to communicate with other users while working out in real-time. Each time a user logs on to the system, a flag is entered into the database in table 708 , identifying their presence in the system and the ID of the individual machine they are on in table 706 . In the exemplary embodiment, users will be prompted to communicate with their workout partners if any of them they are simultaneously logged on to the system, in accordance with the flow shown in FIG. 11 . Or they may send messages for workout partners or any other users, in accordance with the flow shown in FIG. 10 by using their e-mail address as shown in table 708 .
Another exemplary embodiment of the present invention provides for communications, and interactions among users and health clubs. In the conventional exercise environment, even in those scenarios where perhaps hundreds of other users are physically present, a user is isolated from his fellow exercisers as he operates a piece of exercise equipment. This disconnected and isolating experience, which occurs in the midst of so many other people, often leads users to discontinue their exercise pursuits. In contrast, an exemplary embodiment of the present invention provides for users to mutually identify work-out partners in the system (stored in table 902 ), to permit those partners to mutually retrieve and compete against each others saved workouts, and to allow users to communicate with other users in real time, or leave messages for them to retrieve during their next workout on the GWFS.
In the exemplary embodiment, the graphical workout feedback system (GWFS) provides via the website, the capability for users to define and administer leagues and teams within the system, and to establish durations, criteria, and reward systems for those leagues. This data will be administered as shown in FIG. 12 of the drawings. In this embodiment the GWFS will allow users to make the leagues as narrow or as broad as they wish for example: ‘over 40, female members of Golds Gym’. In the exemplary embodiment, eligibility for those leagues will be assessed automatically by the system based on the information retained on member users. In the exemplary embodiment, each individual workout may be attributed to one, two, or as many leagues or teams as they want simultaneously.
In yet another exemplary embodiment, f the present invention comprises a remote data system, a website, a local system, and a method of connecting the remote and local systems.
The remote system comprises a remotely located web and database server(s) which may or may not be co-located, with installed operating system(s), accessible by a large number of local systems, a database, and transmission and communication protocols, and operating system, software technologies, and application programming interfaces (APIs).
The local system comprises a computer and monitor connected to an exercise machine, a set of sensors and drivers for measuring user workout activities/motions on the machine and transmitting them to the system in electronic form, transmission and communication protocols, routers, interface/query programs for sending and retrieving workout data to and from remote database, as well as the software implementing the user interfaces, the graphics, the 3D animation functionality. The animation functionality comprises 3-dimensional visual representations of current and previous actual or mathematically constructed workouts in the same time/space reference (e.g. figures representing the current exercise activity ‘competing against ones own previous workout/time’), 3-dimensional terrains and models of actual places, and objects, as well as graphical presentations of different parameters of current and previous workouts, such as distance covered, resistance, and pulse rate, up to date, in real time, and throughout the duration of the workout.
The connectivity between local and remote systems may be a wired or wireless network, such as, for example, the Internet.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be described with reference to the accompanying drawings, wherein:
FIG. 1 is a block diagram of a conventional client server database architecture with internet connection;
FIG. 2 is a block diagram of a server side software architecture showing a relational database management system in relation to an operating system;
FIG. 3 is a block diagram of an exemplary client software architecture in relation to a network architecture for the present invention;
FIG. 4 is a block diagram of an exemplary exercise machine network in accordance with the present invention;
FIG. 5 is a diagram of an exemplary graphical user interface display in accordance with the present invention;
FIG. 6 is a diagram of an another form of a graphical user interface display in accordance with the present invention;
FIG. 7 is a block diagram of an exemplary relational database design in accordance with the present invention;
FIG. 8 is a flowchart of an exemplary method for providing graphical workout feedback in accordance with the present invention;
FIG. 9 is a block diagram of an exemplary relational database table to provide the capability to establish workout partners in accordance with the present invention;
FIG. 10 is a flowchart of an exemplary method for a messaging system in the invention;
FIG. 11 is a flowchart of an exemplary method for implementing real-time communication with other users in the invention;
FIG. 12 is a block diagram of an exemplary relational database design for providing leagues in accordance with the present invention;
FIG. 13 is a flowchart of an exemplary method for administering leagues in accordance with the present invention;
FIG. 14 is a flowchart of an exemplary method for implementing racing in accordance with the present invention;
FIG. 15 is a block diagram of an exemplary relational database design for providing real-time racing in accordance with the present invention; and
FIG. 16 is a flowchart of an exemplary method for retrieving workout reports of one user by another user.
DETAILED DESCRIPTION
Referring to FIG. 1 , there is illustrated a block diagram of a conventional client server database system with Internet connection. In particular, client server system 10 comprises a server 102 , a database 104 , an Internet network 106 , and a client 108 .
FIG. 2 is a block diagram of a relational database management system in relation to an operating system. In particular, a relational database management system 202 is coupled to an operating system 204 .
FIG. 3 is a block diagram of an exemplary client architecture in accordance with the present invention. In particular, a client architecture comprises a persistence framework (e.g. Hibernate) 302 , a user interface (e.g. SWING) 304 , an exercise machine interface 306 , a relational database design (e.g. MYSQL) 308 , a java virtual machine 310 , and an operating system (e.g. Linux) 312 .
In operation, the persistence framework 302 provides a mechanism for the GWFS application data to be permanently saved. The user interface 304 provides the graphical user interface functionality. The exercise machine interface 306 provides an interface to the sensor coupled to the exercise machine and/or the user. The object model 308 , java virtual machine 310 , and the operating system 312 provide various software support services that enable the GWFS application to operate.
FIG. 4 is a block diagram of an exemplary exercise machine network in accordance with the present invention. In particular, a database 104 is linked to a network 402 . Exercise machines equipped with the GWFS ( 404 , 406 , and 408 ) are linked to the network 402 .
In operation, the exercise machines equipped with the GWFS ( 404 , 406 , and 408 ) store and retrieve data in the database 104 via communication across network 402 . The network 402 may be a wired or wireless network.
Further, the system provides for individual user identification and confirmation. User input is accomplished by the local part of the system, the GWFS units ( 404 , 406 , and 408 ), which are attached to the exercise machines. The GWFS units ( 404 , 406 , and 408 ) prompt the user to enter information identifying the user and intended workout parameters. The visual display of the GWFS units ( 404 , 406 , and 408 ) provides this functionality through a touch-sensitive monitor screen keyboard that is displayed in response to the user initiating the system. The touch-sensitive screen keyboard is a preferred, but not the only, method for the local system interface, and is desirable primarily for eliminating the need for a physical keyboard. The system is initiated when a user touches the application icon, or when a user commences to use the equipment in the normal manner. If the user requests GWFS functionality the local system sends a query to the remote database 104 , via the network 402 using identification information input by the user. As soon as the local part of the system authenticates the user from the remote database, it returns their previous workouts, allows the user to select form those workouts, and then it creates a ‘virtual competition’ environment on a selected area of the visual display (monitor). The system generates different virtual competition environments depending on the particular exercise machine it is attached to. For illustrative purposes the current description assumes it is attached to an exercise bike. In this case, the virtual competition environment consists of a road, or track (circular, linear, or other shaped course) in which cycling figures can be depicted. The GWFS units ( 404 , 406 , and 408 ) depict the current workout as a figure on a bike moving along the track at a speed commensurate with the rate at which the user pedals on the exercise machine. The system moves the ‘cyclist’ around/along the virtual track much in the same way a video game does. But the GWFS in this configuration responds to pedal motion not to input from a joystick or game console. This functionality is accomplished using various graphical animation methods.
When the remote server (not shown) receives the identification request from the local GWFS units ( 404 , 406 , and 408 ), it verifies the user identification and returns a package of data to the local site, i.e. the GWFS units ( 404 , 406 , and 408 ). This package of data is typically a standardized profile of the user's previous workouts.
The initial standard data package depends on the recency and availability of previous workout data. The GWFS units ( 404 , 406 , and 408 ) temporarily store this data on the local hard drive, and then use this data to generate a variety of ‘shadow competitors’ and add them to the visual presentation of the virtual competition. One shadow competitor is generated for each previous workout retrieved. For example, if the individual has already been working out for a minute by the time the local system receives the data package, then the GWFS presents each shadow competitor at the logical location on the virtual track that was reached, one minute after the start of each respective workout. Each shadow competitor is color coded for easy visual identification and with a color intensity in reverse proportion to the recency of that workout. For example, if a shadow represents a workout from a month ago, the shadow would have a very low color intensity. The local system also generates shadow competitors for theoretical workouts such as ‘the previous weeks average’, the ‘previous months average’, ‘weekly average to-date’, ‘personal best’, and others. A preferred number of shadow competitors, depending on several conditions, is 5-10. The standard competition includes the previous five workouts, plus a shadow for the average (of those five), plus a shadow for the user's personal best time for that workout distance. In any case, it is likely that the virtual competition will function best based on a total of less than 10 total shadow competitors. However, the GWFS units ( 404 , 406 , and 408 ) also generate more shadow competitors in response to subsequent user requests.
The GWFS units ( 404 , 406 , and 408 ) recreate the exact movement over time of those previous workouts, but depict them as shadow competitors moving along the same virtual track as the current workout. Each shadow is depicted either behind or ahead of the current workout figure, and each other, at all times in exact proportion to their relative performance from the initiation of the workout. In other words, the GWFS units ( 404 , 406 , and 408 ) take all these workouts that occurred in reality at different times, and recreates them, in the same track, as if they were happening simultaneously. It should be appreciated that the graphical presentation may be in two-dimensional graphics, or in three-dimensional graphic representations. With a result that the GWFS creates a visual effect similar to a real-time computer game using a virtual competition with oneself.
FIG. 5 is a diagram of an exemplary user interface in accordance with the present invention. In particular, a display system 50 comprises a visible screen portion 502 , a touch screen portion 504 , a heart rate graph 506 , a distance graph 508 , a blood oxygen level graph 510 , a first virtual competitor 512 , a second virtual competitor 514 , and a graphical symbol of a current workout 516 .
In operation, the heart rate graph 506 , distance graph 508 , and blood oxygen level graph 510 are responsive to data received from sensors attached to the user or to the exercise machine. The first virtual competitor 512 and second virtual competitor 514 are responsive to historical data retrieved from a database. The graphical symbol of a current workout 516 is responsive to current workout sensed data. The touch screen portion 504 is responsive to user input.
Further, the graphics necessary for the basic visual presentation and functionality of the graphical user interface are retained on, and generated by, the local GWFS. Because the required graphics images are known prior to run time, this is not a problem. It should be appreciated that many different competition environments, or ‘tracks’ could be easily provided as options to the user. The GWFS is configured so that communications between remote and local systems are in the form of conventional protocols, but may be implemented in later developed protocols. By transmitting only data, bandwidth requirements can be kept to a minimum for this functionality.
Conventional systems may provide methods for measuring, recording, and presenting summary information on exercise machine workouts. Known exercise bikes, for example, display (for a few seconds at the finish of the workout); the total number of miles cycled, total number of calories, burned, and total time duration. However, even if systems retained summary information such as that the current user covered 4.86 miles in the previous 15-minute workout, this would provide sub-optimal estimates for creating a virtual competition, and inadequate records for graphical presentations and real time feedback. To remedy this problem the local system of the current invention measures and records several aspects of each workout, in small increments, throughout the duration of the exercise activity.
For some workout variables, such as the pedaling rate and resistance, the GWFS measures and records one or more times per second, others such as pulse rate are recorded at larger intervals, such as once per minute. The GWFS uses straight-line extrapolation to smoothly bridge from one measurement point to the other for those workout variables that are recorded at larger time intervals. Tradeoffs and compromises may have to be made between the number of variables measured, the measurement interval, the number and size of shadow figures, number of dimensions, graphical views and other variables depending on system processing or memory resources. There are many permutations that work perfectly well, and the specific combination is not critical to the functioning of the invention, although at extremes it may affect the degree of realism perceived by users.
On some conventional equipment the variable known as ‘level’ is actually a parameter that varies resistance to the pedaling activity. In the real world this is equivalent to a gear on a bike. A higher gear is a higher resistance level, but covers more distance, per revolution. However, in the current art no accommodation is made of how the resistance variable impacts distance covered. In fact, on some known exercise bikes, pedaling for half an hour causes the display to read the same 10.8 miles covered each time, regardless of the resistance level or even revolutions per minute (RPM) of pedaling. Although varying the level and RPM parameters causes these machines to report different results for ‘calories burned’, it is quite clear that measures generated by some conventional systems are gross, unrealistic, and unreliable. To more realistically reflect distance covered in a manner similar to an actual bike ride in the real world, the GWFS calculates the distance covered using the RPM directly and by multiplying this by an increasingly large factor as the level is increased. Thus the distance covered after ten seconds of pedaling at 100 RPM at resistance level six will be 1.x times as much as the same time and RPM at resistance level five. Calculation of the correct relative distance ratios for each resistance level is obviously an iterative process requiring a different calibration that varies by specific type of exercise equipment, and even by model or version. One of ordinary skill in the current art understands that the specific multiplier for each resistance level is subject to some tweaking, and may even have to vary (ultimately) according to the specific machine brand and model. Nevertheless, the GWFS is designed to consistently and credibly maximize the accuracy of such variables to minimize user disconnectedness from the workout activity, in sharp contrast to methods used in the current art. In practical terms, all the system needs to do to provide a substantial improvement is to have the distance increase with increasing revolutions per minute, not to measure it precisely. The formula for calculating distance will inevitably be approximate initially and improve over time.
Although the conventional systems may provide sensory devices on handles attached to the equipment for measuring pulse rates, these methods are not considered sufficiently accurate or reliable. In a preferred embodiment, the GWFS utilizes a different device that receives sensory information from a source closer to the heart. The device is a sensory device worn like a strap over the shoulder, resting directly over the chest and receiving sensory input through the chest rather than the hands. Such devices are currently available commercially as stand-alone pulse rate measurement devices. This GWFS invention will utilize such devices but will integrate them into the system by directly wiring the sensory device to the GWFS. Those of ordinary skill in the art will recognize that, wireless technology will perform this function equally as well as a physical wiring. The methods to integrate data from this device are also relatively straightforward and well known in the current art. In this configuration the GWFS records the pulse rate continuously using the sensory device, but then instead of replacing previous measurements with new ones as in the current art, the GWFS retains and stores the recorded pulse rate every 60-120 seconds on the local system. As with new data on all parameters, the GWFS then immediately updates graphical presentations. Those of ordinary skill in the art will recognize that it may be desirable to also measure such variables as blood oxygen level, oxygen intake, respirations, and/or the like. These variables vary significantly during intense aerobic activity, and the means to measure, record, and display them are known to the current art, although they are typically utilized in sports medicine or hospital situations. The system and method of the present invention may enable the same level of sophistication to be achieved on exercise machines in a gym.
FIG. 6 is a diagram of an exemplary user interface in accordance with the present invention. In particular, a display system 60 comprises a visible screen portion 602 , a touch screen portion 604 , a calorie chart 606 , a performance graph 608 , a select item button 610 , a show options button 612 , a change mode button 614 , a back button 616 , an end workout button 618 , an annual pie chart 620 , a weekly improvement bar chart 622 , a first virtual competitor 624 , a second virtual competitor 626 , a third virtual competitor 628 , a fourth virtual competitor 630 , and a fifth virtual competitor 632 .
In operation, the select item button 610 , show options button 612 , change mode button 614 , back button 616 , and end workout button 618 are provided for receiving control input from a user. The calorie chart 606 , performance graph 608 , annual pie chart 620 , and weekly improvement bar chart 622 are responsive to current and/or historical workout data. The first virtual competitor 624 represents a workout from ten days ago. The second virtual competitor 626 represents last week's average performance. The third virtual competitor 628 represents yesterday's workout. The fourth virtual competitor 630 represents today's workout. The fifth virtual competitor 632 represents the best performance of the user. The virtual competitors are responsive to historical and/or current data.
The buttons ( 610 - 618 ) are graphical symbols on a touch screen interface and respond to touch pressure from the user applied to the screen. While specific user interface elements are shown in FIG. 6 , it should be appreciated that the user interface elements may be implemented in a variety of forms.
FIG. 7 is a block diagram of an exemplary software relational database design in accordance with the present invention. In particular, an address table 702 has a one-to-one relationship with a Gym table 704 , a one-to-many relationship with a user table 708 , and comprises six elements: 1) UserID, 2) Address1, 3) Address2, 4) City, 5) State, and 6) Zip. The Gym table 704 has a one-to-many relationship with a Machine table 706 , the user table 708 , and a workout table 710 , and a one-to-one relationship with the address table 702 , and comprises three elements: 1) GymID, 2) Name, and 3) Address. The Machine table 706 has a many-to-one relationship with the Gym table 704 , a one-to-many relationship with the workout table 710 , and comprises five elements: 1) MachineID, 2) Type, 3) Brand, 4) Model, and 5) GymID. The User table 708 has a many-to-one relationship with the Gym table 704 , and the Address table 702 , and a one-to-many relationship with the workout table 710 , and comprises five elements: 1) UserID, 2) firstName, 3) lastName, 4) Address, and 5) GymID. The Workout 710 table has a many-to-one relationship with the Gym table 704 , the User table 708 , and the Machine table 706 , and a one-to-many relationship with a WorkoutStep table 712 , and comprises six elements: 1) workoutID, 2) userID, 3) machineID, 4) timeStamp, 5) WorkoutSteps, and 6) distance. The WorkoutStep table 712 has a many-to-one relationship with the Workout table, and comprises five elements: 1) workoutID, 2) timeStamp, 3) heartrate, 4) rpm, and 6) resistance.
FIG. 8 is a flowchart of an exemplary method for providing graphical workout feedback in accordance with the present invention. In particular, the control sequence begins at step 802 and continues to step 804 . In step 804 , instantaneous sensor data is received by the graphical workout feedback system. Control then continues to step 806 .
In step 806 , the instantaneous data is stored. Control then continues to step 808 . In step 808 , historical data is retrieved. Control continues to step 810 .
In step 810 , the GWFS renders a graphical representation of the current workout instantaneous sensed data and the historical data. Control then continues to step 812 when the control sequence ends. However, the nature of the GWFS may require that control remain in a loop. In such an embodiment, control would continue from step 812 back to step 802 and the control sequence would begin again. Such a control loop may operate until terminated by a user, by power off, or by other source.
During the workout activities, all information relating to the workout is recorded and stored on the local system hard drive. As the workout proceeds, and as designated memory is allocated, the local system can periodically copy ‘a partial chunk’ of the current workout data and attempt to transmit it to the remote system to be stored in the database. This allows that storage to be freed up, if the local system threatens to run out. The optimal size or periodicity of these transmissions is between 1-5 minutes of (completed) workout data, depending on the connectivity, usage, and other factors. At the conclusion of the workout, during periods of ‘down time’, and based on availability of connectivity, the local system communicates with the remote system to insure that all data related to complete workouts have been received by the remote system and stored on the remote database. After confirmation of receipt from the remote location, the local system deletes the local copies of workout data on the hard drive, and releases the storage, whether it is needed or not.
In a preferred embodiment, the GWFS segments the visual display into three parts. It allocates the ongoing virtual competition to one area of the visual display, graphs of workout data to a second area, and user input icons to a third area. Optimally, the far right part of the visual display screen (a column approximately 20-25% of screen width) be allocated to user input icons, and the remaining portion of the visual display is segmented by a horizontal line approximately ⅓ of the way down from the top. In the optimal configuration the virtual competition is presented in the larger ⅔ portion at the bottom of the screen.
FIG. 9 is a block diagram of exemplary relational database tables to provide the capability to establish workout partners in accordance with the present invention. In particular, a user table 904 has a one-to-many relationship with a permissions table 902 . The user table 904 comprises fields for 1) userID, 2) firstName, 3) lastName, 4) address, 5) gym, 6) gender, 7) birthdate, 8) loggedOnFlag, and 9) haveMessageFlag. The permissions table 902 comprises four fields: 1) givingUserID, 2) receivingUserID, 3) allowUseWorkouts, and 4) allowViewReports.
The permissions table 902 , through the givingUserID and receivingUserID fields, allows a user to designate one or more other users with which to share information and to partner with for working out. Flags, such as the allow use workout and allowViewReports, are used to determine the details of what information is to be shared and how information is shared between users.
FIG. 10 is a flowchart of an exemplary method for a messaging system in the invention. In particular, the control sequence begins at step 1002 and continues to step 1004 . In step 1004 , a first user logs on to the graphical workout feedback system. Control then continues to step 1006 .
In step 1006 , the system extracts the userID and machineID from the logon transaction and stores them in a database. Control then continues to step 1008 . In step 1008 , the system checks the first user's message box (which may be previously established) for a flag indicating new messages. If no flag is present, control continues to step 1010 .
If a new message flag were found, the first user would be alerted to the presence of a message through an on-screen visual display, an audio cue, or a combination of the above.
In step 1010 , the user may request the messaging function. Control then continues to step 1012 where the first user enters a userID of a second user they want to contact. Control then continues to step 1014 .
In step 1014 the system checks a user table (see for example FIG. 9 , 904 ) for the value in the loggedOnFlag for the userID of the desired contact. If the system detects the presence of the requested contact (i.e., the second user is logged in), control then continues to step 1016 where the system opens a 2-way dialog box on the displays of both the first user and second user, and alerts the second user of the contact seeker. If the user sought does not have a “loggedOn” value in the loggedOnFlag in table 904 , control passes to step 1018 .
In step 1018 , the system allows a message to be typed, and puts a flag in the second user's message box. When the second user logs on, control passes to step 1020 . Control then passes to step 1022 where the system checks user table 904 for the haveMessageFlag for that user, finds the message and passes it to the second user. Then the control sequence ends. The control sequence may be repeated as desired or necessary to fully process messages.
FIG. 11 is a flowchart of an exemplary method for the instant messaging function of the present invention. In particular, the control sequence begins at step 1102 and continues to step 1104 . In step 1104 , a first user (User1) logs on to the GWFS. Control then continues to step 1106 . In step 1006 , the system extracts the machineID from the logon transaction and stores it in a database and enters a flag indicating the first user is logged on. (For example, in the loggedOnFlag in table 904 .) Control then continues to step 1108 . In step 1108 , the system checks for designated workout buddies of the first user, using, for example, table 902 . For all designated workout buddies, the system then checks if they have a logged on indication in the loggedOnFlag in table 904 . Control continues to step 1110 . In step 1110 , for each workout buddy the system identifies as not logged on control passes on to step 1112 . In step 1112 a second user (User2) logs on who has a workout buddy who is already logged on and therefore has loggedOnFlag checked in table 904 . Control then continues to step 1114 .
In step 1114 the system enters a check in the loggedOnFlag in table 904 for the second user. Control then continues to step 1116 .
In step 1116 , the system checks the second user's designated workout buddies in table 902 and identifies the first user. Control then continues to step 1118 where the system checks the loggedOnFlag for user1 and identifies user1 as in the system. Control then passes to step 1120 . In step 1120 the system opens a 2-way dialog box on each of the display systems of the first users and the second users linked by their recorded machineIDs. Then the control sequence ends, and the first and second users are able to exchange messages while working out. The control sequence may be repeated as necessary or desired to maintain communications between users of the GWFS.
FIG. 12 is a block diagram of an exemplary relational database for providing leagues in accordance with the present invention. In particular, a leagues database 1202 is in a one-to-many relationship with a LeagueTeams database 1204 . A Teams database 1208 is in a many-to-one relationship with the LeagueTeams database 1204 . A TeamMembers database 1206 is in a many-to-many relationship with the Teams database 1208 . And a User database 708 is in a many-to-one relationship with the Teams database 1206 .
The Leagues database 1202 includes a LeagueID field for uniquely identifying the league, a LeagueName field for storing the name of the league, a LeagueManager field for storing the name of the league manager, a LeagueStartDate field, a LeagueEndDate field, a MaxTeamsPerLeague field for establishing the maximum number of teams for the league, a MaxPersonsPerTeam field for specifying the maximum number of people per team, a GymIDCriteria field used in limiting the league to one or more specific gyms, a MachineTypeCriteria for limiting the league to one or more specific machine types, a GenderCriteria for limiting the league to a particular gender, and an AgeCriteria field for limiting the league to a particular age or age range.
The LeagueTeams database 1204 includes LeagueID and TeamID fields to associate a team with a league.
The Teams database 1208 includes a TeamID field for uniquely identifying a team, a TeamName field for storing the name of the team, and a Team ManagerID field for storing the ID of the team manager.
The TeamMembers database 1206 includes UserID and TeamID fields to associate a user with a team, and JoinDate and EndDate fields to indicate when a user joined a team and left a team.
The user database is described above in relation to FIG. 7 .
FIG. 13 is a flowchart of an exemplary method for administering leagues in accordance with the present invention. The control sequence starts at 1302 and continues to step 1304 . In step 1304 , a first user (User1) is recorded in a database. Control then continues to step 1306 .
In step 1306 , the first user is associated with a team and league membership. Control then continues to step 1308 .
In step 1308 , the overall league standings are updated. Control then continues to step 1310 where the sequence ends. The control sequence of FIG. 13 may be repeated as desired or needed to update the user, team, and league data.
FIG. 14 is a flowchart of an exemplary method for implementing racing in accordance with the present invention. The control sequence begins at step 1402 and continues to step 1404 . In step 1404 , a first user (User1) logs on and requests a race. The control sequence continues to step 1406 .
In step 1406 , the GWFS creates a “race pool” of competitors and puts the UserID of the first user into the race pool. The control sequence continues to step 1408 .
In step 1408 , a second, user (User2) logs on and requests a race. The control sequence continues to step 1410 .
In step 1410 , the GWFS adds the second user to the race pool created in step 1406 . The race pool now contains the UserIDs for the first user and the second user. Control continues to step 1412 .
In step 1412 , the first user may start the race, or may wish to delay starting the race to allow for other users to join. Control continues to steps 1414 and 1416 . In steps 1414 and 1416 , other users may log on and may be added to the race pool if they request a race. Control continues to step 1418 .
In step 1418 , the first user starts the race. Control continues to step 1420 .
In step 1420 , the GWFS initiates simultaneous tracking for all machineIDs associated with the UserIDs in the race pool. The race continues for a given time, distance, or other criteria as selected by the first user. When the race is complete results may be displayed to each user participating in the race. The control sequence continues to step 1422 , when the sequence ends. The control sequence of FIG. 14 may be repeated as often as a user initiates a race request.
FIG. 15 is a block diagram of an exemplary relational database for providing real-time racing in accordance with the present invention. A Races database 1502 has a many-to-many relationship with a RaceResults database 1504 . The RaceResults database 1504 has a many-to-many relationship with a User database 708 .
The Races database 1502 includes a RaceID field for uniquely identifying a race, a RaceStartDateTime field for storing the start date and time of the race, a RaceDistance field for storing the distance of the race, and a Race duration field for storing the time duration of the race.
The RaceResults database 1504 includes a RaceID field for associating the results with a race in the Races database 1502 , a UserID field for associating a user form the User database 708 with a race result, and a UserPositionInRace field for storing a user's finishing position in a race. The User database 708 is described above in relation to FIG. 7 .
FIG. 16 is a flowchart of an exemplary method for retrieving workout reports of one user by another user. In particular, the control sequence begins at step 1602 and continues to step 1604 .
In step 1604 , a first user (User1) logs onto a website coupled to the GWFS and associated databases containing workout information. Control then continues to step 1606 .
In step 1606 , the first user requests permission to view (or retrieve) workout reports or data of a second user (User2). Control then continues to step 1608 .
In step 1608 , the GWFS records the “View Reports” request in the permissions database in a field associated with the second user. Control then continues to step 1610 .
In step 1610 , the second user logs onto the website coupled to the GWFS and associated databases. Control then continues to step 1612 .
In step 1612 , the second users is presented with the request from the first user to view the workout reports of the second user. And, in this example, the second user permits the request, allowing the first user to view the workout reports of the second user. Alternatively, the second user may reject the request and the first user would not be permitted to view the workout reports of the second user. Control then continues to step 1614 .
In step 1614 , the GWFS sets the “View Reports” flag and the UserID of the first user in the permissions table entry for the second user. Control then continues to step 1616 .
In step 1616 , the GWFS enables the first user to view the workout reports of the second user. Control then continues to step 1618 .
In step 1618 , when the first user logs onto the website again, the acceptance of the “view Reports” request is displayed, and the first user may view or retrieve the workout reports for the second user.
The sequence shown in FIG. 16 may be used by employers, insurers, health professionals, or others, to monitor, verify, and track the workouts of selected users who have accepted the request for the viewing of their workout reports. For example, a health insurer may wish to monitor the workouts of its subscribers or customers. In another example, an employer or insurer may wish to monitor workouts to determine the usefulness and effectiveness of a fringe benefit such as a gym membership.
The graphical workout feedback method and system, as shown in the above figures, may be implemented on a general-purpose computer, a special-purpose computer, a programmed microprocessor or microcontroller and peripheral integrated circuit element, and ASIC or other integrated circuit, a digital signal processor, a hardwired electronic or logic circuit such as a discrete element circuit, a programmed logic device such as a PLD, PLA, FPGA, PAL, or the like. In general, any process capable of implementing the functions described herein can be used to implement a system for graphical workout feedback according to this invention.
Furthermore, the disclosed system may be readily implemented in software using object or object-oriented software development environments that provide portable source code that can be used on a variety of computer technologies and platforms. Alternatively, the disclosed system for providing graphical workout feedback may be implemented partially or fully in hardware using standard logic circuits or a VLSI design. Other hardware or software can be used to implement the systems in accordance with this invention depending on the speed and/or efficiency requirements of the systems, the particular function, and/or a particular software or hardware system, microprocessor, or microcomputer system being utilized. The graphical workout feedback methods and systems illustrated herein can readily be implemented in hardware and/or software using any known or later developed systems or structures, devices and/or software by those of ordinary skill in the applicable art from the functional description provided herein and with a general basic knowledge of the computer and mark-up language arts.
Moreover, the disclosed methods may be readily implemented in software executed on programmed general-purpose computer, a special purpose computer, a microprocessor, or the like. In these instances, the systems and methods of this invention can be implemented as program embedded on personal computer such as JAVA® or CGI script, as a resource residing on a server or graphics workstation, as a routine embedded in a dedicated encoding/decoding system, or the like. The system can also be implemented by physically incorporating the system and method into a software and/or hardware system, such as the hardware and software systems of an image processor.
It is, therefore, apparent that there is provided in accordance with the present invention, systems and methods for providing graphical workout feedback. While this invention has been described in conjunction with a number of embodiments, it is evident that many alternatives, modifications and variations would be or are apparent to those of ordinary skill in the applicable arts. Accordingly, applicants intend to embrace all such alternatives, modifications, equivalents and variations that are within the spirit and scope of this invention.
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A system and method for providing visual feedback to a user of an exercise machine for gauging fitness progress of the user. The system provides a user of an exercise machine with a virtual competition in which the user competes against virtual competitors based on his past performances or those of other users, either as an individual or as a member of a team. The team may also be part of a league. For an individual competing against his own past performance(s), the system may raise the level of performance required to win the virtual competition, and may also lower the level of performance required if the user is not performing well on a particular day. For an individual competing against others in either real-time or against designated results, either as part of a team or a league, the system may reduce the isolation, disconnection, and tedium often experienced by users of cardiovascular exercise equipment and provide a social outlet. The system attempts to keep the user engaged and motivated to achieve desired fitness goals by providing real-time performance data and historical performance data displayed in a graphical manner coupled with the entertainment and excitement of competition and social interaction.
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BACKGROUND TO THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to the production of stencils for screen printing.
[0003] 2. Related Background Art
[0004] The production of screen printing stencils is generally well known to those skilled in the art.
[0005] One method, referred to as the “direct method” of producing screen printing stencils involves the coating of a liquid light-sensitive emulsion directly onto the screen mesh. After drying, the entire screen is exposed to actinic light through a film positive held in contact with the screen in a vacuum frame. The black portions of the positive do not allow light to penetrate to the emulsion which remains soft in those areas. In the areas which are exposed to light, the emulsion hardens and becomes insoluble, so that, after washing out with a suitable solvent, the unexposed areas allow ink to pass through onto a substrate during a subsequent printing process.
[0006] Another method, referred to as the “direct/indirect method”, involves contacting a film, consisting of a pre-coated unsensitised emulsion on a support base, with the screen mesh by placing the screen on top of the flat film. A sensitised emulsion is then forced across the mesh from the opposite side, thus laminating the film to the screen and at the same time sensitising its emulsion. After drying, the base support is peeled off and the screen is then processed in the same way as in the direct method.
[0007] In the “indirect method” a film base is pre-coated with a pre-sensitised emulsion. The film is exposed to actinic light through a positive held in contact with the coated film. After chemical hardening of the exposed emulsion, the unexposed emulsion is washed away. The stencil produced is then mounted on the screen mesh and used for printing as described above for the direct method.
[0008] In the “capillary direct method” a pre-coated and pre-sensitised film base is adhered to one surface of the mesh by the capillary action of water applied to the opposite surface of the mesh. After drying, the film is peeled off and the screen then processed and used as described for the direct method.
[0009] In addition to the above methods, hand-cut stencils can be used. These are produced by cutting the required stencil design into an emulsion coating on a film base support. The cut areas are removed from the base before the film is applied to the mesh. The emulsion is then softened to cause it to adhere to the mesh. After drying, the base is peeled off. The screen is then ready for printing. This method is suitable only for simple work.
[0010] One problem generally associated with the prior art methods is that many steps are necessary to produce the screen, thus making screen production time-consuming and labour-intensive.
[0011] Another problem is that normal lighting cannot be used throughout the screen production process in any of the methods except hand cutting. This is because the stencil materials are light-sensitive. In addition, it is necessary to provide a source of actinic (usually UV) light for exposing the stencil. This usually incurs a penalty of initial cost, space utilisation and ongoing maintenance costs.
[0012] Other methods of preparing printing screens are available. CA-A-2088400 (Gerber Scientific Products. Inc.) describes a method and apparatus in which a blocking composition is ejected directly onto the screen mesh surface in a pre-programmed manner in accordance with data representative of the desired image. The blocking composition directly occludes sections of the screen mesh to define the desired stencil pattern.
[0013] EP-A-0492351 (Gerber Scientific Products, Inc.) describes a method wherein an unexposed light-sensitive emulsion layer is applied to a screen mesh surface and a graphic is directly ink-jet printed on the emulsion layer by means of a printing mechanism to provide a mask through which the emulsion is exposed before the screen is further processed.
[0014] Both the above methods require the use of very specialised equipment which incurs a certain cost as well as imposing restrictions arising from the limitations of the equipment, in particular in terms of the size of screen and its resolution. The second method also requires sensitised films and emulsions, requiring exposure units and vacuum frames.
[0015] Ink-jet printers operate by ejecting ink onto a receiving substrate in controlled patterns of closely spaced ink droplets. By selectively regulating the pattern of ink droplets, ink jet printers can be used to produce a wide variety of printed materials, including text, graphics and images on a wide range of substrates. In many ink jet printing systems, ink is printed directly onto the surface of the final receiving substrate. An ink jet printing system where an image is printed on an intermediate image transfer surface and subsequently transferred to the final receiving substrate is disclosed in U.S. Pat. No. 4,538,156 (AT&T Teletype Corp.). Furthermore, U.S. Pat. No. 5,380,769 (Tektronix Inc.) describes reactive ink compositions containing at least two reactive components, a base ink component and a curing component, that are applied to the receiving substrate separately. The base ink component is preferably applied to the receiving surface using ink jet printing techniques and, upon exposure of the base ink component to the curing component, a durable, crosslinked ink is produced.
[0016] EP-A-0108509 (Pilot Man-Nen-Hitsu KK) describes a process in which a coating on a porous support is selectively chemically solubilised and then washed away.
[0017] EP-A-0770552 (Riso Kagaku Corporation) describes a machine in which a porous substrate forms the cylindrical surface of a drum. The substrate has a coating layer which is selectively solubilised prior to ink being passed outwardly through the substrate to be transferred to a substrate.
[0018] GB-A-180778 (Carter) describes a stencil paper which is coated with varnish prior to application of an ink. The ink and the varnish below is then washed away to form a stencil for a rotary duplicating machine.
[0019] Our co-pending Application PCT/GB97/01881 (WO99/02344, the content of which is incorporated herein by reference, describes a method of producing a screen-printing stencil which requires the image applied to a receptor element to be a negative image (this known as “negative working”). In the present application, a method is disclosed which uses a positive image (“positive working”). Each method has its advantages compared with the other, depending upon the circumstances of use.
[0020] One object of the present invention is to make screen-printing stencil production less time-consuming and labour-intensive.
[0021] Another object is to allow normal lighting to be used throughout the stencil production process and to avoid both the problems of prior art stencil materials which are light-sensitive and also the need to provide a source of actinic (usually UV) light for exposing the stencil.
SUMMARY OF THE INVENTION
[0022] The present invention provides a method of producing a screen-printing stencil having open areas and blocked areas for, respectively, passage and blocking of a printing medium, the method comprising:
[0023] providing a receptor element comprising an optional support base and an image-receiving layer comprising a first substance,
[0024] applying imagewise to the image-receiving layer a second substance in areas corresponding to the open areas of the stencil to be produced,
[0025] bringing the image-receiving layer into contact with a third substance applied in a layer to a screen-printing screen,
[0026] causing or allowing chemical reaction to take place to form on the screen a stencil-forming layer having areas of relatively higher and relatively lower solubility corresponding to the open and the blocked stencil areas respectively, and
[0027] washing away the stencil-forming layer in the higher solubility areas, thereby to produce the screen-printing stencil,
[0028] the first, second and third substances being such that the said chemical reaction takes place as stated.
[0029] Within this overall scope, four particular methods can be identified as preferred aspects of the invention, although the invention is not limited to these four preferred aspects.
[0030] In a first preferred aspect, the invention provides a method of producing a screen-printing stencil having open areas and blocked areas for, respectively, passage and blocking of a printing medium, the method comprising:
[0031] providing a receptor element comprising an optional support base and an image-receiving layer comprising a chemical agent reactive with a stencil-forming chemical agent,
[0032] applying imagewise to the image-receiving layer an inhibitor for the reaction between the chemical agent and the stencil-forming agent,
[0033] the areas to which the inhibitor is applied corresponding to the open areas of the stencil to be produced,
[0034] applying a composition comprising the stencil-forming chemical agent to a screen-printing screen,
[0035] bringing the image-receiving layer of the receptor element into contact with the stencil-forming composition to allow the uninhibited chemical agent to react to produce on the screen a stencil-forming layer having areas of lower solubility corresponding to the blocked stencil areas and areas of higher solubility corresponding to the open stencil areas,
[0036] removing any unreacted part of the receptor element, and
[0037] washing away the stencil-forming chemical agent in the higher solubility areas, thereby to produce the screen-printing stencil.
[0038] In a second preferred aspect, the invention provides a method of producing a screen-printing stencil having open areas and blocked areas for respectively passage and blocking of a printing medium, the method comprising:
[0039] providing a receptor element comprising an optional support base and an image-receiving layer,
[0040] applying imagewise to the image-receiving layer a reaction inhibitor,
[0041] the areas to which the inhibitor is applied corresponding to the open areas of the stencil to be produced,
[0042] applying to a screen-printing screen a composition comprising a stencil-forming chemical agent, a chemical agent reactive therewith and a temporary inhibitor for the reaction therebetween, the said reaction being inhibited by the reaction inhibitor,
[0043] bringing the image-receiving layer of the receptor element into contact with the composition applied to the screen-printing screen,
[0044] causing or allowing the temporary inhibitor to leave the composition applied to the screen and thereby allow the stencil-forming chemical agent and the chemical agent reactive therewith to react where not inhibited by the reaction inhibitor and thereby produce on the screen a stencil-forming layer having areas of lower solubility corresponding to the said blocked areas and areas of higher solubility corresponding to the open stencil areas, removing any unreacted part of the receptor element, and
[0045] washing away unreacted composition from the higher solubility areas, thereby to produce the screen-printing stencil.
[0046] In a third preferred aspect, the invention provides a method of producing a screen-printing stencil having open areas and blocked areas for respectively passage and blocking of a printing medium, the method comprising:
[0047] providing a receptor element comprising an optional support base and an image-receiving layer comprising a chemical agent reactive with a stencil-forming chemical agent,
[0048] applying imagewise to the image-receiving layer a masking agent which prevents migration of the chemical agent from the image-receiving layer,
[0049] the areas to which the masking agent is applied corresponding to the open areas of the stencil to be produced,
[0050] applying a composition comprising the stencil-forming chemical agent to a screen-printing screen,
[0051] bringing the image-receiving layer of the receptor element into contact with the stencil-forming chemical agent to allow the reactive chemical agent in areas not masked by the masking agent and the stencil-forming chemical agent to react to produce on the screen a stencil-forming layer having areas of lower solubility corresponding to the blocked areas and areas of higher solubility corresponding to the open stencil areas,
[0052] removing the unreacted part of the receptor element, and
[0053] washing away the second stencil-forming chemical agent in the higher solubility areas, thereby to produce the screen-printing screen.
[0054] In a fourth preferred aspect, the invention provides a method of producing a screen-printing stencil having open areas and blocked areas for, respectively, passage and blocking of a printing medium, the method comprising:
[0055] providing a receptor element comprising an optional support base, and an image-receiving layer comprising at least one component of a polymerisation system,
[0056] applying imagewise to the image-receiving layer an inhibitor for the polymerisation,
[0057] the areas to which the inhibitor is applied corresponding to the open areas of the stencil to be produced,
[0058] applying a stencil-forming composition comprising further components, including polymerisable material, of the polymerisation system to a screen-printing screen,
[0059] bringing the image-receiving layer of the receptor element into contact with the stencil-forming composition to allow the polymerisation to take place where not inhibited by the inhibitor to produce on the screen a stencil-forming layer having areas of lower solubility corresponding to the blocked stencil areas and areas of higher solubility corresponding to the open stencil areas,
[0060] removing any unreacted part of the receptor element, and
[0061] washing away the stencil-forming composition in the higher solubility areas, thereby to produce the screen-printing stencil.
[0062] In any of these aspects, the image-receiving layer of the receptor element may comprise a substance which takes part in the reaction between the stencil-forming chemical agent and the chemical agent reactive therewith, whereby the chemical agent of the image-receiving layer forms a part of the stencil-forming layer of the stencil produced after washing away unreacted composition from the higher solubility areas.
[0063] The invention further provides a coated film product for use in the production of a screen-printing stencil, the product comprising an optional support base and an image-receiving layer which comprises one or more of the following active agents:
[0064] boric acid;
[0065] a boron salt, for example Group I and Group II metal borates;
[0066] an aldehyde, for example formaldehyde:
[0067] a dialdehyde, for example glyoxal and glutaraldehyde, optionally with a mineral acid; and
[0068] transition metal compounds, for example iron (III), zirconium and titanium salts and chromium compounds, for example, pentahydroxy (tetradecanoate) dichromium and its derivatives.
[0069] Such a film product is particularly useful in methods according to the first and third preferred aspects of the invention but is not limited to such use.
[0070] The invention further provides a coated film product for use in the production of a screen-printing stencil, the product comprising an optional support base and an image-receiving layer which comprises at least one component of a free-radical generating system.
[0071] Preferably, the image-receiving layer further comprises a compound capable of taking part in a free-radical polymerisation process.
[0072] Such a film product is particularly useful in methods according to the fourth preferred aspect of the invention but is not limited to such use.
[0073] The invention also provides a pre-filled cartridge for a dropwise application device such as an ink-jet printer of plotter, the cartridge containing one or more of the following, optionally in a suitable liquid solvent or carrier:
[0074] a substance capable of reacting with boric acid or a boron salt, for example a Group I or Group II metal borate, in order to produce an insoluble borate;
[0075] a chelating agent, preferably an alkylene diaminetetraacetic acid, for example ethylenediaminetetraacetic acid, or a derivative thereof, or a mixture of two or more such chelating agents; and
[0076] an aromatic polyol, preferably an hydroxy-substituted benzene derivative, for example pyrogallol or catechol.
[0077] Such a cartridge is particularly useful in any of the four stated preferred aspects of the invention but is not limited to such use.
[0078] Still further, the invention provides a composition for use in coating a screen-printing mesh in the preparation of a screen-printing stencil, the composition comprising at least one compound capable of taking part in a free-radical polymerisation process to produce a hardened stencil material, and at least one component of a free-radical generating system.
[0079] Preferably, the composition includes a further substance which is incorporated into the polymerisation product upon polymerisation. The further substance may be, for example, polyvinyl alcohol.
[0080] Such a composition is particularly useful in methods according to the fourth preferred aspect of the invention but is not limited to such use.
[0081] Yet further, the invention provides a composition for use in coating a screen-printing mesh in the preparation of a screen-printing stencil, the composition comprising at least one compound capable of taking part in an ion-bridged cross-linking reaction to produce a hardened stencil layer on the mesh, a source of cross-linking ions, and a temporary inhibitor for the polymerisation reaction.
[0082] Such a composition is particularly useful in methods according to the second aspect of the invention but is not limited to such use.
[0083] According to the present invention, the stencil is formed by chemical means, without the need to use either special lighting conditions or actinic radiation.
[0084] Also, it is possible to carry out the invention with reduced expenditure in time and labour, compared with known processes.
[0085] The method of the invention is positive working: the material which is applied imagewise is applied in areas which correspond to the open areas of the eventual stencil.
[0086] When dropwise application is employed, the application is preferably controlled according to data encoding the desired pattern of blocked and open areas of the stencil to be produced. This control is conveniently by a computer, for example a personal computer. Thus, data representative of the desired output pattern can be input to a controller as pre-recorded digital signals which are used by the ejection head to deposit or not deposit the material applied imagewise as the head scans the surface of the receptor element. The invention is not however restricted to dropwise application of the material applied imagewise: other methods of application will achieve the same essential end, for example, the material applied imagewise could be applied with a hand-held marker pen.
BRIEF DESCRIPTION OF THE DRAWINGS
[0087] The invention will now be described by way of example with reference to the drawings of this specification, in which:
[0088] FIGS. 1 to 5 show schematically the successive steps in the production of a printing screen in accordance with the first or the fourth preferred aspect of the invention;
[0089] FIGS. 6 to 10 correspond to FIGS. 1 to 5 but show the successive steps in a modified method according to the first or the fourth preferred aspect of the invention;
[0090] FIGS. 11 to 15 show schematically the successive steps in the production of a printing screen in accordance with the second preferred aspect of the invention;
[0091] FIGS. 16 to 20 correspond to FIGS. 11 to 15 but show the successive steps in a modified method according to the second preferred aspect of the invention:
[0092] FIGS. 21 to 25 show schematically the successive steps in the production of a printing screen in accordance with the third preferred aspect of the invention; and
[0093] FIGS. 26 to 30 correspond to FIGS. 21 to 25 but show the successive steps in a modified method according to the third preferred aspect of the invention.
[0094] Referring to FIGS. 1 to 5 , these show the production of a screen printing stencil shown in FIG. 5, starting with a receptor element 10 shown in FIG. 1.
[0095] [0095]FIG. 1 shows the receptor element 10 which consists of an image-receiving layer 11 coated on a flexible film support base 12 . In this example, the image-receiving layer is about 10 μm in thickness and the support base about 75 μm.
[0096] [0096]FIG. 2 shows a liquid inhibitor 14 being applied to the image-receiving layer 11 in droplets 13 which are ejected from an ejection head (not shown) of, for example, an ink-jet printer controlled by a computer. The inhibitor 14 is applied imagewise to the image-receiving layer 11 in areas which correspond to the open areas of the stencil to be formed. The screen preparation method is therefore positive working.
[0097] The inhibitor 14 is shown in FIG. 2 to be absorbed into the image-receiving layer 11 . With other materials, the inhibitor might instead form a surface layer on the image-receiving layer. This point applies equally to the processes shown in FIGS. 5 to 10 , 11 to 15 and 16 to 20 .
[0098] [0098]FIG. 3 of the drawings shows a screen mesh 15 , to one surface of which the receptor element of FIG. 2 has been applied and to the other surface of which a stencil-forming agent 16 is being applied using a suitable spreader 17 . In FIG. 3, the image-receiving layer 11 of the receptor element is brought into contact with the stencil-forming agent 16 when the latter is forced through the mesh 15 by the spreader 17 .
[0099] This could alternatively have been achieved by first coating the mesh 15 with the stencil-forming agent 16 and then applying the receptor element 10 to the coated mesh 15 .
[0100] When the receptor element is in contact with the screen mesh 15 as shown in FIG. 3, the areas of the image-receiving layer 11 to which no inhibitor 14 has been applied react with the corresponding areas of the stencil-forming agent 16 to form areas 18 which are insoluble or, at least, of lower solubility. The areas of the stencil-forming agent 16 which correspond to the areas where the inhibitor 14 is applied do not react with the image-receiving layer 11 and therefore retain a higher solubility.
[0101] [0101]FIG. 4 of the drawings shows the receptor element 10 being peeled away from the screen mesh 15 . The areas 16 of the stencil-forming agent corresponding to the areas of the image-receiving layer 11 to which the inhibitor 14 was applied are of significantly higher solubility than the remaining areas 16 where reaction with the image-receiving layer has produced areas 18 of insoluble material.
[0102] [0102]FIG. 5 shows the final screen separated from the receptor element 10 after the latter has been removed and the stencil has been washed out. The areas 18 of the stencil-forming layer corresponding to areas of the image-receiving layer 11 to which no inhibitor was applied remain to form the blocked areas of the stencil. The areas corresponding to those to which the inhibitor 14 was applied have been washed away and form the open areas 19 of the stencil.
[0103] Referring now to FIGS. 6 to 10 , these show the production of a screen printing stencil shown in FIG. 10, starting with a receptor element shown in FIG. 6. The method is a modification of that described above. Primed reference numerals are used in FIGS. 6 to 10 to indicate features which correspond to features of FIGS. 1 to 5 .
[0104] In this modified method, the image-receiving layer 11 ′ contains a quantity of stencil-forming agent 16 ′. This is achieved by coating the component of the image-receiving layer 11 ′ which reacts with the stencil-forming agent 16 ′ as a separate layer of about 1 μm thickness coated over a pre-coated and solidified layer of stencil-forming agent.
[0105] An inhibitor 14 ′ is applied imagewise in droplets 13 ′, as shown in FIG. 7, again in areas to correspond to the open areas of the stencil to be formed. The receptor element 10 ′ is brought into contact with a screen mesh 15 ′ and a stencil-forming agent 16 ′ applied. The alternative mentioned above could be employed if desired.
[0106] When the receptor element 10 ′ is brought into contact with the mesh 15 ′ as shown in FIG. 8, the reaction which takes place between the reactive component of the image-receiving layer 11 ′ and the stencil-forming agent 16 ′ applied to the mesh 15 ′ involves also the stencil-forming agent in the image-receiving layer 11 ′. As a result, the stencil layer formed on the mesh 15 ′ has an increased thickness compared with the thickness of the stencil layer in the unmodified method. A stencil of a thickness considerably greater than the mesh thickness is formed, the stencil being particularly enhanced in thickness on the print substrate side in use of the printing screen. This property of the screen is known as a “profile” and is advantageous in terms of the printing quality obtainable by use of the screen.
[0107] Referring now to FIG. 9 of the drawings, this shows the receptor element 10 ′ being peeled away from the mesh 15 ′. In this case, only the support base 12 ′ remains to be peeled away in a coherent layer, the image-receiving layer having reacted as described above.
[0108] [0108]FIG. 10 of the drawings shows the final screen, from which the “profile” can be readily seen.
[0109] FIGS. 11 to 15 of the drawings show the production of a screen-printing stencil shown in FIG. 15, starting with a receptor element 20 shown in FIG. 11. The method of production of the stencil is in accordance with the second referred aspect of the invention.
[0110] [0110]FIG. 11 shows a receptor element 20 which again consists of an image-receiving layer 21 coated on a flexible film support base 22 . In this example, the image-receiving layer 21 and the support base 22 are again about 10 μm and 75 μm in thickness, respectively.
[0111] [0111]FIG. 12 shows a liquid reaction inhibitor 24 being applied to the image-receiving layer 21 in droplets 23 which are ejected from an ejection head (not shown) of, for example, an ink-jet printer controlled by a computer. The function of the reaction inhibitor is explained below. It is applied to the image-receiving layer 21 imagewise in areas 24 which correspond to the open areas of the stencil to be formed. The method is therefore again positive-working.
[0112] [0112]FIG. 13 shows a screen mesh 25 , to one surface of which the receptor element 20 has been applied and to the other surface of which a stencil-forming composition 26 is being applied with a spreader 27 . The stencil-forming composition 26 and the image-receiving layer of the receptor element 20 are thus brought into contact, as the spreader 27 forces the composition 26 through the mesh 25 . The same contact could alternatively be achieved by first coating the mesh 25 with the composition 26 and then applying the receptor element 20 to the coated mesh.
[0113] The stencil-forming composition 26 has three components. The first and second components are substances which are capable of reacting with each other to form a stencil composition of substantially reduced solubility in a given wash-out solvent (see below). The third component is a temporary inhibitor for the reaction between the first and second components, in the presence of which the reaction therebetween does not take place.
[0114] With the receptor element 20 applied to the screen mesh 25 as shown in FIG. 13, the temporary inhibitor in the screen-forming composition is caused or allowed to leave the composition. For example, this may be achieved by application of moderate heat, such as from a warm-air blower, if the temporary inhibitor is of an appropriate volatility. In the absence of the temporary inhibitor, the reaction between the first and second components of the stencil-forming composition 26 takes place in the areas of the composition 26 which do not correspond to areas of the image-receiving layer 21 of the receptor element 20 to which the reaction inhibitor 24 was applied (see FIG. 12).
[0115] The support base 22 of the receptor element 20 can now be peeled away from the screen mesh 25 , as shown in FIG. 14. This leaves low-solubility hardened areas 28 of the stencil-forming composition, corresponding to the areas of the receptor element to which no reaction inhibitor 24 was applied, and unhardened areas of high solubility corresponding to the areas where the reaction inhibitor 24 was applied.
[0116] The stencil screen 25 is now washed-out using a suitable solvent in which the unhardened parts of the stencil-forming layer are soluble. After washing-out, a final stencil screen as shown in the upper part of FIG. 15 is obtained. It will be noted that the open areas 29 of the stencil correspond to the areas 24 of the receptor element 20 to which the reaction inhibitor was applied imagewise in FIG. 12. The screen production method is therefore positive-working.
[0117] In a modification of the method described with reference to FIGS. 11 to 15 , the image-receiving layer of the receptor element is formed from a material which is reactive with the stencil-forming composition. This is shown in FIGS. 16 to 20 of the drawings, in which primed reference numerals are used to indicate features which correspond to features of FIGS. 11 to 15 . In this modified method, the image-receiving layer 21 ′ is formed from a substance which can take part in the reaction between first and second components of the stencil-forming composition 26 ′. Thus, in this modification, the hardening reaction which takes place in the stencil-forming layer also takes place in the image-receiving layer 21 ′ of the receptor element 20 ′, with the result that part of the receptor element becomes incorporated into the stencil layer of the final screen and provides a desirable “profile” or increased thickness of the stencil-layer. Thus, when the receptor element 20 ′ is brought into contact with the mesh 25 ′ as shown in FIG. 18, the reaction which takes place between the first and second components of the stencil-forming composition 26 ′ involves also the material of the image-receiving layer 21 ′ of the receptor element 20 ′. As a result, a screen having a substantial “profile” is produced, as can readily be seen from FIG. 20 which shows the final screen, after the support base 22 ′ of the receptor element 20 ′ has been peeled away, as shown in FIG. 19.
[0118] FIGS. 21 to 25 of the drawings show the production of a screen-printing stencil shown in FIG. 25, starting with a receptor element 30 shown in FIG. 21. The method of production of the stencil is in accordance with the third preferred aspect of the invention.
[0119] [0119]FIG. 21 shows a receptor element 30 which as before consists of an image-receiving layer 31 coated on a flexible film support base 32 . The layer 31 and base 32 have thickness of about 10 μm and about 75 μm, respectively, in this example.
[0120] The image-receiving layer 31 of the receptor element 30 contains a chemical agent which is capable of reacting with a stencil-forming agent (see below) in order to produce a hardened stencil composition forming a stencil layer on a screen-printing screen.
[0121] [0121]FIG. 22 shows the application to the image-receiving layer 31 in droplets 33 of a masking agent 34 , for example a liquified wax or a solidifying polymer which functions to prevent migration of the chemical agent from the image-receiving layer 31 in areas to which the masking agent 34 is applied. The masking agent 34 is applied imagewise in areas corresponding to the open areas of the final stencil. The method is therefore positive-working.
[0122] [0122]FIG. 23 shows a screen mesh 35 , to one surface of which the receptor element 30 has been applied and to the other surface of which a stencil-forming composition 36 is being applied with a spreader 37 . The stencil-forming composition 36 and the image-receiving layer of the receptor element 30 are thus brought into contact, as the spreader 37 forces the composition 36 through the mesh 35 . The same contact could alternatively be achieved by first coating the mesh 35 with the composition 36 and then applying the receptor element 30 to the coated mesh.
[0123] The stencil-forming composition 36 contains a second, stencil-forming chemical agent which can react with the chemical agent referred to above and contained in the image-receiving layer 31 to produce a stencil layer of substantially reduced solubility to a given wash-out solvent (see below).
[0124] With the receptor element 30 applied to the screen mesh 35 as shown in FIG. 23, the reaction between the stencil-forming chemical agent in the composition 36 and the chemical agent in the image-receiving layer takes place in the areas which do not correspond to these at which the masking agent 34 is applied to the receptor element 30 .
[0125] The receptor element 30 is next peeled away from the screen mesh 35 , as shown in FIG. 24. This leaves low-solubility hardened areas 38 of the stencil-forming composition, corresponding to the areas of the receptor element to which no masking agent 33 was applied, and unhardened areas of high solubility corresponding to the areas where the masking agent 34 was applied.
[0126] The stencil screen is now washed-out using a suitable solvent in which the unhardened parts of the stencil-forming layer are soluble. After washing-out, a final stencil screen as shown in FIG. 25 is obtained. FIG. 25 also shows the separated receptor element 30 . It will be noted that the open areas 39 of the stencil correspond to the areas of the receptor element 30 to which the reaction inhibitor was applied imagewise in FIG. 22. The screen production method is therefore positive-working.
[0127] Referring now to FIGS. 26 to 30 , these show the production of a screen printing stencil shown in FIG. 30, starting with a receptor element shown in FIG. 26. The method is a modification of the method described above with reference to FIGS. 20 to 25 . Primed reference numerals are used in FIGS. 26 to 30 to indicate features which correspond to features of FIGS. 20 to 25 .
[0128] In this modified method, the image-receiving layer 31 ′ contains a quantity of stencil-forming agent 36 ′. This is achieved by coating the component of the image-receiving layer 31 ′ which reacts with the stencil-forming agent as a separate layer of about 1 μm thickness coated over a pre-coated and solidified layer of stencil-forming agent 36 ′.
[0129] A masking agent 34 ′ is applied imagewise in droplets 33 ′ as shown in FIG. 27, in areas corresponding to the open areas of the eventual stencil. The receptor element 30 ′ is then brought into contact with a screen mesh 25 ′ and a stencil-forming agent 26 ′ applied.
[0130] The alternative method mentioned above of achieving contact could be employed if desired.
[0131] When the receptor element 30 ′ has been brought into contact with the mesh 35 ′ as shown in FIG. 28, the reaction which takes place between the reactive component of the image-receiving layer 31 ′ and the stencil-forming agent 36 ′ applied to the mesh 35 ′ involves also the stencil-forming agent in the image-receiving layer 31 ′. As a result, the stencil layer formed on the mesh 35 ′ has an increased thickness compared with the thickness of the stencil layer in the unmodified method. A stencil of a thickness considerably greater than the mesh thickness is formed, the stencil being particularly enhanced in thickness on the print substrate side in use of the printing screen. This property of the screen is known as a “profile” and is advantageous in terms of the printing quality obtainable by use of the screen.
[0132] Referring now to FIG. 29 of the drawings, this shows the receptor element 30 ′ being peeled away from the mesh 35 ′. In this case, only the support base 32 ′ remains to be peeled away in a coherent layer, the image-receiving layer having reacted as described above.
[0133] [0133]FIG. 30 of the drawings shows the final screen, from which the “profile” can be readily seen.
DETAILED DESCRIPTION OF THE INVENTION
[0134] In some methods according to the present invention, for example as described above with reference to FIGS. 1 to 5 , 11 to 15 and 21 to 25 of the drawings, the image-receiving layer is substantially inert and functions as a carrier for the material applied to it imagewise, the stencil-forming layer being formed substantially from the layer of the third substance only. In methods and coated film products according to the invention the layer may comprise one or more of the following polymers: water-soluble cellulose derivatives, for example hydroxypropyl cellulose, hydroxyethyl cellulose, carboxymethyl cellulose; polyvinylpyrrolidone and polyacrylic acids. The polymer(s) is/are preferably present in the image-receiving layer in an amount of 5 to 100 wt % of the image-receiving layer. The layer may also comprise, one or more of: suitable other polymers, fillers, binders, surfactants and plasticisers.
[0135] Alternatively, papers including ordinary papers and coated papers, can be used as the inert image-receiving layer, and, thereby, require no supporting base.
[0136] The key criterium in selecting a suitable combination of image-receiving layer and substance applied imagewise thereto is that a good image should be formed on the layer; for example, a drop of the substance should neither be so repelled by the layer as to produce a defective image nor it should not spread so far as to reduce the resolution of the image. Moreover, it should not spread so anisotropically (because of irregularities in the layer) as to deform the image.
[0137] In methods according to the invention, for example as described above with reference to FIGS. 6 to 10 , 16 to 20 and 26 to 30 of the drawings, in which the stencil-forming layer is formed at least in part from the layer of the third substance and the image-receiving layer and thus forms a substantial, profile part of the final stencil, the image-receiving layer may comprise a substance which takes part in a polymerisation process involving the third substance and thereby forms the stencil layer of the final screen.
[0138] A typical example of the material of a reactive image-receiving layer in methods and products according to the invention is polyvinyl alcohol and which is preferably present in an amount of 5 to 100 wt % of the image-receiving layer and the balance comprising, for example, other suitable polymers, suitable fillers, binders, surfactants and plasticisers. The polyvinyl alcohol preferably has a degree of hydrolysis of 20 to 99.9 mole % and, independently thereof, a degree of polymerisation of 100 to 3500.
[0139] Numerous other reactive polymers could alternatively be utilised in the present invention in this context. Examples of such polymers are:
[0140] polyvinyl alcohol derivatives, including carboxylated and acrylamide-grafted derivatives and polyvinyl acetate;
[0141] gelatin and its derivatives;
[0142] carboxylated polymers capable of becoming water soluble on addition of alkali, e.g. carboxylated acrylics, ethylene-acrylic acid and styrene-acrylic acid copolymers; and
[0143] polyacrylamides and derivatives thereof, including carboxylated derivatives.
[0144] In general, the active component(s) of the image-receiving layer may constitute from 0.5 to 100 wt % of the image-receiving layer.
[0145] In methods and products according to the present invention, polymers and other components used are chosen so that the material applied imagewise forms a good image when applied. Layers that are not compatible with any solvent (typically, water) used in the material applied imagewise will produce insufficient spread of the liquid and a poor-quality image will result. If the layer to which the material is supplied is too compatible, then the material will spread too far, giving a blurred, low resolution image.
[0146] As mentioned, the receptor element can be with or without a support base. Without the support base, the image receiving layer is typically 6 to 250 μm in thickness. With a support base the coating thickness is typically from 0.1 to 50 μm.
[0147] The support base may comprise a non-reactive polymer, preferably an organic resin support, e.g. polyethylene terephthalate, polyethylene, polycarbonate, polyvinyl chloride or polystyrene. Alternatively a coated paper could be used as the receptor element, the paper and coating constituting the support base and the image-receiving layers, respectively. An uncoated paper can alternatively constitute the image-receiving layer of a receptor element without a support base. Such an image-receiving layer is usually removed as a coherent film prior to washing away of the high solubility areas of the stencil-forming layer. The thickness of the support base film is preferably from 10 to 200 μm. The organic resin supports can optionally be coated with a subbing layer to give desired adhesion properties with the image-receiving layer. When used, the support base is usually removed as a coherent film in the screen production method prior to the removal of the areas of higher solubility, though it can be removed during this process.
[0148] When a liquid comprising an inhibitor is applied imagewise to the image-receiving layer, the liquid may be applied dropwise, conveniently by an ink-jet system such as (but not confined to) an ink-jet printer or ink-jet plotter. Alternatively, application can be continuous, for example by a hand-held delivery device, such as a pen. The liquid applied should exhibit desirable stability, surface tension and viscosity characteristics and may therefore contain surfactants, viscosity modifiers, light stabilisers and/or anti-oxidants. When the active component(s) of the material applied imagewise is/are not liquids, the material may include a suitable carrier, for example a suitable solvent or dispersant for the active components(s).
[0149] The third substance may be applied to the screen from one side thereof after the image-receiving layer of the receptor element has been brought into contact with the other side thereof. This may be achieved by placing the receptor element on a solid flat surface and placing the screen on top such that there is close contact between the screen and the receptor element. The third substance may be applied by a coating trough or ‘squeegee’. Alternatively, a thin layer of the composition applied to the screen can be coated onto the screen mesh by a coating trough or ‘squeegee’ and the receptor element mounted manually with slight pressure, a technique well known to those skilled in the screen-printing art.
[0150] If a base support is used, this can conveniently be removed once the reaction taking place caused by contact between the image-receiving layer and the composition applied to the screen is substantially complete. The resulting screen stencil can be developed by washing away the portion of higher solubility with a suitable solvent, thereby leaving behind areas of reduced solubility to occlude areas of the mesh (this act of washing could also remove the optional support base and any other coherent film part of the receptor element if not removed earlier).
[0151] In some methods according to the invention, the chemical reaction(s) forming the stencil-forming layer on the screen may involve reactive agents which the first and third substances comprise, the second substance comprising a chemical inhibitor for the reaction.
[0152] The third substance may then comprise at least one polymeric material capable of taking part in a cross-linking reaction, the first substance comprises a cross-linking agent for the cross-linking reaction and the second substance comprises an inhibitor for the cross-linking reaction.
[0153] In preferred methods, the cross-linking agent of the first substance comprises one or more of:
[0154] boric acid;
[0155] boron salts, for example Group I and Group II metal borates; aldehydes, for example formaldehyde;
[0156] dialdehydes, for example glyoxal and glutaraldehyde, optionally with a mineral acid; and
[0157] transition metal compounds, for example iron (III), zirconium and titanium salts and chromium compounds, for example pentahydroxy (tetradecanoate) dichromium and its derivates.
[0158] In methods and products of the invention, the active agent(s) of the image-receiving layer may be coated as a separate, surface layer on the polymer layer. The surface layer may be, for example, from 0.1 to 5 μm, preferably 1 to 2 μm, in thickness.
[0159] The inhibitor may comprise a metal salt which reacts with the cross-linking agent(s) to form a compound of reduced reactivity. If the cross-linking agent comprises boric acid and/or a metal borate then the inhibitor may comprise at least one metal salt which reacts with the cross-linking agent to form an insoluble borate.
[0160] In other methods, the inhibitor may comprise a chelating agent which chelates the inhibitor(s) to form a complex of reduced reactivity.
[0161] When the cross-linking agent comprises one or more transition metal complexes then the inhibitor may comprise an alkylenediaminetetraacetic acid, for example ethylenediaminetetraacetic acid, or a derivative thereof, such as a sodium salt, or a mixture of two or more such compounds.
[0162] It is preferred that the inhibitor(s) should constitute 0.5 to 50 wt % of the second substance.
[0163] In other methods, the third substance comprises at least one compound capable of taking part in a free-radical polymerisation reaction, the first substance comprises at least one component of a free-radical generating system, further component(s) of which the third substance optionally comprises, and the second substance comprises an inhibitor for the free-radical generating system.
[0164] The polymerisable compound in methods, compositions and coated film products of the invention may be an acrylamide which is optionally grafted onto a polymeric compound, preferably polyvinyl alcohol.
[0165] The free-radical generating system may be an oxidative system and the second substance comprises a trapping agent. The system may comprise a source of iron (II) ions and oxidising agent, for example ammonium persulphate. Preferred trapping agents are polyhydric alcohols, more preferably aromatic polyhydroxyl compounds, for example pyrogallol and catechol.
[0166] Preferably, the first substance comprises the ion source and the third substance comprises the oxidising agent.
[0167] In other methods according to the invention, the chemical reaction(s) forming the stencil-forming layer on the screen may involve reactive agents which the first and the third substances comprise, the second substance forming a physical barrier between the first and the third substances.
[0168] The third substance may then comprise at least one polymeric material capable of taking part in a cross-linking reaction and the first substance comprises a cross-linking agent for the cross-linking reaction.
[0169] Suitable cross-linking agents are as listed above.
[0170] The second substance may comprise a wax which is applied in a molten state and then caused or allowed to solidify. Alternatively, the second substance may be a toner powder.
[0171] In further methods according to the invention, the chemical reaction(s) forming the stencil-forming layer on the screen may take place between agents which the third substance comprises, the second substance comprising a chemical inhibitor for the reaction.
[0172] The third substance may then comprise a temporary inhibitor for the reaction between the said agents, the method including a step of terminating the effect of the temporary inhibitor to allow the said reaction to take place where not inhibited by the chemical inhibitor.
[0173] Preferably, the third substance comprises at least one polymeric substance having reactive functional groups capable of taking part in a pH-sensitive ion-bridged cross-linking reaction and a source of ions for the reaction, the temporary inhibitor comprising a pH-adjusting agent which maintains the pH at a value at which the generation of cross-linking ions is suppressed.
[0174] The chemical inhibitor may comprise a chelating agent of the cross-linking ions, preferably an alkylenediaminetetraacetic acid, for example ethylenediaminetetraacetic acid, or a derivative thereof, such as a sodium salt, or a mixture of two or more such compounds.
[0175] If, in methods and compositions of the invention, the pH-adjusting agent is an acid source which maintains a pH sufficiently low to suppress generation of cross-linking ions, the acid source is preferably volatile and its effect is terminated by causing or allowing its evaporation.
[0176] In any method according to the invention, the third substance may comprise one or more of the following polymers:
[0177] polyvinylalcohol and its derivatives, including carboxylated and acrylamide-grafted derivatives and polyvinyl acetate; gelatin and its derivatives;
[0178] carboxylated polymers capable of becoming water soluble on addition of alkali, including carboxylated acrylics, ethylene-acrylic acid and styrene-acrylic acid copolymers; and
[0179] polyacrylamides and derivatives thereof, including carboxylated derivatives.
[0180] Table 1 which follows lists examples of first, second and third chemical substances which can be used in accordance with the invention in order to produce a non-profiled stencil, that is one in which the stencil-forming layer is formed substantially from the layer of the third substance only.
TABLE 1 First Cross-Linking Agents Substance Aqueous solutions of boron salts e.g. boric acid, Na or K tetraborate; transition metal compounds e.g. iron (III) salts such as chloride and sulphate, zirconium or titanium salts or pentahydroxy(tetradecanoate)dichromium and its derivatives. Polymers Cellulose and its derivatives that are water soluble e.g. hydroxypropyl cellulose, carboxymethyl cellulose, hydroxyethyl cellulose; polyvinyl alcohol and its derivatives with a degree of hydrolysis of 20 to 99.9 mole % and/or a degree of polymerisation of 100 to 3500; polyvinyl pyrrolidone and its derivatives and copolymers. Second Inhibitors Substance Chelating agents e.g. disodium ethylenediaminetetraacetate, di or trisodium nitriloacetate; Group (II) metal salts which react to produce insoluble borate complexes e.g. zinc nitrate. Masking Agents Solid wax or solidifying polymer which becomes liquid upon heating; or electrostatic toner powder. Third Temporary Chemical Inhibitors Substance Volatile organic or inorganic acid e.g. acetic acid or aqueous hydrochloric acid. Stencil Forming Agents Polyvinyl alcohol/polyvinyl acetate blends; polyvinyl alcohol and its derivatives with a degree of hydrolysis of 20 to 99.9 mole % and a degree of polymerisation of 100 to 3500; carboxylated polymers capable of becoming water soluble upon addition of alkali e.g. carboxylated acrylics, ethylene-acrylic acid and styrene-acrylic acid copolymers; carboxylated polyacrylamides. Ion-Bridging Cross-Linking Agents Iron (III) salts, e.g. iron (III) sulphate.
[0181] Table 2 which follows lists examples of first, second and third chemical substances which can be used in accordance with the invention in order to produce a profiled stencil, that is one in which the stencil-forming layer is formed from the layer of the third substance and the image-receiving layer.
TABLE 2 First Cross-Linking Agents Substance Aqueous solutions of boron salts e.g. boric acid, Na or K tetraborate; transition metal compounds e.g. iron (III) salts such as chloride or sulphate, zirconium or titanium salts or pentahydroxy(tetradecanoate)dichromium and its derivatives. Free-Radical Sources Transition metal salts capable of oxidation by oxidising agents (such as inorganic persulphates) to form free radicals as polymerisation initiators e.g. iron (II) sulphate. Polymers Polyvinyl alcohol and its derivatives with a degree of hydrolysis of 20 to 99.9 mole % and/or a degree of polymerisation of 100 to 3500; carboxylated polymers capable of becoming water soluble upon addition of alkali e.g. carboxylated acrylics, ethylene-acrylic acid and styrene-acrylic acid copolymers; carboxylated polyacrylamides; acrylamide monomers blended with polyvinyl alcohol or acrylamide monomers grafted onto polyvinyl alcohol e.g. N,N′-methylenebisacrylamide. Second Inhibitors Substance Chelating agents e.g. disodium ethylenediaminetetraacetate, di or trisodium nitriloacetate; Group (II) metal salts which react to produce insoluble borate complexes e.g. zinc nitrate. Free-Radical Trapping Agents Polyhydric alcohols, e.g. pyrogallol and catechol. Third Stencil-Forming Agents Substance Polyvinyl alcohol and its derivatives with a degree of hydrolysis of 20 to 99.9 mole % and a degree of polymerisation of 100 to 3500; carboxylated polymers capable of becoming water soluble upon addition of alkali e.g. carboxylated acrylics, ethylene-acrylic acid and styrene-acrylic acid copolymers; carboxylated polyacrylamides; acrylamide monomers blended with polyvinyl alcohol or acrylamide monomers grafted onto polyvinyl alcohol e.g. N,N′-methylenebisacrylamide Temporary Chemical Inhibitors Volatile organic acid e.g. acetic acid or aqueous hydrochloric acid. Free-Radical Sources: Oxidising Agents Ammonium persulphate. Ion-Bridging Cross-Linking Agents Iron (III) salts, e.g. iron (III) sulphate.
[0182] The method of the invention preferably includes a further, reclaim step. When the first chemical agent comprises a borate, the reclaim may be carried out at a pH of 4 or less.
[0183] Where the chemicals used are those cited in the examples which follow, the broad physical properties, chemical resistances, washout solvent (water) and reclaim chemicals (typically periodate systems) will in many cases be those used routinely by screen printers. So, although the method of producing the stencil and the products and compositions used therein are new, the resulting screens will often be familiar and highly acceptable to screen printers.
[0184] The advantages of the processes of the present invention include: a screen stencil can be produced directly from digital information sources; it is not necessary to use safe-lights during the stencil making process; there is no requirement for an exposure step utilising an actinic radiation source; a finished stencil can be produced in a shorter time than by conventional screen printing techniques. The positive working system is more convenient than a negative system when small areas of the screen are to be printed. For instance, if 5% of the area is to be printed, a negative system would require 95% of the film to be covered with material applied imagewise, whereas a positive system would require only 5% coverage, a saving in computer memory, time and chemical agent.
EXAMPLES
[0185] The present invention is illustrated by the following examples 1 to 12 without however being limited thereto. In these examples, various commercially-available materials are listed by their trade names; the letters identifying the following companies:
[0186] (a) Hercules Inc., USA
[0187] (b) 3M, UK
[0188] (c) Nippon Gohsei, Japan
[0189] (d) ISP, UK
[0190] (e) DuPont, UK
[0191] (f) Autotype International, UK
[0192] (g) Kuraray, Japan
[0193] (h) Allied Colloids, UK
[0194] (i) W. R. Grace, Germany
[0195] Examples 1 to 4 are in accordance with the first preferred aspect of the invention, with examples 3 and 4 incorporating the modification described above to produce a “profiled” stencil. Examples 5 and 6 are in accordance with the fourth preferred aspect of the invention. Examples 7 to 10 are in accordance with the second preferred aspect of the invention with examples 9 and 10 incorporating the modification just mentioned above. Examples 11 and 12 are in accordance with the third preferred aspect of the invention.
Example 1
[0196] “Klucel E” (a) a hydroxypropyl cellulose was coated onto a polyethylene terephthalate support base from an aqueous solution at a coating weight of 10 g m −2 .
[0197] A dispersion of sodium tetraborate tetrahydrate (borax) was prepared by grinding a 33 wt. % mixture of borax in IMS in a ball mill for 48 hours.
[0198] The dispersion was diluted to 5 wt % and coated onto the hydroxypropyl cellulose with a 0.009 in Meyer bar, to give a coating weight of about 1 g m −2 . The resulting receptor element was passed through a commercial thermal ink jet printer (Hewlett Packard HP550) and liquid containing a chemical inhibitor agent was applied according to the formula:
water 39 wt % zinc nitrate (prepared from zinc carbonate/hydroxide and nitric 10 wt % acid) glycerine 50 wt % “Fluorad FC-93” (b) (1%) - anionic fluorinated surfactant 1 wt %
[0199] In this example, the hydroxypropyl cellulose constitutes a non-reactive image-receiving layer coated on the polyethylene terephthalate support base. The borax dispersion is the first chemical agent which reacts with a stencil-forming agent which is polyvinyl alcohol which is provided in a 20 wt % aqueous solution of “Gohsenol GH-20” (c) (see below). The reaction which takes place between the borax dispersion and the polyvinyl alcohol is a chemical cross-linking which is inhibited by the zinc nitrate through formation of insoluble zinc borate. The receptor element was dried, then placed on a glass plate, with the coated layer facing uppermost. The receptor element was covered with a screen mesh of mesh count 62 threads per cm. Then a bead of “Gohsenol GH-20” (c) 20 wt % aqueous solution was placed on the mesh and drawn over the receptor element by means of a squeegee so that a thin layer of polyvinyl alcohol was forced through the mesh. The screen was dried by hot air fan until the polyethylene terephthalate support base could be peeled cleanly from the mesh. The screen was left to dry and then washed out using cold running water, until the portion of the assembly of higher solubility was washed away to waste.
Example 2
[0200] A 10 wt % aqueous solution of “K90” (d) polyvinyl pyrrolidone was coated onto a polyethylene terephthalate support base at a coating weight of 10 gm −2 .
[0201] A 10 wt % solution of pentahydroxy(tetradecanoate)dichromium “Quilon C” (e) in acetone/isopropanol was coated onto the polyvinyl pyrrolidone coating using a 0.009 in Meyer bar. This gave an approximate coating weight of 1 to 2 g m −2 .
[0202] The resulting receptor element was passed through a commercial thermal ink jet printer (Hewlett Packard HP550) and liquid containing a chemical inhibitor agent was applied according to the formula:
water 95 wt % disodium ethylenediaminetetraacetic acid 5 wt %
[0203] In this example, the non-reactive image-receiving layer has been changed to polyvinyl pyrrolidone. The first chemical agent is “Quilon C” which reacts with the polyvinyl alcohol stencil-forming agent to effect a chemical cross-linking. This reaction is inhibited by the disodium ethylenediaminetetraacetic acid which complexes the chromium component of the “Quilon C”. The receptor element was then treated in exactly the same manner as in example 1 above to give a screen stencil.
Example 3
[0204] Polyvinyl alcohol—“Gohsenol GH-20” (c) of 88% hydrolysis and degree of polymerisation 2000 was coated onto a polyethylene terephthalate support base from an aqueous solution at a coating weight of 10 g m −2 .
[0205] A dispersion of sodium tetraborate tetrahydrate (borax) was prepared by grinding a 33 wt % mixture of borax in IMS in a ball mill for 48 hours.
[0206] The dispersion was diluted to 5 wt % and coated onto the polyvinyl alcohol with a 0.009 in Meyer bar, to give a coating weight of about 1 g m −2 . The resulting receptor element was passed through a commercial thermal ink jet printer (Hewlett Packard HP550) and liquid containing a chemical inhibitor agent was applied according to the formula:
water 39 wt % zinc nitrate (prepared from zinc carbonate/hydroxide and nitric 10 wt % acid) glycerine 50 wt % “Fluorad FC-93” (b) (1%) - anionic fluorinated surfactant 1 wt %
[0207] In this example, the non-reactive image-receiving layer of example 1 has been replaced by polyvinyl alcohol which reacts with the borax dispersion when, as described below, the receptor element is brought into contact with the mesh and further polyvinyl alcohol is applied. In this way, a stencil having a desirable “profile” is produced.
[0208] The receptor element was then treated in exactly the same way as in example 1 above to give a screen stencil. The screen stencil produced has a “profile” formed from the image-receiving layer.
Example 4
[0209] A 50:50 wt % blend of polyvinyl alcohol—“Gohsenol GH-20” (c) and polyvinyl acetate was coated onto a polyethylene terephthalate support base from an aqueous solution at a coating weight of 8 g m −2 .
[0210] A 10 wt % solution of pentahydroxy(tetradecanoate)dichromium “Quilon C” (e) in acetone/isopropanol was coated onto the polyvinyl alcohol/polyvinyl acetate coating using a 0.009 in Meyer bar. This gave an approximate coating weight of 1 to 2 g m −2 .
[0211] The resulting receptor element was passed through a commercial thermal ink jet printer (Hewlett Packard HP550) and liquid containing a chemical inhibitor agent was applied according to the formula:
water 95 wt % disodium ethylenediaminetetraacetic acid 5 wt %
[0212] In this example, compared with example 3, the polyvinyl alcohol reactive image-receiving layer has been replaced by a blend of polyvinyl alcohol and polyvinyl acetate which remains reactive to the first chemical agent as in example 3, the reaction being inhibited by the inhibitor which is as in example 2.
[0213] The receptor element was then treated in exactly the same manner as in example 1 above to give a profiled screen stencil.
Example 5
[0214] A blend of 10 g “Gohsenol GH-20” (c) polyvinyl alcohol, 2.0 g iron (II) sulphate, 2.0 g N,N′-methylenebisacrylamide, 1.0 g water-soluble pigment and 100 g water was coated onto a polyethylene terephthalate support at a coating weight of 10 g m −2 .
[0215] The resulting dried receptor element was passed through a commercial thermal ink jet printer (Hewlett Packard HP550) and liquid containing a polymerisation inhibitor was applied imagewise according to the formula:
water 90 wt % pyrogallol 10 wt %
[0216] The receptor element was dried, then placed on a glass plate, with the coated layer facing uppermost. The receptor element was covered with a screen mesh of mesh count 62 threads per cm and was laminated to the mesh using an emulsion of composition:
“GH-20” (c) 10.0 wt % N,N′-methylenebisacrylamide 2.0 wt % ammonium persulphate 2.0 wt % aqueous pigment dispersion 1.0 wt % water 85.0 wt %
[0217] The screen was dried and processed as in example 1 to give a profiled screen stencil.
[0218] In this example, the coated blend of materials constitute a reactive image-receiving layer coated on a polyethylene terephthalate support base. The first chemical agent in this case is provided by the iron (II) sulphate which is oxidised by the ammonium persulphate contained in the stencil-forming composition to produce iron (III) ions and free radicals which initiate polymerisation of the N,N′-methylenebisacrylamide. The polymerisation process incorporates the polyvinyl alcohol into the stencil-forming layer formed by the polymerisation. The inhibitor for this reaction is provided by the pyrogallol which acts as a free-radical trapping agent.
Example 6
[0219] A blend of 12 g of an acrylamide-grafted polyvinyl alcohol (graft level 10 wt %) produced by grafting a formyl-containing acrylamide monomer onto polyvinyl alcohol in an acid-catalysed condensation reaction, 2.0 g iron (II) sulphate, 1.0 g water-soluble pigment and 100 g water was coated onto a polyethylene terephthalate support at a coating weight of 10 g m −2 .
[0220] The resulting dried receptor element was passed through a commercial thermal ink jet printer (Hewlett Packard HP550) and liquid containing a polymerisation inhibitor was applied imagewise according to the formula:
water 90 wt % catechol 10 wt %
[0221] The receptor element was dried, then placed on a glass plate, with the coated layer facing uppermost. The receptor element was covered with a screen mesh of mesh count 62 threads per cm and was laminated to the mesh using an emulsion of composition:
acrylamide grafted polyvinyl alcohol 12.0 wt % (graft level 10 wt %), ammonium persulphate 2.0 wt % aqueous pigment dispersion 1.0 wt % water 85.0 wt %
[0222] The screen was dried and processed as in example 1 to give a robust profiled screen stencil.
[0223] Compared with example 5, the polyvinyl alcohol and the N,N′-methylenebisacrylamide are replaced in this example by the acrylamide-grafted polyvinyl alcohol and the pyrogallol inhibitor by catechol.
Example 7
[0224] Polyvinyl alcohol—“Gohsenol GH-20” (c) of 88% hydrolysis and degree of polymerisation 2000 was coated onto a polyethylene terephthalate support base from an aqueous solution at a coating weight of 10 g m −2 .
[0225] The resulting receptor element was passed through a commercial thermal ink jet printer (Hewlett Packard HP550) and liquid containing a chemical inhibitor agent was applied according to the formula:
water 95 wt % disodium ethylenediaminetetraacetic acid 5 wt %
[0226] The receptor element was then laminated to the mesh using the same procedure as in example 1, but using a solution of composition:
KL-318 (g) - a carboxylated polyvinyl alcohol 8.5 wt % acetic acid 5 wt % iron (III) sulphate 5 wt % aqueous pigment dispersion 1 wt % water 80.5 wt %
[0227] The screen was dried using a warm-air dryer and processed as in example 1 to give a screen stencil.
[0228] In this example, the polyvinylalcohol constitutes a non-reactive image-receiving layer coated on a polyethylene terephthalate support base. The first and second chemical agents are the carboxylated polyvinyl alcohol and the iron (III) ions, respectively, the iron (III) ions reacting with the carboxyl groups to form bridges between the polyvinyl alcohol chains which are thereby cross-linked. The EDTA salt functions as an inhibitor for this reaction as it has a chelating action on the iron (III) ions. The reaction between the carboxylated polyvinyl alcohol and the iron (III) ions takes place only at pH values of about 5.5 and higher and is therefore temporarily inhibited by the acetic acid which is removed by evaporation when the screen is dried using the warm-air dryer.
Example 8
[0229] A 10 wt % aqueous solution of “K90” (d) polyvinyl pyrrolidone was coated onto a polyethylene terephthalate support base at a coating weight of 10 g m −2 .
[0230] The resulting receptor element was passed through a commercial thermal ink jet printer (Hewlett Packard HP550) and liquid containing a chemical inhibitor agent was applied according to the formula:
water 95 wt % disodium ethylenediaminetetraacetic acid 5 wt %
[0231] The receptor element was then laminated to the mesh using the same procedure as in example 1, but using a solution of composition:
“WSRN-25” (h) - a partially carboxylated 25% aqueous 8.5 wt % solution of polyacrylamide acetic acid 5 wt % iron (III) sulphate 5 wt % aqueous pigment dispersion 1 wt % water 80.5 wt %
[0232] The screen was dried and processed as in example 1 to give a screen stencil.
[0233] Compared with example 7, the non-reactive image-receiving layer has been changed to polyvinyl pyrrolidone and the carboxylated polyvinyl alcohol to carboxylated polyacrylamide.
Example 9
[0234] A carboxylated polyvinyl alcohol—“Kuraray KL-318” (g) was coated onto a polyethylene terephthalate support base from an aqueous solution at a coating weight of 10 g m −2 .
[0235] The resulting receptor element was passed through a commercial thermal ink jet printer (Hewlett Packard HP550) and liquid containing a chemical inhibitor agent was applied according to the formula:
water 95 wt % disodium ethylenediaminetetraacetic acid 5 wt %
[0236] The receptor element was then laminated to the mesh using the same procedure as in example 1, but using a solution of composition:
KL-318 (g) 8.5 wt % acetic acid 5 wt % iron (III) sulphate 5 wt % aqueous pigment dispersion 1 wt % water 80.5 wt %
[0237] The screen was dried and processed as in example 1 to give a profiled screen stencil.
[0238] Compared with example 8, the non-reactive polyvinyl pyrrolidone image-receiving layer has been replaced by carboxylated polyvinyl alcohol which takes part in the cross-linking reaction involving the iron (III) ions.
Example 10
[0239] “WSRN-25” (h)—a partially carboxylated 25% aqueous solution of polyacrylamide was coated onto a polyethylene terephthalate support base at a coating weight of 10 gm −2 .
[0240] The resulting receptor element was passed through a commercial thermal ink jet printer (Hewlett Packard HP550) and liquid containing a chemical inhibitor agent was applied according to the formula:
water 95 wt % disodium ethylenediaminetetraacetic acid 5 wt %
[0241] The receptor element was then laminated to the mesh using the same procedure as in example 1, but using a solution of composition:
“WSRN-25” (h) 8.5 wt % acetic acid 5 wt % iron (III) sulphate 5 wt % aqueous pigment dispersion 1 wt % water 80.5 wt %
[0242] The screen was dried and processed as in example 1 to give a screen stencil.
[0243] In this example, compared with example 8, the non-reactive polyvinyl pyrrolidone of the image-receiving layer has been replaced by carboxylated polyacrylamide which takes part in the cross-linking process to produce a profiled screen stencil.
Example 11
[0244] A blend of 90 g “Klucel E” (a) a hydroxypropyl cellulose, 10 g sodium tetraborate and 900 g water was coated onto a polyethylene terephthalate support at a coating weight of 10 g m −2 .
[0245] The resulting dried film was passed through a hot wax printer (Tektronix Inc., USA) and hot wax was applied imagewise to the surface of the coated film.
[0246] The receptor element was dried, then placed on a glass plate, with the coated layer facing uppermost. The receptor element was covered with a screen mesh of mesh count 62 threads per cm. Then a bead of “Autosol 2000” (f) a screen printing emulsion comprising a blend of polyvinyl alcohol and polyvinyl acetate was placed on the mesh and drawn over the receptor element by means of a squeegee so that a thin layer of emulsion was forced through the mesh. The screen was dried and processed as in example 1 to give a screen stencil.
[0247] In this example, the hydroxypropyl cellulose forms a non-reactive image-receiving layer on a polyethylene terephthalate support base. The sodium tetraborate constitutes the first chemical agent which reacts with the polyvinyl alcohol in the “Autosol 2000” to produce the stencil layer of the final screen stencil, the polyvinyl alcohol constituting the second chemical agent and the reaction being inhibited by the hot wax mask where applied.
Example 12
[0248] A blend of 90 g “Natrosol 250L” (a) a hydroxyethyl cellulose, 10 g sodium tetraborate, 900 g water and 4 g “Syloid ED41” (i) an inorganically treated silica, was coated onto a polyethylene terephthalate support at a coating weight of 10 g m −2 .
[0249] The resulting dried film was passed through a laser printer (Xante 8300), and toner powder as a masking agent was applied imagewise to the surface of the coated film.
[0250] The receptor element was then treated in the same way as example 11 to give a screen stencil.
[0251] Compared with example 11, the hydroxyethyl cellulose has replaced hydroxypropyl cellulose as the image-receiving layer in this example. The hot wax masking agent has been replaced by the dry toner. The purpose of the inorganically treated silica is to facilitate toner adhesion to the surface of the receiving layer.
[0252] [0252]FIG. 31 of the drawings is a perspective view of a cartridge for use in an ink-jet printer or plotter, and pre-filled with a liquid such as is applied to the receptor elements shown in FIGS. 2, 7, 12 , 17 , 22 and 27 of the drawings.
[0253] Referring to FIG. 31 of the drawings, this shows a cartridge 40 for use in an ink-jet printer or plotter and pre-filled with a liquid such as is applied to the receptor elements 10 , 10 ′, 20 , 20 ′, 30 and 30 ′ in the above description with reference to those figures.
[0254] It should be understood that the invention is not limited to the particular embodiments shown and described herein but that various changes and modifications may be made without departing from the scope and spirit of the invention.
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Screen printing stencils are produced by a positive-working method which involves no light-sensitive materials and does not require the use of safe lights. A coated receptor film having a coating layer and a support layer is imaged using an ink-jet printer or plotter in areas corresponding to the open stencil areas. The film is then applied to a mesh and an emulsion applied. Chemical hardening of the emulsion takes place in the non-imaged areas. The stencil is then produced by removing the support layer of the film and washing away the unhardened emulsion. The receptor film may include a layer which is incorporated into the stencil layer to form a profile. In addition to screen production methods, coated films, coating compositions and compositions for imagewise application are disclosed.
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FIELD OF THE INVENTION
The present invention pertains to water fountain displays and more particularly to a water pump arrangement for displays of this nature, comprised of two electric motor operated pumps for each of a plurality of formations of nozzles utilized to produce a very wide range of rhythmic visual effects generally in synchronization with music.
BACKGROUND OF THE INVENTION
Fountains of the type of the present invention generally are provided with pluralities of groups and formations of nozzles. A relatively wide range of different types of nozzles may be employed, however, the nozzle structure forms no part of the instant invention and will be referred to hereinafter simply as nozzles. It is customary to vary the height of the water sprays or streams rhythmically, for example, in synchronization with music to achieve some of the desired effects.
Heretofore, a single electric motor operated pump in combination with a gate valve has been utilized to vary the height of the water sprays or streams from each group of nozzles.
The present invention provides two electric motor operated pumps in each water discharge conduit to a single formation of nozzles. Both pumps are disposed in the water and each pump has a suction opening thereinto and they are connected to a common discharge conduit. A gate valve is disposed in a discharge conduit portion adjacent each pump, said gate valves being initially fixed in a set position to determine the maximum or desired full height of the water stream from the nozzles fixed in the discharge conduit. When the motor of the second of the two pumps is energized the streams of water emitted from the nozzles will attain approximately one-third of the maximum height because approximately one-half of the water being pumped out through the discharge conduit will escape through the intake opening of the first pump. The second of the two pumps has a check valve in the discharge conduit portion so that when the first pump is actuated, the spray nozzles discharge streams of water to approximately two-thirds of the maximum height as no water can escape through the check valve to the second pump. When both pumps are actuated simultaneously, the spray nozzles discharge streams of water to the maximum height.
Therefore, one of the principal objects of the present invention is to provide two electric motor operated pumps in each water discharge conduit to a single formation of nozzles in a fountain display.
Another object of the invention is to provide a gate valve in a portion of the discharge conduit adjacent each pump.
A further object of the invention is to provide a check valve in the discharge conduit portion adjacent the second of said two pumps.
Yet another object of the instant invention is to provide electric circuitry controlled by pluralities of switches to determine the height of the water streams emitted from the respective nozzles and to universally control the activation of individual, various groups and formations of nozzles to produce a wide range of different rhythmic effects.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic illustration of two electric motor operated water pumps connected in a water discharge conduit provided with a plurality of nozzles;
FIG. 2 is a schematic illustration of one of the pumps in relation to the water level in the fountain pool;
FIG. 3 is a wiring diagram of the electrical control system for the fountain display.
DETAILED DESCRIPTION OF THE INVENTION
With reference to the drawings in which like reference characters designate like or corresponding parts throughout the various views and with particular reference to FIG. 1, a typical electric motor operated pump arrangement, designated generally at 10 is illustrated connected in a water discharge conduit 12, provided with a plurality of nozzles, three illustrated at 14, 15 and 16. In practice a substantial plurality of pump and nozzle assemblies, sixteen for example, is utilized.
The pumps P-1 and P-2 are powered by respective electric motors such as M-1 and M-2 and the discharge conduit 12 includes water conduit portions 18 and 20 connecting between the discharge ports of the respective pumps P-1 and P-2 and a main horizontal portion 22 of conduit 12 which is provided with the nozzles 14, 15 and 16. Gate valves 24 and 26 are interposed in the conduit portion 18 and 20 of the respective pumps P-1 and P-2. The gate valve 24 and 26 are set once to determine a desired maximum height of the water stream. A third gate valve 27 may be interposed in conduit 22, as illustrated, as a master control for both pumps. A check valve 28 is interposed in the conduit portion of pump P-2.
With reference to FIG. 2 each pump and motor assembly such as P-1 and M-1 is mounted with the pump P-1 located beneath the water level W as is the discharge conduit assembly 12. Nozzles such as 14, 15 and 16 extend above the water level W.
In operation, when the motor M-2 is individually energized to operate pump P-2, water enters the suction port 30, FIG. 2, thereof and creates streams from nozzles 14, 15 and 16. However, approximately one-half of the water discharged through conduit portion 20 escapes out through the suction port 30 of pump P-1 which is not in operation. As a result the streams from nozzles 14, 15 and 16 are approximately one-third of the maximum height, determined by gate valves 24 and 26. When motor M-1 is energized to operate pump P-1, the streams from nozzles 14, 15 and 16 is achieved approximately two-thirds of their maximum heights because check valve 28 in conduit portion 20 to pump P-2 prevents passage of water outwardly through suction port 30 thereof. When both pumps P-1 and P-2 are simultaneously operated by motor M-1 and M-2, the streams from nozzles 14, 15 and 16 achieve their maximum heights.
The above described pump and nozzle assembly assembly comprises a single formation utilized in the fountain display of the present invention. In practice a plurality of pump and nozzle assemblies, 16 by way of example, may be utilized to achieve a like plurality of formations. The number and types of nozzles in the various formations may be varied to achieve any desired visual effect. The wide variety of nozzle types which may be utilized forms no part of the present invention which is directed to the universal control of the formations to achieve a selective actuation of any desired single or combination of formations along with the stream heights from the individual formations
With reference to the wiring diagram of FIG. 3, six main control switches are designated generally at 40 for selective control of the operation of the plurality of formations with both pumps P-1 and P-2 in operation to achieve the maximum water stream height. Four switches are designated generally at 42 for selective control of the operation of the formation with pump P-1 in operation to achieve two-thirds of the water stream height, and four switches are designated generally at 44 for selective control of the operation of the formation with pump P-2 in operation to achieve one-third of the water stream height.
In the diagram of FIG. 3, two single formations are illustrated, a first formation designated generally at 50 for operation by pumps P-1 and P-2, and a second formation designated generally at 52 for operation by a similar pair of pumps designated P-3 and P-4. As above stated a substantial plurality of formations, sixteen for example, may be incorporated in the fountain display, each incorporating a similar pair of pumps. All of the formations are interconnected by the common conductors 54 through 72.
As all of the formations are identical in function and operation, the single formation 50 will be described in detail. The six switches designated 40 include three main control switches 80, 82 and 84 which are of a hold type which must be physically made and broken. Main control switches 86, 88 and 90 are of the push button type which may be spring loaded to the off position and, therefore, must be held in on positions. The six switches define three pairs, switches 80 and 86, 82 and 88, and 84 and 90 in respective common circuits to three group selector switches 92, 94 and 96 which are connected between the respective common conductors 56, 58 and 60 and a single formation switch 98 by a conductor 100. When switch 98 is in the position illustrated, a circuit may be completed to the solenoid switch 102 by conductors 104, 106 and 72, in a manner to be subsequently described, to complete circuits to both pumps P-1 and P-2 by conductors 108, and 110 respectively. A main on-off switch 112 is provided in conduit 114 which connects with one contact 116 of each switch 80 through 90. Second contacts 118 of the switches 80 through 90 connect respectively to group selector switches 92, 94 and 96 by conductors 120, 122 and 124. Each pair of the main control switches such as 80, 86 is connected in a circuit with one of the conductors such as 124 of conductors 120, 122 and 124, to one switch such as 96 of switches 92, 94 and 96, whereby a circuit is completed to P-1 and P-2 by means of solenoid switch 102, conductor 104, switch 98, switch 96 when closed, conductor 124, either switch 80 or 86 when closed through conductor 114 and main switch 112.
In like manner, a circuit is completed to both pumps P-1 and P-2 when one of the main control switches 82 or 88 is closed and switch 94 is closed or when one of main control switches 84 or 90 is closed and switch 92 is closed.
As each of the plurality of formation circuits, sixteen for example, such as 50 and 52 connect to a pair of pumps such as P-1 and P-2, the group selector switches 92, 94 and 96 when selectively preset in each formation will define three groups when one of each pair of switches 80 through 90 is actuated.
For example, if group selector switch 92 is closed in eight formations, group selector switch 94 is closed in six formations and group selector switch 96 is closed in two formations and one switch of each of the main control pairs 80 through 90 is closed, three groups of nozzles will be activated by the respective pairs of pumps in the various formations to their maximum heights. The eight formations which may be provided with a first type of nozzle comprises the first group, the six formations which may have a second type of nozzle comprises the second group, and the two formations which may have a third type of nozzle comprises the third group. Therefore, a very substantial variety of groups of formations may be selected by the actuation of selector switches 92, 94 and 96 in any desired number of formations and by closing either one of the pairs of switches in one, two or three of the main control switch pairs 80 through 90.
The above described formations all provide water streams to the maximum height. Therefore, a second plurality of main control switches 42 are provided to accomplish the same purposes of main control switches 40 with the single pump P-1 in operation to achieve two-thirds of the water stream height.
Main control switches 42 comprise two pairs of switches, first switches 130 and 132 of the hold type and second switches 134 and 136 of the spring loaded push button type. The first pair 130 and 134 are connected between a conductor 138 from conductor 114, and a conductor 140 to a switch 142, through a conductor 144 to a switch 146, closed in a first position, to a conductor 148 to pump P-1 to achieve two-thirds height water streams.
The second pair of switches 132, 136 are connected between conductor 138 and a conductor 150 to a switch 152, through conductor 144, switch 146, and conductor 148 to pump P-1. Therefore as with the full height switches 92, 94 and 96, group selector switches 142 and 152 may be preset in the various formations such as 50 to define groups operable by the main control pairs of switches 130 through 136 to function in the above described manner relative to the full height formations.
Main control switches 44 comprises two pairs of switches, first switches 160 and 162 of the hold type and second switches 164 and 166 of the spring loaded push button type. The first pair 160, 164 connect between conductor 138 from conductor 114, and a conductor 168 to a group selector switch 170, through a conductor 172 to a switch 174, closed in a first position, to a conductor 176 to pump P-2 to achieve one-third height water streams.
The second pair of main control switches 162, 166 are connected between conductors 114 and a conductor 180 to a group selector switch 182, through conductor 172, switch 174, and conductor 176 to pump P-2 for one-third height water streams. As with the full and two-thirds height group selector switches, switches 170 and 182 may be preset in the various formations such as 50 to define groups operable by the main control switches 160 through 166 to function in the above described manner relative to the full and two-thirds height formations.
Therefore, it can be seen that by means of the main control switches 80 through 90, 130 through 136, and 160 through 166 any desired group arrangements of one-third, two-third and full height water streams can be produced in the various formations, which, as above stated, can be sixteen in number by way of example.
Switch 98 in the position illustrated serves to complete the circuit to a single formation such as 50. When switch 98 is moved to its second position to span contacts 190, 192 and the hold switch 194 is closed, switches 92, 94 and 96 in the formation are disconnected and the pair of pumps P-1 and P-2 are actuated through conductors 54, 104, solenoid switch 102 and conductors 108, 110.
When switch 146 is operated to a second position to complete a circuit through contacts 196 and 198, the pump P-1 is activated through conductors 114, 138, 200, switch 146 and conductor 148 to P-1 and switches 142, 152 in the formation are thereby disconnected or bypassed.
Switch 174, when moved into engagement across contacts 202, 204, completes a circuit to pump P-2 through conductors 114, 138, 200, switch 174 and conductor 176 to P-2. Switches 170 and 182 are thereby disconnected.
Therefore, the various group selector switches 92, 94, 96, 142, 152, 170 and 182 may be bypassed and each individual formation such as 50 and 52 can be selectively activated by switches 98, 146 and 174 to energize pumps P-1, P-2 or both pumps P-1 and P-2 simultaneously.
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An arrangement of water pumps comprising two electric motor operated pumps for each of a plurality of formations of nozzles whereby the water flow from the pairs of pumps to the various formations of nozzles may be selectively controlled by pluralities of electric switches located in a remote station. Electric circuitry associated with the switches controls the electric current flow to the various pump motors in a manner whereby the height of the water sprays emitted from the respective nozzles is selectively controlled along with providing a generally universal control over the activation of individual, various groups and formations of nozzles to produce a very wide range of different rhythmic visual effects.
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This is a continuation of application Ser. No. 449,915, filed Mar. 11, 1974, now abandoned. .Iaddend.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to apparatus for analyzing gases and vapors to determine the presence of compounds and, more particularly, to apparatus for improving the range and sensitivity of electron-capture ionization detectors which are used in such analyzing apparatus.
2. Description of the Prior Art
In the copending application of Conrad S. Josias, et al., Ser. No. 835,290, filed May 29, 1969, and assigned to the assignee of the present invention, a gas detector and analyzer was described which utilized an electron-capture ionization detector to signal the presence of very low concentrations of different chemical compounds in an environment. That application cited and relied upon a prior patent to James E. Lovelock, U.S. Pat. No. 3,247,375, which taught an electron-capture ionization detector and circuits which made such a device a useful tool for analysis.
Recently, Dr. James E. Lovelock delivered a paper entitled "Analysis by Gas Phase Electron Absorption" at the Seventh International Symposium on Gas Chromotography Discussion Group of the Institute of Petroleum held at the Falkoner Centret, Copenhagen, Denmark, from June 25 to June 28, 1968. The paper was subsequently published by the Institute of Petroleum of London, W1, Great Britain in 1969 as part of a volume entitled "Gas Chromotography, 1968," edited by C. L. A. Harbourn.
The Lovelock paper described in some detail the history of the electron-capture detector noting that electron absorption was a technique almost entirely dependent upon gas chromatography for its existence, the "electron-capture" detector being so sensitive that it could function efficiently only with pure vapors greatly diluted in a clean stream of carrier gas emerging from a chromatograph column. That article is considered supplementary to and cumulative of Dr. Lovelock's prior papers, including the article "Ionization Methods for the Analysis of Gases and Vapors," published at page 162 in the Feb., 1961, issue of "Analytical Chemistry," Volume 33, No. 2, and a subsequent paper entitled "Electron Absorption Detectors and the Technique for their Use in Quantitative and Qualitative Analysis by Gas Chromatography," published at page 474 of Analytical Chemistry, Volume 35, No. 4, of April 1963.
In the Gas Chromatography 1968 article, Lovelock also described the chemical and physical basis for the operation of the electron-capture detector and discussed the parameters that were important in the construction of such a detector. At page 102, Lovelock discussed the methods of operating such electron-capture detectors. A severe drawback of the earliest versions was the limited dynamic range of such detectors. The dc method then employed applies a fixed potential difference between the electrodes of the detector. The detector is subjected to a stream of inert carrier gas which does not itself absorb electrons. The potential is adjusted to a value sufficient to collect all of the electrons liberated from the carrier gas by a radiation source which ionizes the gas.
An electron-absorbing vapor introduced into the gas stream collects the free electrons to produce negative molecular ions which then recombine with the positive ions resulting from ionizing radiation. The change in current flow attributable to the presence of electron-capturing compounds is determined. If the decrease of current flow is measurable, then a quantitative indication of the electron-absorbing compound can be achieved.
Alternatively, the potential can be increased to a value that maintains the current flow at a constant value and the change of potential would also represent a measure of the quantity of electron-absorbing compound present. Yet other methods utilize higher potentials, but generally, such higher potentials result in a nonlinear response to vapor concentration.
As described by Lovelock in the 1963 Analytical Chemistry paper, supra, a pulsed sampling technique can be employed involving the use of brief pulses of potential, at relatively infrequent intervals. Lovelock suggested a 50-volt pulse of 0.5-microseconds duration, at intervals of approximately 100 microseconds. This pulsed sampling procedure enjoyed several advantages in that:
1. For most of the time, no field is applied to the detector so that free electrons are in thermal equilibrium with gas molecules;
2. The sampling pulse is so brief that no significant movement of negative ions occurs, avoiding inaccuracies due to space-charge effects or the collection of negative ions at the anode;
3. A pulse amplitude of 30 volts is sufficient to collect all of the electrons;
4. The ultimate sensitivity is increased since the time for encounter between absorbing molecules and electrons is extended to the point where natural recombination limits any further increase in sensitivity; and
5. Except for those compounds whose absorption cross-sections increase greatly with small increases in energy, and for which sensitivity improves only in dc systems, the pulse method is much more reliable, and in general, sensitivity is improved.
In the copending Josias, et al. application, the pulsed sampling technique as described by Lovelock was modified. A highly-stable pulse source, for example, a crystal-controlled oscillator whose frequency stability exceeds one part in 10 8 , was provided. The magnitude of the pulses was reduced to approximately 30 volts, and the pulse duration was extended to 3 microseconds. These pulses were repeated at 100-microsecond intervals. It appeared that the lower-voltage pulses of longer duration also adequately swept all of the electrons from the ionization detector and provided a current which, when averaged, could be used to signal concentration.
In the Gas Chromatography article, Lovelock, at pages 102 and 103, disclosed yet other improved pulse methods for increasing the dynamic range of the detector. Detectors were described in which a signal for measurement was not produced directly. Rather, the detector serves as a sensor to indicate a departure from a steady-state condition.
One circuit was disclosed in which the output of an electrometer amplifier was fed back to a pulse generator where it was compared to a reference current. The result of the comparison was used to set the pulse interval. The output of such a system was not a current to a recorder, but was a digital or frequency signal.
SUMMARY OF THE INVENTION
Applicants herein have conceived of an improved extended-dynamic-range device which they have termed a "frequency-programmed electron-capture detector." It is noted that Lovelock, at page 103 of the Gas Chromatography article, without the consent of the inventors, discussed in general terms the present invention without describing it in detail. A block diagram was published (FIG. 6) which omitted some of the elements of the present invention that are deemed to be essential to the proper operation of the invention.
According to the present invention, it is not enough to merely provide a comparator which compares the electrometer output with a reference to control a pulse generator; it is also necessary that the reference be applied in the form of a ramp signal.
The electrometer output is initially "zeroed" in the presence of a stream of pure carrier gas to establish a "baseline." A reference voltage is applied to a relaxation circuit, such that the voltage changes in a linear, ramp fashion between an upper and a lower reference voltage over an interval related to the period for the lowest useful frequency.
In one embodiment, the interval selected to provide maximum sensitivity was 200 microseconds during which the ramp voltage had a 10-volt excursion. The relationship between the electrometer output and the concentration of a predetermined electron-capturing compound is extremely nonlinear. However, the relationship between frequency and concentration is, for all practical purposes, a highly linear one. The change in frequency can then be a measure of concentration and can directly provide an output signal.
The novel features which are believed to be characteristic of the invention, both as to organization and method of operation, together with further objects and advantages thereof, will be better understood from the following description considered in connection with the accompanying drawings in which several preferred embodiments of the invention are illustrated by way of example. It is to be expressly understood, however, that the drawings are for the purpose of illustration and description only and are not intended as a definition of the limits of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of a frequency-programmed electron-capture detector system; and
FIG. 2 is a circuit diagram of a preferred embodiment of the system of FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Turning first to FIG. 1, there is shown, in block diagram, a frequency-programmed electron-capture detector system which is operable in a gas detector and analyzer such as that disclosed in the copending application of Conrad S. Josias, et al., Ser. No. 835,290, filed May 29, 1969, and assigned to the assignee of the present invention. There is shown a capature-detector circuit 10 which includes the electron-capture detector 12. The capture detector 12 may be identical to that disclosed in the above-identified Josias, et al. application or as described in any of the Lovelock publications. The output of the capture detector 12 is applied to an electrometer amplifier 14, the output of which is fed back via an integrating circuit 16 so that a steady-state output can be provided in response to a pulse input. A baseline-adjusting circuit 18 also applies a current to the input of the electrometer amplifier 14.
A comparator circuit 20 has one input connected to a mode switch 22 which, in a first position, couples the comparator to a source of reference voltage 24 and, in an alternative configuration, couples the comparator 20 to the output of the electrometer amplifier 14. A second input to the comparator 20 is provided from a ramp generator 26, to be described in greater detail below. The output of the comparator 20 is applied to a pulse generator 28. It is the output of the pulse generator 28 that represents the capture-detector circuit 10 signal output. For output or display purposes, the pulse generator is coupled to a frequency-to-voltage converter 30 so that the concentration of the unknown electron-capturing compound can be displayed utilizing a conventional voltage meter or recorder (not shown).
The output of the pulse generator 28 is also applied to the ramp generator 26, where it is used to initiate an interval during which a voltage having a first value linearally changes to a second value at a predetermined rate. The output of the ramp generator, as noted above, provides the second input to the comparator 20. It is the comparison of the magnitude of the voltage of the ramp generator 26 with the magnitude of the output of the electrometer amplifier 14 that, when equal, provides an output to the pulse generator 28 which, in turn, triggers the generation of a pulse signal that initiates a new ramp interval in the ramp generator 26.
The output of the pulse generator 28 is also applied to a switch 32 which is coupled through a capacitor 34 to the detector 12.
The individual pulses generated by the pulse generator 28 and applied to the switch 32 "sweep" the detector 12 of all charged particles and, as described in the Josias, et al. application, provide an input to the electrometer amplifier 14.
The pulses are also applied to an attenuator circuit 36 to provide a direct pulse output. Such an output can drive a digital counter (not shown), which can provide a number proportional to the concentration of an electron-capturing compound.
The mode switch 22 when connected to the source of reference voltage 24 (usually zero volts) causes the pulse generator 28 to operate at a fixed frequency (usually 5 kHz) and enables a "zeroing" of the electrometer amplifier by appropriate adjustment of the baseline current through the baseline-adjust circuit 18. This zeroing is done in the presence of a pure carrier gas and establishes a lower signal limit which can be utilized to zero any display devices that may be used.
In the presence of an electron-capturing compound, the electrometer amplifier will provide an output signal to the comparator with the mode switch 22 in the operating configuration. When the output of the ramp generator 26 falls to a value equal to the voltage applied to the comparator 20 through the mode switch 22, the pulse generator 28 will be triggered. As the magnitude of the output signal of the electrometer amplifier 14 increases resulting from a decrease in detector current, the equality relationship will be reached after an increasingly shorter interval, and the pulse generator 28 will provide pulses at a higher frequency.
The higher frequency of pulses applied to the detector 12 necessarily reduces the probability that an electron will be captured by an electronegative compound or a positive ion, thereby increasing the current to the electrometer amplifier 14. The increased current output then requires that a longer portion of the ramp interval ensue before equality is reached, thereby reducing the frequency.
It will be seen that the system will stabilize at a frequency value which is directly proportional to the concentration of electron-capturing compounds in the stream of carrier gas.
Given the apparatus illustrated in FIG. 1, the mathematical basis for the linear relationship between frequency and concentration can be derived from a consideration of the following relationships.
Consider a mixture of a carrier gas 1 and an electron absorber compound 2.
Table I______________________________________t = time from the end of the application of a voltage pulseR.sub.e = rate of electron production from a radioactive β-emitter including electron- multiplication processes in the carrier gasN.sub.T = total number of molecules in the detectorN.sub.D.sbsb.1 = number of positively-ionized carrier gas molecules in the detector at t = 0N.sub.D.sbsb.2 = number of electron-absorbing gas molecules in the detector at t = 0N.sub.A.sbsb.1 (t) = number of ionized carrier-gas molecules that have captured one electron at a time tN.sub.A.sbsb.2 (t) = number of electron-absorbing gas molecules that have captured one electron at a time tN.sub.e (t) = total number of electrons in the detector at a time tσ.sub.1 = probability per unit time of capture of an electron by an ionized carrier-gas molecule which has not captured one electron (i.e., "recombination" rate)σ .sub.2 = probability per unit time of capture of an electron by an electron-capturing gas molecule which has not captured one electron______________________________________
The rate of production of electrons is given by: ##EQU1##
The rate of removal of electrons by means of electron capture by gas molecules is given by: ##EQU2## The first term in Equation (2) represents recombination of electrons with positive ions in the carrier gas. These ions were produced by the electron multiplicative processes starting with the energetic β particles. The second term in Equation (2) represents the capture of electrons by electronegative gas molecules. Both of these terms can be trivally generalized to include more than two as species.
Combining the differential Equations (1) and (2) gives the net rate of electron production: ##EQU3##
Assume that at the end of a given period T all the electrons in the detector are swept out by a voltage pulse with a width short with respect to T. In addition, assume that N A is negligible with respect to N D . Then at equilibrium:
N.sub.e (0) = 0 ##EQU4## where
α.sub.1 .tbd. σ.sub.1 N.sub.D.sbsb.1 +σ.sub.2 N.sub.D.sbsb.2. (4)
integration and evaluation of the integration constant by utilization of the boundary condition N e (t) = 0 when t = 0 gives: ##EQU5## If α 1 t <<1, the exponential may be expanded in a power series, neglecting all but the first, second and third order terms: ##EQU6##
The average detector current is given by: e1 ? N e (T)q? ? ? I D =? , (7)? T where T is the pulse interval and q is the charge on the electron (1.6 × 10.sup. -19 C). In Equation (7) is contained implicitly the assumption that Equations (1) and (2) apply during the period when the voltage pulse is present. This assumption is based on the discussion presented by Wentworth, Chen and Lovelock on page 449 of their article appearing in the Journal of Physical Chemistry, 70, 445 (1966). In that discussion, they determined that, for a carrier gas containing 90% argon and 10% methane, the average electron energy would be increased only slightly above its thermal value during the application of the pulse. They then presented data to confirm this prediction. From (6) and (7), the expression for the average detector current then becomes: ##EQU7##
If the baseline detector current is defined by
I.sub.B .tbd. qR.sub.e , (9)
then the decrease in baseline current due to electron-capture processes is derived from (8) and (9): ##EQU8## For α 1 T/3 << 1, the fractional decrease in baseline current is: ##EQU9## indicating that ΔI is approximately proportional to α 1 .
If the definition of α 1 given in Equation (4) is used, Equation (11) then becomes: ##EQU10## indicating the approximate proportionality of detector current change to the number of electron-absorbing gas molecules in the detector.
In the derivation of Equation (11), α 1 T/3 was assumed to be small with respect to 1. Thus Equation (11) is accurate only if 2ΔI/3I B is kept small. If the period T is allowed to be programmed so that this inequality holds, then the dynamic range for linear operation can be vastly increased over that resulting from fixed-period (or fixed-frequency) operation.
The relationship can be demonstrated by considering that the output voltage V 1 of the electrometer 14 of FIG. 1 is proportional to the decrease in detector current:
I.sub.B - I.sub.D = ΔI (Equation 10).
In the preferred embodiment, the electrometer 14 was set for a maximum value of its output of +10 volts.
The voltage, V 2 , produced by the ramp generator 26 is an inverse saw-tooth wave which is created by subtracting the voltage across a capacitor within the ramp generator from a fixed reference voltage, V r , which is set at +10 volts. The ramp generator 26 is designed so that the capacitor discharges at a constant rate. Thus, the output of the ramp generator at any time t is: ##EQU11## where I s represents the current from a source within the ramp generator and V 2 = V r at t = 0. C r is the capacitance of the capacitor within the ramp generator 26.
When V 2 falls to a value equal to V 3 , the comparator 20 causes the pulse generator 28 to produce a pulse with a width (ΔT) of 50 to 100 ns. This pulse closes the switch in the ramp generator for 50 to 100 ns, causing V 2 to once again equal V r . Equation (13) then describes the behavior of V 2 for times measured from the opening of the switch. This behavoir repeats at a frequency determined by V 3 . The period T of this oscillation is given by the solution of the following equation: ##EQU12##
The pulse generator 28 also causes the switch 32 to apply a pulse to the detector 12. This pulse sweeps the electrons from the detector in the manner described above and causes the detector current I D to flow. The magnitude of this current is described by Equations (7) and (5), and by Equation (11) when 2ΔI/3I B << 1.
A current I o is subtracted from the detector current by the baseline-adjust circuit 18. The difference of these currents then flows in the electrometer 14 feedback resistor having a resistance R f . (The feedback capacitor having a capacitance C f filters the high frequency variations of the detector current.) For an ideal electrometer 14, its output voltage V 1 becomes:
V.sub.1 = V.sub.3 = (I.sub.o - I.sub.D)R.sub.f . (15)
Applying Equations (10), (14) and (15), one obtains for the period T: ##EQU13##
If, in addition, it is assumed that 2ΔI/3I B is negligible compared to unity, then Equation (11) is valid and ##EQU14## The frequency of oscillation f then becomes: ##EQU15## Note that this frequency is approximately proportional to the number of electron-absorbing gas molecules in the detector N D .sbsb.2, as can be seen from Equations (4) and (18) combined.
In the preferred embodiment, the value of I o is chosen so that the frequency f o , resulting when N D .sbsb.2 = 0, is made independent of R f . This choice allows the use of a relatively unstable resistor for R f , which typically has a value near 10 10 ohms. In this case, ##EQU16## and ##EQU17##
With this choice, then Equations (18), (19) and (20) imply that ##EQU18## In terms of concentration C, defined as the ratio of N D .sbsb.2 to the total number of molecules in the detector N T , then ##EQU19## were ##EQU20## and ##EQU21##
In order for this analysis to be accurate, the inequality, 2ΔI/3I B << 1, must be satisfied. The magnitude of this quantity can be calculated from Equations (16) and (21) to yield: ##EQU22## The first term in this description of the deviation from Equation (11) is a constant as a functon of N D .sbsb.2 or f and thus does not represent a nonlinearity in the relationship between f and N D .sbsb.2 as described by Equation (18). The second term does represent such a nonlinearity, but can be made infinitesimal by suitable choices of V r and R f . In the preferred embodiment, V r = +10 V, R f = 10 10 ohms, and I B = 3 × 10.sup. -8 A, so that 2ΔI/3I B changes only +1% for f o <f <∞.
Typically for a carrier gas in the detector consisting of 95% argon with 5% methane,
N.sub.D.sbsb.1 σ.sub.1 = 1.5 KHz. (26)
For this case in the preferred embodiment, f o is chosen to be 5 kHz so that the first term of Equation (25) has a value of 10%.
The restriction that f o be large compared to N D .sbsb.1 σ 1 /3 is essential only for computational convenience in deriving Equation (17). Even if f o has a lower frequency or the frequency corresponding to σ 1 N D .sbsb.1 is higher as a result of electronegative gases being present, the proportionality between Δf and C still holds. The proportionality constant k must be modified, however, to take into account such nonlinearities in the baseline. Thus, one can write:
Δf .tbd. f - f.sub.o = kC. (27)
the lower limit for Δf is given by the instabilities in the baseline frequency f o . In the preferred embodiment, these fluctuations are determined by small changes in the properties of the carrier gas (or impurities contained in it) and not by electronic drifts. Typically these fluctuations are about 5 Hz for f o = 5 kHz in nearly pure 95% A, 5% CH 4 carrier gas.
The upper limit for f results from the non-zero time required to collect the electrons from the detector. Typically this time is less than 100 ns. In the preferred embodiment, an upper operating frequency of 5 MHz was choosen, resulting in a 200-ns minimum period between pulses. Experimentally it has been found that total charge collection can be made to occur during the 50- to 100-ns wide pulse from the switch 32. A slight deviation from linear performance has been found at frequencies above 1 MHz, probably resulting from the fact that the electron energies are not precisely thermal during the period that the pulse from switch 32 is applied to the detector. However, satisfactorily linear operation has been achieved using the preferred embodiment for values of Δf between 5 Hz and 5 MHz, thus extending the linear dynamic range for the electron-capture detector over six decades.
Therefore, it will be appreciated that the expected dynamic range of the detector for compounds, such as sulfur hexafluoride (SF 6 ), would be approximately six decades. This dynamic range would also be applicable to electron-capturing compounds that are up to 1/100 as electronegative as sulfur hexafluoride.
Turning next to FIG. 2, there is shown a preferred embodiment of circuits mechanizing the several blocks of FIG. 1. As illustrated, the mode switch 22 is shown as alternatively connected to the reference source 24 which, in the illustrated embodiment, is ground. Alternatively, the switch 22 connects to the output of the electrometer amplifier 14.
The comparator circuit 20 is mechanized by a pair of FET devices 42a, 42b. The electrometer signal is applied to the gate of one of the FET devices 42a, and similarly, the reference signal from the ramp generator is applied to the gate of the other of the FET device 42b.
The drains of the two FET devices 42a, 42b are coupled together through a pair of diodes 44, 46 connected in parallel in respectively opposite directions. The output of the comparator 20 is provided from a pair of common-emitter comparator transistors 48a, 48b, which are commonly coupled through their emitters to a negative potential source 50.
In order to maintain the flow of current through the comparator, the sources of the FET devices 42a, 42b are commonly connected to the collector of a supply transistor 52, the emitter of which is connected to a source of positive potential 54 through a resistor. The supply transistor 52 is operated as an amplifier to provide a reasonably constant current flow to the comparator 20. A voltage divider 56, connected between the positive source 54 and a common reference point 58, provides a predetermined bias to the bae of the current-source transistor 52 to control the amount of current supplied thereby.
As long as the reference voltage exceeds the electrometer voltage, the FET device 42b conducts less than one-half of the current from the supply transistor 52, while the FET device 42a conducts more than 50% of this current. Similarly, the comparator transistor 48a is conducting, while the other comparator transistor 48b is held nonconducting. The output of the conducting comparator transistor 48a is applied to the pulse generator 28.
The voltage drop across the diodes 44, 46 is sufficient to create a differential between the voltage applied to the base of the first comparator transistor 48a and the second comparator transistor 48b. This differential is sufficient to maintain the differential operation of the transistor pair.
The pulse generator 28 includes a trigger transistor 60 and an accelerating transistor 62 connected in parallel therewith. The output of the trigger transistor 60 is applied to the base of first-stage inverter transistor 64, the output of which is applied to the base of a second-stage inverter transistor 66, the output of which, in turn, is applied in parallel to the bases of a pair of inverting output transistor 68 and 70.
The collector of the one output transistor 68 is coupled to the collector of the other, complementing output transistor 70. The output of the pulse generator 28 is taken from the common connection of the collectors of the output transistor 68, 70. The output of the pulse generator 28 is applied to the switching circuit 32, a frequency-to-voltage conversion device 30, the ramp generator circuit 26, and an attenuator 36.
The switch circuit 32 functions as a pulse amplifier operating in a switching mode. An input transistor 72 applies its output to the base of an intermediate-stage transistor 74, which in turn is coupled to the base of an output-stage transistor 76. The input transistor 72 is normally "off," the intermediate-stage transistor is normally "on," and the output transistor is normally "off."
The output transistor 76 is capacitively coupled as an emitter follower to the detector circuit 12. Further, the input to the base of the input transistor 72 is by way of a capacitive coupling so that the circuit responds only to pulses, rather than to steady-state or dc levels.
The pulse output of the output transistor 68 of the pulse generator 28 is also applied through a capacitive coupling to the emitter of a frequency-to-voltage transistor 78. The base of the frequency-to-voltage transistor 78 is connected to the positive potential source 54, and the collector is coupled through an RC filter circuit 81 to the source of common potential 58. The values of the emitter-coupling capacitor 80 and the capacitor in the filter circuit 81 are selected to provide a nearly steady voltage output that is proportional to the frequency of the applied input pulses within the operating frequency range. The time constant of the output fiter circuit 81 determines the speed of response of the analog output.
The pulse output of the pulse generator 28 is also applied to the ramp-generator circuit 26, which includes a pair of transistors 82, 84 connected together in parallel as normal-mode choppers. A ramp capacitor 86 is connected across the pair of transistors 82, 84 between a positive precision reference potential source 91 and a source of current supplied by transistor 88a. During the positive portion of the pulse from the pulse generator 28, the ramp capacitor 86 is charged to a voltage V r , which is equal to the potential of the precision reference source 91. During the negative portion of the pulse-generator pulse, the rampe capacitor 86 is permitted to decay linearly with time as a result of the current supplied by transistor 88a.
The current source for the ramp generator is made up of a pair of transistors 88a, 88b which are connected to a voltage divider 90. The transistor 80a and 88b are coupled and biased so that each branch contributes an equal current flow through the common emitter resistor 92, which is coupled to the negative potential source 50.
In operation, the ramp capacitor 86 is initially charged to the potential of the positive precision reference potential source 91 by the action of switching transistors 82, 84, which are held in conduction by the output of the pulse generator 28 being near the positive potential 58. The reference potential 91, which in the preferred embodiment is +10 volts, is applied to the gate of comparator FET device 42b, which forces that device to conduct less than one half of the current of the supply transistor 52.
More than one half of the supply current is drawn through the other input FET device 42a, which biases the comparator transistor 42a into conduction. The bias of the pulse generator then forces the trigger transistor 60 out of conduction.
When the timing network 94 allows the accelerating transistor 62 to stop conducting, the intermediate-stage transistor 64 and the output-stage transistor 68 are placed in conduction, and the other intermediate-stage transistor 66 and the complementary output transistor 70 are forced out of conduction. The output of the pulse generator 28 then falls to the voltage of the common reference point 58. Switching transistors 82, 84 then stop conducting, and the voltage on the ramp capacitor 86 drops according to the predetermined relationship. The voltage at the gate of the reference FET device 42b thus approaches the voltage which is applied to the gate of the input FET device 42a.
The drain coupling diodes 42, 46 maintain a sufficient voltage differential between the bases of the comparator transistors 48a, 48b to maintain the conduction of transistor 48a when the voltage on the reference gate exceeds the voltage on the input gate. As the voltage at the reference gate approaches the input voltage, the reference FET device 42b begins to conduct more heavily and diverts current from the input FET device 42a. The effect is reflected in the output of comparator transistor 48a which begins to turn off, resulting in a voltage rise at the base of the trigger transistor 60 of the pulse generator 28.
As the trigger transistor 60 begins to conduct, the intermediate-stage transistor 64 and the output-stage transistor 68 are turned "off," and the second intermediate-stage transistor 66 and the complementing output transistor 70 begin to turn "on." Considering the propagation delays, by the time the complementary transistor 70 is turned on, the trigger transistor 60 is saturated in the conducting mode. The output of the output transistor 68 is sent back to a timing network 94 to turn on the accelerating transistor 62 to maintain the intermediate-stage transistor 64 in the nonconducting state.
The output of the intermediate-stage transistor 66 is coupled through a diode 96 to turn off the trigger transistor 60, thereby resetting it for a new pulse. However, the timing network 94 maintains the accelerating transistor 62 in conduction.
The leading edge of the output pulse produced by the output transistors 68, 70 of the pulse generator 28 is applied to the ramp switch transistor 82, 84, turning them on, which reapplies the full 10-volt potential to the ramp capacitor 86. This results in the reapplication of a 10-volt signal to the gate of the reference FET device 42b, thereby increasing the conduction in the input FET device 42a and assuring conduction of transistor 48a. The resulting collector current of transistor 48a then maintains the trigger transistor 60 of the pulse generator out of conduction until once again the reference voltage falls to the value of the input voltage.
At this point, the output pulse has completed its rise and has reached the "flap-top" portion that is maintained until the timing circuit 94 decays sufficiently to turn off the accelerator transistor 62, thereby restoring all of the other circuit elements to their original, quiescent state. As the pulse at the output transistor 68 decays, the falling wave is applied to the base of the accelerating transistor 62 and rapidly discharges the timing network 94 through diode 92 to restore the timing network to its quiescent state in readiness for succeeding pulses, thus making the output pulse duration relatively independent of operating frequency. As the voltage of the ramp capacitor 86 again falls to a value equal to the magnitude of the input signal from the electrometer, a new pulse will be generated and the ramp capacitor will again be reset.
In the preferred embodiment, the apparatus is calibrated by first placing the mode switch 22 in the "zero" position and adjusting the ramp-current-source potentiometer 90 to produce a 5.0-kHz output frequency. This adjustment frequently will compensate for possible errors in the comparator circuit in determining the equality between the input signal and the reference signal. The mode switch 22 is then placed in the "operate" position, and the baseline adjustment 18 is varied to give an output frequency of 5.0 kHz while pure carrier gas is flowing through the electron-capture detector 12. This adjustment establishes the conditions required by Equation (19).
To verify proper operation at the upper frequency end, the electrometer signal can be replaced with a voltage about 5 mV below the voltage of the 10-volt source. For this voltage the output frequency should be 5 MHz for ΔT = 100 ms. Varying this frequency usually necessitates an adjustment of the response characteristics of the pulse-generator circuit 28, which, in this made, would be operating virtually continuously.
Thus, there has been shown an improved frequency-programmed electron-capture detector circuit. The improved circuit provides a signal whose frequency is proportional to the concentration of electron-capturing compounds in the sample under analysis. Moreover, the actual current and/or voltage of the electron-capture detector device and electrometer amplifier is not amplified to provide an analog-type output signal, but rather is used to determine the output frequency. This output signal, in turn, controls the time available for exposure of the sample in the detector to thermalized electrons resulting from radioactive decay.
As will be readily appreciated, higher concentrations of electron-capturing compounds will be subjected to relatively briefer intervals of exposure to the electrons, while low concentrations permit longer exposure intervals. Accordingly, throughout the dynamic range of the apparatus, the number of electrons captured is small compared to the number produced, and thus the capture detector remains in a linear operating region.
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Improved circuitry for increasing the sensitivity of an electron-capture ionization detector includes a closed-loop feedback circuit which varies the frequency of pulses which are applied to the detector. The circuit responds to greater concentrations of predetermined compounds such as gases by increasing the pulse repetition frequency and responds to lower concentrations by decreasing the pulse repetition frequency, always tending to keep the current flowing in the detector circuit near a constant preset value. The pulse frequency will then vary directly with the concentration of sampled compound in the detector, and simple frequency-to-voltage conversion devices can be used to signal such concentrations. .Iadd.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Application Serial No. 60/107,266 filed Nov. 3, 1998.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to the oil field industry. More particularly, the invention relates to hydrocarbon production systems in horizontal wellbores.
2. Prior Art
Horizontally disposed wellbores i.e, wellbores having deviation angles exceeding ±70 have been employed in growing numbers in recent years to access oil reservoirs not previously realistically producible. Where the formation is consolidated, relatively little is different from a vertical wellbore. Where the formation is unconsolidated however, and especially where there is water closely below the oil layer or gas closely above, horizontal wells are much more difficult to produce.
Pressure drop produced at the surface to pull oil out of the formation is at its highest at the heel of the horizontal well. In an unconsolidated well, this causes water coning and early breakthrough at the heel of the horizontal well. Such a breakthrough is a serious impediment to hydrocarbon recovery because once water has broken through at the heel, all production from the horizontal is contaminated in prior art systems. Contaminated oil is either forsaken or separated at the surface. Although separation methods and apparatuses have become very effective they still add expense to the production operation. Contamination always was and still remains undesirable. Zonal isolation has been attempted using external casing packers and open hole packers in conjunction with gravel packing techniques but the isolation of individual zones was not complete using this method and the difficulties inherent in horizontal unconsolidated formation wells have persisted.
Another inherent drawback to unconsolidated horizontal wells is that if there is no mechanism to filter the sand prior to being swept up the production tubing, a large amount of sand is conveyed through the production equipment effectively sand blasting and damaging the same. A consequent problem is that the borehole will continue to become larger as sand is pumped out. Cave-ins are common and over time the sand immediately surrounding the production tubing will plug off and necessitate some kind of remediation. This generally occurs before the well has been significantly depleted.
To overcome this latter problem the art has known to gravel pack the horizontal unconsolidated wells to filter out the sand and support the bore hole. As will be recognized by one of skill in the art, a gravel packing operation generally comprises running a screen in the hole and then pumping gravel therearound in known ways. While the gravel effectively alleviates the latter identified drawbacks, water coning and breakthrough are not alleviated and the horizontal well may still be effectively occluded by a water breakthrough.
Since prior attempts at enhancing productivity in horizontal wellbores have not been entirely successful, the art is still in need of a system capable of reliably and substantially controlling, monitoring and enhancing production from unconsolidated horizontal wellbores.
SUMMARY OF THE INVENTION
The above-identified drawbacks of the prior art are overcome or alleviated by the unconsolidated horizontal zonal isolation and control system of the invention.
The invention teaches a zonally isolated horizontal unconsolidated wellbore where packers are not employed on the outside of the basepipe but a reliable zonal isolation is still created. Zones are created by interspersing blank basepipe with slotted or otherwise “holed” basepipe. The blank pipe is not completely blank but rather includes closeable ports therein at preselected intervals. Screens are employed over these ports and (as conventional) over the slotted basepipe. Upon gravel packing, a near 100% of pack is achieved over the blank pipe section because of the closeable ports. Only about 60% is achievable without the ports. With a full gravel pack of a preselected distance, i.e., the distance of the blank pipe, and the ports closed, isolation is assured with fluid produced for a bad zone being virtually completely prevented from migrating to the next zone. By shutting off production from the undesirable zone, then, through production string seals, only the desired fluid is produced.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic cross section view of an unconsolidated zonal isolation and control system of the invention;
FIG. 1A is a schematic cross section as in FIG. 1, illustrating the washpipe;
FIG. 2 is a schematic cross section view of a horizontal gravel packed zonal isolation system with dehydration ports in a blank pipe section;
FIG. 3 is an enlarged schematic cross section view of a dehydration section from the invention of FIG. 2; and
FIG. 4 is a cross section view of FIG. 3 taken along section line 4 — 4 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In order to most effectively produce from a hydrocarbon reservoir where a horizontal wellbore in an unconsolidated formation is indicated, a gravel pack is ideally constructed. Moreover, the gravel packed area is most desirably zonally isolatable for reasons discussed above. Such zonal isolation preferably is effected by creating unfavorable flow conditions in the gravel pack at selected areas. To complete the system, a number of alternatives are possible: a production string including flow control devices may be run into the hole, each zone being isolated by a locator and a seal; production may commence directly from the base pipe and bridge plugs may be added later to seal certain offending zones; or a straddle packer which extends from blank pipe to blank pipe may be installed on an offending zone. The latter two alternatives are installed conventionally. The various components of the system are illustrated in FIGS. 1 and 1A wherein those of skill in the art will recognize a liner hanger or sand control packer 10 near heel 12 of horizontal wellbore 14 . From liner hanger or packer 10 hangs a production string including flow control device 16 which may be hydraulic, mechanical, electrical, electromechanical, electromagnetic, etc. operated devices such as sliding sleeves and seal assemblies 18 . Seal assembly 18 operates to create selectively controllable zones within the base pipe of a horizontal wellbore 14 . Seal assemblies 18 (in most cases there will be more than one though only one is depicted in FIG. 1) preferably seal against a polished bore in the original gravel packing basepipe 22 which remains in the hole from the previous gravel packing operation. Although the seal assemblies on the inside of the basepipe are effective and controllable, the gravel pack is generally a source of leakage zone to zone as hereinbefore noted. Not visible in FIG. 1 but shown in FIG. 1A for clarity is washpipe 20 which is conventional and known to the art for many years. Additionally, a shifting profile 21 is illustrated in FIG. 1A depending from washpipe 20 . The shifting profile may be of any conventional or unconventional type. Shifting profiles in general are known in the art. Still referring to FIGS. 1 and 1A, one of skill in the art will recognize conventional holes 23 in the base pipe and production string 25 .
In a preferred zonal isolation embodiment of the invention, referring to FIG. 2, one will recognize the open hole wall 50 and the gravel pack 52 . Centered within the packed gravel 52 are several sections of attached pipe. On the left and right sides of the drawing are standard gravel pack zones 54 and 55 which include a slotted or otherwise “holed” base pipe with screen thereover. Between these zones 54 is an elongated section of essentially blank pipe 56 . The blank pipe does, however, have what is referred to herein as a dehydration zone which comprises short sections of screen 58 over at least one, preferably several, closeable port(s). The ports enable full packing of gravel around the blank pipe 56 . Without the dehydration ports, only about 60% of the annular region surrounding a blank pipe will be packed. Since this provides a 40% open annulus, zonal isolation would be impossible. With a full pack (about 100%), very good zonal isolation is achieved. The isolation between zones is created by the length of blank pipe. Whatever that length be, undesired fluid would have to travel through the gravel pack in the annulus in order to get to a producing zone once the production pipe has shut off the offending zone. For example, if water had been produced from zone 55 but not from zone 54 the answer would be to shut off zone 55 from production in some conventional way and continue to produce from zone 54 . Although it is possible to move fluids from zone 55 to zone 54 through the pack 52 , it requires a tremendous pressure differential to move any significant volume of fluid. Tests have indicated that at 1500 psi of differential pressure and 40 feet of gravel packed annulus, only 0.6 barrels of the unwanted fluid will migrate to the producing zone through the gravel pack per day. Since in reality it is unlikely that more than 200-300 psi of differential pressure could exist between the zones, the leakage is so small as to be negligible.
As stated above, gravel packing blank pipe is generally an unsuccessful venture. This is because there is no leak-off of the gravel carrier fluid. When there is no leak-off, the velocity of the fluid stays high and the gravel is carried along rather than deposited. Thus, with respect at least to the P wave of the gravel packing operation, very little sand or gravel is deposited in the annulus of the blank pipe. To slow the gravel carrier fluid down, leak-off must occur. With slower fluid, gravel deposition occurs and the desired result is obtained.
The purpose of the blank pipe is zonal isolation. If there can be leak-off in the blank pipe, the zones will be not be isolated. The inventor of the present invention solved the problem by supplying the temporary leak-off paths introduced above as dehydration zones. Referring to FIG. 3, one of the dehydration zones is illustrated in an enlarged format to provide an understanding thereof to one of ordinary skill in the art. The screen 58 is an ordinary gravel pack screen employed as they are conventionally i.e. wrapped around a length of pipe to screen out particles. Under the screen is the essentially blank pipe 56 but which includes one of preferably several ports 60 which operate identically to a selected base pipe in a conventional gravel pack assembly while the ports 60 are open. Ports 60 allow for leak-off and therefore cause gravel to deposit.
When the gravel packing operation is complete and the otherwise conventional washpipe is withdrawn, a profile on the end thereof (not shown but any type of shifting profile is acceptable) is pulled past closing sleeve 62 to close the same. The sleeve 62 completely shuts off port 60 with the sleeve and it seals 64 and is not permitted to open again because of any number of conventional locking mechanisms such as dogs, collet, lock ring, etc. existing preferably at 66 . The locking arrangement is needed only to prevent accidental opening of the closing sleeve 62 after it has been closed. Once the closing sleeve 62 is closed, the pipe 56 is indeed completely blank pipe and is a zonal isolator.
Preferably the screen 58 is about one foot in length. Ports 60 may be distributed in many different patterns thereunder with as many ports as desired. One preferred embodiment employs four one quarter inch holes radially arranged about the circumference of the pipe. With respect to the blank pipe section length between the dehydration zones, a range of about five feet to about ten feet is preferred.
Since the provision of different zones and flow control devices in the invention allow the metering of the pressure drop in the individual zones, the operator can control the zones to both uniformly distribute the pressure drop available to avoid premature breakthrough while producing at a high rate. Moreover, the operator can shut down particular zones where there is a breakthrough while preserving the other zones' production.
After construction of one of the assemblies above described, and the washpipe has been removed, a production string is installed having preferably a plurality of the seal assemblies with at least one tool stop mechanism to locate the seal assemblies at points where the basepipe is smooth and the inner diameter is not reduced. Location may also be assured based upon the liner hanger. The seal assemblies allow different zones to be created and maintained so that selective conditions may be generated in discrete zones.
In an alternative embodiment of the dehydration ports, the closing sleeve 62 is not locked and remains operable so that if needed, individual closing sleeves may be opened. This alternative embodiment provides the invention with even more utility in that it allows the well operator to contaminate selected sections of the gravel pack to even more strongly hamper the ability of fluid to move longitudinally through the gravel pack. More specifically, the sleeve 62 would be opened by a shifting tool and an injection tool (one of many known to the art) would be used to apply a contamination fluid through the open port 60 . The contamination fluid could be cement, drilling mud, epoxy, etc. and once injected into the gravel pack through the port it would fill all interstitial spaces in the pack making it even more impermeable.
While preferred embodiments have been shown and described, various modifications and substitutions may be made thereto without departing from the spirit and scope of the invention. Accordingly, it is to be understood that the present invention has been described by way of illustration and not limitation.
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A system for enhancing oil production and reducing contamination thereof by such things as water breakthrough in unconsolidated horizontal wells comprises gravel packing, zonal isolation and selective flow control in combination. The significant control provided by the system enables the well operator to create a uniform pressure drop form heel to toe of the horizontal well and avoid commonly experienced water coning and early breakthrough at the heel of the horizontal borehole.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a novel fiber, high airtightness fabrics and a fabricating method, more particularly a fabricating method for a tetragon fiber and fabrics made of the tetragon fiber. The present invention provides high airtightness fabrics by compact arrangement of the tetragon fibers.
[0003] 2. Description of the Related Art
[0004] High airtightness fabrics have been used extensively in clothing-related products such as waterproof, windproof, and warmth-retention fabrics. Industrial applications of high airtightness fabrics include the leisure articles, packing materials, shoes materials, conveying belts, automobile airbags and other textile products. In general, the fibers used in air-tight fabrics must be able to yield high degrees of compaction and thus low interstices among the fibers to lower the air permeability.
[0005] Conventional man-made fibers typically have round cross sections. These round fibers stack up with a high degree of interstices among the fibers, which leads to high air permeability. In order to fabricate a high airtightness fabric, the inter-fiber spaces must be reduced or minimized. The prior art uses resin coating to seal or weaving with high shrinkage fibers to reduce the inter-fiber spaces. Nevertheless, resin coating may cause environmental problems and, in addition, induce higher production costs. On the other hand, fabrics with high shrinkage fibers may encounter a difficulty of controlling the final fabric density or basis weight after shrinking processing. Moreover, high shrinkage fibers in general do not have sufficient tensile strength for industrial applications.
[0006] One of the industrial applications which imposes stringent requirements on airtightness of the fabric is the automobile airbag. The airbag fabric must have low air permeability, in addition to dimensional stability and durability, to ensure high performance on instant inflation of the airbag in action. Commercial products generally have air permeability less than 1.0 cc/cm 2 ·sec. The desired air permeability is as low as possible.
[0007] In order to achieve the lowest air permeability possible, the fibers should be designed to provide lowest degree of inter-fiber spaces. Tetragon fibers, preferably square fibers, are most desirable for this purpose. The prior arts JP2002-129444 and JP2003-183945, both are Japanese patents, disclose a flat fiber and airtight fabrics made of this fiber. However, the flat fibers have relatively low tensile strength. Furthermore, it is necessary but difficult to control the fiber orientation during the weaving process.
[0008] In order to improve the prior art of high airtight fabrics, it is worth to develop a fabrication method of high airtight fabrics with low-cost and mild pollution.
SUMMARY OF THE INVENTION
[0009] As the descriptions above, the prior technology of fabricating airtight fabrics usually adopts resin coating and have environmental pollution problems. The present invention provides a method for fabricating tetragon fibers. The main purpose of the invention is to achieve ultrahigh airtightness in fabrics by altering the cross section of the fiber to tetragonal shape and compacting the stacking of the tetragon fibers in fabrics. A fiber of tetragonal cross section may be partially oriented yam (POY), fully oriented yam (FOY) or spin draw yam (SDY).
[0010] By the nature of the tetragon cross section, the fibers can be arranged with minimal interstices in the fabricated fabrics to achieve the objective of high airtightness. Futhermore, the production is straightforward, using no polluting coating and therefore potentially low-cost as compared to the prior arts.
[0011] Another objective of the present invention is to provide a fabric made of the tetragonal fiber that may be used in the production of airbag, safety belt, tent, and other industrial products requiring high airtightness or fabric density.
[0012] To achieve the objectives aforesaid, the present invention provides a method for fabricating tetragon fibers, comprising the steps of melting a thermoplastic polymer; extruding the molten polymer from a special contoured nozzle which yields the tetragonal cross section in the molten polymer threads; passing the molten polymer threads through a modified quenching zone, in which the cooling air blocking section is reduced at the upper part of the quenching zone; solidifying the molten polymer threads to form solid polymer threads; and finally, rolling up and stretching the polymer threads to form fibers with a tetragonal cross section. Preferably the length of the shortened air-blocked zone is within 0.1-15 cm; the ratio of the long to the short side of the tetragonal cross-section is in the range of 1.0-2.0.
[0013] The tetragon fiber provided by the present invention is produced by the method aforementioned. The cross section of the tetragon fiber is preferably a rectangle, and most preferably a square. The tetragon fiber of the present invention may be a non-hollow tetragon fiber or a hollow tetragon fiber, preferably the non-hollow tetragon fiber.
[0014] The fiber material is a thermoplastic polymer, copolymer or mixture thereof. The thermoplastic polymer includes, but is not limited to polyamide resin, polyester or polyolefin; the preferred polyamide resin is the nylon family, e.g. Nylon 6, Nylon 11, Nylon 12, Nylon 46, Nylon 66, Nylon 610, and Nylon 612, etc. Other examples of polyamide resin suitable for the present invention are described in pp. 19-20 of J. Gordon Cook's Handbook of Textile Fibres, 5th edition, Trowbridge GB (1984). The relative viscosity of the polyamide resin used for fabricating the fiber of the present invention is preferably in the range of 30-150 (tested with 90% HCOOH at a concentration of 1.0 g/dl and 25° C.). The polyester used by the present invention includes but is not limited to polyethylene terephthalate (PET), polytrimethylene terephthalate (PTT) or polybutylene terephthalate (PBT). The polyolefin used by the present invention includes but not limited to polyethyelene (PE) and polypropylene (PP).
[0015] The present invention further provides a fabric made of the aforementioned tetragon fiber, in which the warp and the weft fibers may be consisted of monofilament or multifilament fibers.
[0016] The present invention presents a novel method of producing a tetragonal non-hollow fiber by the design of a special contour-shaped nozzle hole and the design of a shortened air-blocked zone in the spinning duct. The shape of the fiber thereof differs from the round or elliptical shape of traditional fibers. The fiber with a tetragon cross section of the present invention yields a denser fabric construct than traditional fibers with round cross sections in the weaving process; hence the airtightness and thus the windproof performance of the fabrics increase. In summary, the tetragon fiber, fabrics thereof and the manufacturing method of the present invention present a new technology of making airtight fabrics to reach a performance level which has not been achieved before by noncoated fabrics. These high performance airtight fabrics are suitable for many apparel and industrial applications.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 illustrates the modified quenching zone with a shortened air-blocked section of the spinning apparatus of the present invention as compared to the prior art.
[0018] FIG. 2 exhibits the cross section of fibers fabricated according to Example 1 of the present invention.
[0019] FIG. 3 shows the comparison of the cross section views of Example 1 in the present invention (a) and the traditional round fiber (b).
[0020] FIG. 4 shows the stacking-up cross section of Example 1 in the present invention (a), and the cross section of traditional round fibers (b).
DETAILED DESCRIPTION OF THE INVENTION
[0021] The present invention is described as follows. The diagrams accompanying the descriptions below are not presented in actual proportion; they are used only for illustration of the equipment setup of the present invention.
[0022] The present invention relates to a special tetragon fiber and a high airtightness fabric made by the fiber. The airtight fabric may be used in applications requiring low air permeability such as automobile airbags and others. The fiber of the present invention is produced by melting a thermoplastic polymer to form a molten polymer, which is extruded from special contoured nozzles and passed through a shortened air-blocked section in the air quenching zone for accelerated solidification of the filaments. The spinning conditions are controlled to maintain the tetragonal shape in the spinning line.
[0023] The spinning apparatus, which only shows the portion corresponding to the description in the specification, is shown in FIG. 1 . More specifically, FIG. 1 ( a ) illustrates the design of the shortened air-blocked section in the air quenching zone in the present invention; FIG. 1 ( b ) displays the corresponding design of the air quenching zone in a traditional setup. Referring to FIG. 1 ( a ), the method of fabricating the tetragon fiber of the present invention comprises the steps of: heating and melting a thermoplastic polymer; extruding the molten polymer from the special contour-shape nozzle; passing it through an air-blocked zone in the form of molten filaments; cooling and solidifying the molten filaments in the air quenching zone to form solid filaments; finally, drawing the filaments to form fibers of the desired tetragon cross section and winding up on a winder.
[0024] The cross section of the tetragon fiber preferably has a rectangular shape, and more preferably a square shape. The shape of the nozzle hole is determined by the shape of the target fiber. More precisely, the tetragon fiber is made with a nozzle of contoured tetragon holes; similarly, the square fiber is extruded through a nozzle of contoured square holes. The molten polymer, after leaving the nozzle, swells to the desired tetragonal or square shape with proper control of spinning conditions.
[0025] Another important feature of the present invention which renders easier control of the fiber cross section is the shortened air-blocked section in the air quenching zone to accelerate cooling which leads to the fixation of the desired cross section in the molten filaments. In this apparatus, the molten polymer, after being extruded from the nozzle, enters the air quenching zone more quickly than in conventional spinning apparatus as a result of the reduced length of the air-blocked zone. Preferably the length of the air-blocked zone is set at 0.1-15 cm, and more preferably 0.1-5 cm. The length of the traditional air-blocked zone is approximately 20-30 cm, as shown in FIG. 1 ( b ).
[0026] The method for preparing the airtightness fiber of the invention comprises the following steps. First, heat and melt the fiber material. The nozzle temperature, which varies with the fiber material, is generally set in the range of 180-320° C., above the melting point of the fiber material. For example, the nozzle temperature for preparing the polyamide 66 fiber is set at 285-300° C. Second, the melted fiber material extruded from the nozzle is cooled and solidified quickly to form solid filaments in the air quenching zone. Cooling and solidifying is conducted by blowing cold air of 15-23° C. and application of finish oil to consolidate the filament bundle. The cooling air speed is 0.1-1.5 m/sec, and more preferably 0.5-1.0 m/sec. The solidified filaments are subsequently winded up or further drawn in a heated roller set to achieve desired fiber properties before being winded up.
[0027] The spun fiber may be subjected to texturing processes such as false twisting, air texturing or others to enhance the bulkiness of the fiber and fabrics. It should be noted that the cross section of the fiber must be maintained throughout the process of drawing or texturing. The tetragon fiber produced by the aforementioned process may have. the ratio of the long side vs. the short side of tetragon cross-section is preferably between 1.0 and 2.0.
[0028] The fibers produced by the aforementioned process are used to construct fabrics by weaving. The fabrics comprise weft and warp yarns of 10-500 threads/inch. In general the tetragon fibers herein can be used to produce all kinds of fabrics, but not limited to woven, knitted, and non-woven structures. The fabrication methods for the fabrics are known to all skilled textile professionals and are not otherwise specified or described.
[0029] By the nature of tetragon cross section, fibers can be arranged and stacked in a very compact format, which leads to high airtightness in the fabrics. The fabrics can be applied in windproof and thermal wears, shoe material, tent, conveying belt, and air bag, etc.
[0030] The present invention is further illustrated in the following Examples; however, the Examples should not be construed as a limitation of the present invention. Professionals familiar with the skill in the art are able to make various modifications and alterations without departing from the spirit and the scope of the present invention.
EXAMPLES
Example 1
Fabrication of Square Fibers Used for the Production of High Airtightness Fabrics
[0031] With the method of the present invention, Nylon 66 chips of RV 100 is charged into an extruder, heated and melted at 290° C. and extruded, at a rate of 72 g/min, from a special contoured nozzle to form molten polymer threads of tetragonal cross section; The molten filaments are passed through an air-cooling zone, in which air is blocked for a length of 5 cm at the upper part of the zone; a quenching air of 0.7 m/sec is blown at the rest of the cooling zone. The molten filaments are solidified and sprayed with finish oil to achieve a dynamic coefficient of friction of 0.35 (F/Uμd) at the location of 150 cm below the exit of the spinning nozzle. The solidified tetragon filaments are fed into a heated roller set and drawn at a ratio of 5.0. The winding tension of the filaments is controlled around 0.15 g/d, and the winding speed is set at 3200 m/min. The fiber obtained has a tenacity of 8.3 g/denier and a breaking elongation of 19%. The cross section of the fiber is as shown in FIG. 2 .
[0032] FIG. 3 ( a ) is a sketch of the perfectly stacked squares, while FIG. 3 ( b ) is a sketch of the perfectly stacked spheres. The higher packing density of the squares is the logic behind the present invention. FIG. 4 ( a ) and ( b ) show the scanning electron micrographs of the physical fibers of square and round cross section. By comparing FIG. 3 and FIG. 4 , it is found that the fabric produced by the fibers of the present invention comprise less gap among square cross sections, which leads to higher fabric density and lower permeability. The fabric produced by the cross sections of traditional round fibers, on the contrary, contains more interstitial spaces.
Example 2
Preparation of High Airtightness Fabric with the Fibers of Present Invention
[0033] The square fiber obtained in Example 1 is used to produce woven fabrics to investigate its effect on air permeability. Two weaving densities have been adopted in the construction of the fabrics: 49 and 55 threads/inch for both the warp and the weft directions. The first part of the experiments uses the square fiber to investigate the effect of the square fiber on air permeability as the weft yarn only. The second part of the experiments employs the square fiber in both the weft and the warp directions to fully exploit the effect of the square fiber on airtightness. In construction of the first part, Du Pont's T725 420d /68f M1V297 industrial yarn, which is of round cross section, is used for the warp; the square fiber obtained in Example 1 and Du Pont's round fiber, same as the warp, are used for the weft. The content of the fibers in the fabrics is therefore roughly 50% round fiber and 50% square fiber. The air permeability data are shown in Table 1. For the 65*49*49 construction, the fabric with the square fiber as the weft yarn has a permeability of 0.335 cc/cm 2 ·sec, which is 57% lower than the 0.782 cc/cm 2 ·sec of the control sample with all round fibers. For the denser 65*55*55 construction, the fabric with the square fiber as the weft yarn has a permeability of 0.117 cc/cm 2 ·sec, which is 45% lower than the 0.213 cc/cm 2 ·sec of the controlled sample with 100% round fibers.
[0034] In the second part of the experiments, both the warp and the weft yarns employ the square fiber. The air permeability is further decreased to 0.168 and 0.057 cc/cm 2 ·sec for the 65*49*49 and 65*55*55 constructions, respectively. The data are shown in Table 1.
[0035] In the production of the above fabrics, the weaving tension is controlled to be 95 and 100 kg for the 65*49*49 and 65*55*55 constructions, respectively. The woven fabrics are subsequently heat-set at 185° C. at a conveyor speed of 30 m/min.
TABLE 1 Comparison of the air permeability of the fabrics constructed with the square and the round fiber Woven fabric Width (inch)* warp density Air (threads/inch)* weft density Warp Weft permeability Difference (threads/inch) (420d/68f) (420d/68f) (cc/cm 2· sec) (%) 65*49*49 Dupont Dupont 0.782 — (round fiber) (round fiber) Dupont ITRI 0.335 57.2 (round fiber) (square fiber) ITRI ITRI 0.168 78.5 (square fiber) (square fiber) 65*55*55 Dupont Dupont 0.213 — (round fiber) (round fiber) Dupont ITRI 0.117 45.1 (round fiber) (square fiber) ITRI ITRI 0.057 73.2 (square fiber) (square fiber)
[0036] In summary, the fibers disclosed in the present invention have a tetragonal cross section and the woven fabrics made thereof exhibit higher air permeability than the fabrics with conventional round fibers. As a comparison, the fiber in the prior art JP2002129444 may also be used to produce airtight fabrics; however, the strength uniformity of the fabrics is not adequate due to the difficulty of the tension control in the weaving process. In the prior art JP2003183945, airtight fabrics are fabricated by coating the fabrics with resin. Coating uses chemicals which generally cause environmental pollution; furthermore, resin coating may peel off in use and involve higher production cost. On the contrary, the tetragon fiber, and in particular the square fiber, of the present invention employs the physical principle of compact stacking of the special cross section.
[0000] Other Embodiments
[0037] The preferred embodiments of the present invention have been disclosed in the Examples. However the Examples should not be construed as a limitation on the actual applicable scope of the invention, and as such, all modifications and alterations without departing from the spirits of the invention and appended Claims shall remain within the protected scope and Claims of the invention.
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The present invention provides a new tetragon fiber and a method for fabricating the same. The present invention includes: heating a thermoplastic material, extruding it from a tetragon-shaped nozzle, passing it through an airless zone, then cooling and solidifying to form threadlike substances, rolling up then processing the threadlike substances to form fibers with tetragon cross sections. The fabrics of present invention comprises a property of fine air-tightness.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a vibration wave driving apparatus such as a vibration wave motor using a vibration, which an elastic member is caused to generate, as a driving force and, more specifically, to a structure of an electro-mechanical energy conversion element for causing the elastic member to generate a vibration.
2. Related Background Art
FIG. 13 is a sectional view of a vibration wave motor.
In the figure, reference numeral 40 denotes a vibration member, which is constituted of an elastic member 10 made of metal or the like, a piezoelectric element 20 functioning as an electro-mechanical energy conversion element and a frictional member 30 . The piezoelectric element 20 is fixed to one side of the elastic member 10 and the frictional member 30 is fixed to the other side.
The vibration member 40 is fixed to a housing 50 and a case 110 is fixed to the housing 50 . Bearings 120 a and 120 b are fixed to the case 110 and the housing 50 . The bearings 120 a and 120 b rotatably support a rotary shaft 100 .
A rotor 60 having the rotary shaft 100 as a center is pressurized to contact the frictional member 30 of the vibration member 40 . The rotor 60 is pressurized toward the vibration member 40 by a pressurizing mechanism 90 consisting of a pressurizing spring 70 and a spring bracket 80 . The spring bracket 80 is fixed to the rotary shaft 100 and the rotor 60 , the pressurizing spring 70 , the spring bracket 80 and the rotary shaft 100 integrally rotate.
The piezoelectric element 20 used for a vibration wave motor of a shape shown in FIG. 13 has a structure in which electrode films are provided on both sides of one piezoelectric ceramic of a circular plate shape. It is assumed that the electrode provided on one side is an electrode for applying a voltage from a power feeding substrate and the electrode provided on the other side is an electrode for ground. When an alternating voltage is applied to the piezoelectric element 20 , standing wave vibrations of different phases A and B are composited to generate a travelling wave on the surface of the elastic member 10 .
FIG. 14A shows an example of a conventional electrode pattern for inputting an alternating voltage. Given that a wavelength of a travelling wave is λ, a plurality of electrodes for the A phase that are alternately polarized in opposite directions at a λ/2 pitch in their thickness direction and a plurality of electrodes for the B phase that are λ/4 apart from the electrodes for the A phase and are alternately polarized in opposite directions at a λ/2 pitch in their thickness direction are formed. FIG. 14B shows an example of an electrode pattern for ground, in which a circular electrode along a shape of a piezoelectric element is formed.
In the electrode pattern shown in FIG. 14A , the electrodes for the A phase are formed on one side of the circle and the electrodes for the B phase are formed on the other side. A vibration generated in the electrodes for the A phase has a smaller amplitude as the vibration travels farther from the electrodes. A vibration generated in the electrodes for the B phase has a smaller amplitude as the vibration travels farther from the electrodes.
This state is shown in FIGS. 15A to 15 C. In the figures, the horizontal axis indicates a distance in a peripheral direction of the piezoelectric element and the vertical axis indicates a magnitude of a vibration amplitude. FIG. 15A shows a standing wave vibration generated in the electrodes for the A phase in its left half and shows a standing wave vibration generated in the electrodes for the B phase in its right half.
FIG. 15C shows a vibration amplitude of a travelling wave in which an A phase standing wave and a B phase standing wave are composited. Since the amplitude of the travelling wave is nonuniform in the peripheral direction, loci of rotational movements generated on the surface of the elastic member 10 are different as shown in FIG. 15 B.
When there is unevenness in the vibration amplitude generated by the piezoelectric element as described above, since slipping occurs between the frictional member 30 of the elastic member 40 and the rotor 60 , vibration energy cannot be used efficiently as driving energy. Therefore, unevenness in the vibration amplitude is not preferable.
There might be other factors that cause unevenness in the vibration amplitude generated by the piezoelectric element. Polarization processing of the piezoelectric element is performed by applying a voltage to the parts between the electrode patterns formed on both the sides of the piezoelectric element. Since an electric field at this point does not act on non-electrode portions as shown in FIG. 16 , if the electrode patterns on both the sides of the piezoelectric element are different, a direction of an electric field applied to the parts between the electrode patterns becomes nonuniform and unevenness also occurs in a polarization direction. If unevenness exists in the polarization direction, since an elastic modulus of the piezoelectric element varies, unevenness also occurs in a vibration generated when a vibration wave driving apparatus is driven.
Therefore, in order to raise driving efficiency of the vibration wave driving apparatus, it is considered that there is still room for improvement.
SUMMARY OF THE INVENTION
The present invention has been devised in view of the above-mentioned drawbacks. It is an object of the present invention to provide a vibration member of a vibration wave driving apparatus including a vibration member constituted of an elastic member and an electro-mechanical energy conversion element; and a rotor contacting the vibration member. The vibration member generates a traveling wave in the elastic member when an alternating signal is applied to the electro-mechanical energy conversion element, in which an electrode film provided on a surface of the electro-mechanical energy conversion element of the vibration member is divided into a plurality of circular areas with different radiuses and each circular area is divided into a plurality of electrodes along its peripheral direction.
It is another object of the present invention to provide a vibration member of a vibration wave driving apparatus including a vibration member constituted of an elastic member and an electro-mechanical energy conversion element; and a rotor contacting the vibration member. The vibration member generates a traveling wave in the elastic member when an alternating signal is applied to the electro-mechanical energy conversion element, in which electrodes provided on opposing both sides of the electro-mechanical energy conversion element of the vibration member are formed in an identical shape and arranged in an identical phase.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of an elastic member and a piezoelectric element in accordance with the present invention.
FIG. 2 is a view showing an electrode pattern formed in a plurality of circular areas with different radiuses on a front surface of a piezoelectric element.
FIG. 3 is a view showing an electrode film for applying an alternating voltage to the piezoelectric element shown in FIG. 2 .
FIG. 4 is a view showing a positional relationship of electrodes in the electrode pattern shown in FIG. 2 .
FIGS. 5A , 5 B, 5 C and 5 D are views showing amplitudes of vibrations generated in the piezoelectric element shown in FIG. 2 .
FIG. 6 is a view showing an electrode pattern formed in a plurality of circular areas with different radiuses on a front surface of a piezoelectric element.
FIG. 7 is a view showing an electrode pattern formed in a plurality of circular areas with different radiuses on a front surface of a piezoelectric element.
FIG. 8 is a view showing an electrode pattern formed in a plurality of circular areas with different radiuses on a front surface of a piezoelectric element.
FIG. 9 is a view showing an electrode pattern formed in a plurality of circular areas with different radiuses on a front surface of a piezoelectric element.
FIGS. 10A and 10B are views showing electrode patterns that are formed on both sides of a piezoelectric element in an identical shape and an identical phase.
FIGS. 11A and 11B are views showing electrode patterns that are formed on both sides of a piezoelectric element in an identical shape and an identical phase.
FIG. 12 is a view showing a direction of an electric field at the time of polarization of the piezoelectric element of FIGS. 10A , 10 B, 11 A and 11 B.
FIG. 13 is a sectional view of a vibration wave motor.
FIGS. 14A and 14B are views showing electrode patterns on both sides of a conventional piezoelectric element.
FIGS. 15A , 15 B and 15 C are views showing amplitudes of vibrations generated in the piezoelectric element of FIGS. 14A and 14B .
FIG. 16 is a view showing a direction of an electric field at the time of polarization of the conventional piezoelectric element.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention is for raising a driving efficiency of a vibration wave driving apparatus by improving an electrode pattern of a piezoelectric element that is fixed to a vibration member 40 of the vibration wave driving apparatus.
FIG. 1 shows a vibration member in accordance with an embodiment of the present invention.
In the figure, reference numeral 10 denotes an elastic member, which is the same as a conventional elastic member. Reference numeral 21 denotes a piezoelectric element, which is different from the conventional piezoelectric element 20 in an electrode pattern for applying an alternating voltage when the vibration wave driving apparatus is driven.
FIG. 2 shows a plan view of the piezoelectric element 21 . One side of the piezoelectric element 21 is divided into two circles with different radiuses. In each circle, positive electrodes (+) and negative electrodes (−) are formed which are polarized while being alternately reversed in their thickness direction. In FIG. 2 , electrodes 201 to 206 on the left outer circumference side and electrodes 207 to 212 on the right inner circumference side form a first electrode group, and electrodes 301 to 306 on the right outer circumference side and electrodes 307 to 312 on the left inner circumference side form a second electrode group. Electrodes shown in FIG. 3 are formed on the piezoelectric element 21 . An alternating voltage is applied to the first electrode group from an electrode 22 A and an alternating voltage, whose phase is shifted by 90 degrees from the alternating voltage applied from the electrode 22 A, is applied to the second electrode group from an electrode 22 B. Wavelengths and amplitudes of these alternating voltages are equal. When these alternating voltages are applied, a fifth order standing wave vibration is generated in the first electrode group and the second electrode group. The electrodes 22 A and 22 B are formed on one side of the piezoelectric element 21 by, for example, screen printing and evaporation.
FIG. 4 is a view showing a size and a positional relationship of the electrodes. The electrodes 202 to 205 , the electrodes 208 to 211 , the electrodes 302 to 305 and the electrodes 308 to 311 have a size that is ½ of a wavelength λ of the above-described standing wave in the peripheral direction of the piezoelectric element 21 . In addition, positions of the electrodes on the outer circumference side and positions of the electrodes on the inner circumference side deviate from each other in the peripheral direction by λ/4. However, in each electrode group, respective pairs of the electrodes 206 and 207 , the electrodes 306 and 307 , the electrodes 212 and 201 and the electrodes 312 and 301 , which are in positions where the inner circumference side and the outer circumference side change places, have the size of λ/2. Further, in order to equalize an area of the electrodes on the outer circumference side with an area of the electrodes on the inner circumference side, the electrodes are formed such that the electrodes located on the inner circumference side has a larger width in the radius direction of the piezoelectric element.
Consequently, areas of the electrodes 202 to 205 , the electrodes 208 to 211 , the electrodes 302 to 305 and the electrodes 308 to 311 are equalized with each other. In addition, a total area of the electrodes 201 and 212 , a total area of the electrodes 206 and 207 , a total area of the electrodes 301 and 312 and a total area of the electrodes 306 and 307 are also equalized with each other. That is, the total areas of the first electrode group and the second electrode group are equal, and each electrode group can form an electrode having an equal area over the entire circumference.
FIGS. 5A to 5 D show standing wave vibrations generated in the first and second electrode groups and a composited vibration of these standing wave vibrations. In the figure, the horizontal axis indicates a position in the peripheral direction of the piezoelectric element 21 .
FIG. 5C shows an A phase standing wave vibration generated by the first electrode group and FIG. 5D shows a B phase standing wave vibration generated by the second electrode group. As described above, alternating voltages of an identical wavelength and an identical amplitude, whose phases are shifted by 90 degrees from each other, are applied to the first electrode group and the second electrode group, and the first electrode group and the second electrode group are arranged to deviate from each other in the peripheral direction by λ/4. When these standing wave vibrations are composited, a traveling wave vibration shown in FIG. 5B is obtained. This traveling wave vibration has a uniform wavelength and a uniform amplitude over the entire circumference of the piezoelectric element 21 and, as shown in FIG. 5A , loci of rotational movements generated on the surface of the elastic member 10 are uniform. Thus, slipping does not occur between the frictional member 30 of the elastic member 40 and the rotor 60 , and vibration energy can be efficiently utilized as driving energy. Therefore, a driving force is increased and, moreover, generation of noise due to unevenness of vibrations and deviated wear of a frictional member can be prevented.
FIG. 6 shows a plan view of a piezoelectric element 22 that generates a third order standing wave vibration. Sixteen electrodes are formed on one side of the piezoelectric element 22 . The one side of the piezoelectric element 22 is divided into two circles with different radiuses. In each circle, positive electrodes (+) and negative electrodes (−) are formed which are polarized while being alternately reversed in their thickness direction. In FIG. 6 , electrodes 400 to 403 on the left outer circumference side and electrodes 404 to 407 on the right inner circumference side form a first electrode group, and electrodes 500 to 503 on the right outer circumference side and electrodes 504 to 507 on the left inner circumference side form a second electrode group.
Then, when alternating voltages of an identical wavelength and an identical amplitude, whose phases are shifted by 90 degrees from each other, are applied to the first electrode group and the second electrode group, two types of third order standing wave vibrations are generated in the piezoelectric element 22 . These two standing wave vibrations are composited to generate a traveling wave vibration on a surface of an elastic member.
The electrodes 401 , 402 , 405 and 406 and the electrodes 501 , 502 , 505 and 506 have a size that is ½ of a wavelength λ of the above-described standing wave in the peripheral direction of the piezoelectric element 22 . In addition, positions of the electrodes on the outer circumference side and positions of the electrodes on the inner circumference side deviate from each other in the peripheral direction by λ/4. However, in each electrode group, respective pairs of the electrodes 403 and 404 , the electrodes 503 and 504 , the electrodes 407 and 400 and the electrodes 507 and 500 , which are in positions where the inner circumference side and the outer circumference side change places, have the size of λ/2. Further, in order to equalize an area of the electrodes on the outer circumference side with an area of the electrodes on the inner circumference side, the electrodes are formed such that the electrodes located on the inner circumference side have a larger width in the radius direction of the piezoelectric element.
Consequently, areas of the electrodes 401 and 402 , the electrodes 501 and 502 , the electrodes 405 and 406 and the electrodes 505 and 506 are equalized with each other. In addition, a total area of the electrodes 403 and 404 , a total area of the electrodes 503 and 504 , a total area of the electrodes 407 and 400 and a total area of the electrodes 507 and 500 are also equalized with each other. That is, the total areas of the first electrode group and the second electrode group are equal, and each electrode group can form an electrode having an equal area laterally.
As a result, a traveling wave vibration generated on the surface of the elastic member 10 has a uniform wavelength and a uniform amplitude over the entire circumference of the piezoelectric element 22 and loci of rotational movements are uniform.
FIG. 7 shows another embodiment of the present invention.
A piezoelectric element 23 shown in FIG. 7 has an electrode pattern on one side that is different from that of the piezoelectric element 21 shown in FIG. 2 .
One side of the piezoelectric element 23 is also divided into two circles with different radiuses. In each circle, positive electrodes (+) and negative electrodes (−) are formed which are polarized while being alternately reversed in their thickness direction. However, the piezoelectric element 23 is different from the piezoelectric element 21 in that a first electrode group for generating an A phase standing wave vibration is arranged only on its outer circumference side and a second electrode group for generating a B phase standing wave vibration is arranged only on its inner circumference side.
Each electrode has a size that is ½ of a wavelength λ of a standing wave vibration it generates in the peripheral direction. In addition, a phase of the electrodes on the outer circumference side and a phase of the electrodes on the inner circumference side deviate from each other by λ/4. Moreover, in order to equalize an area of the electrodes on the outer circumference side with an area of the electrodes on the inner circumference side, the electrodes are formed such that the electrodes located on the inner circumference side have a larger width in the radius direction of the piezoelectric element compared with the electrodes located on the outer circumference side.
Then, when alternating voltages of an identical wavelength and an identical amplitude, whose phases are shifted by 90 degrees from each other, are applied to the first electrode group and the second electrode group, a traveling wave vibration is generated in the piezoelectric element 23 . Also, in this piezoelectric element 23 , this traveling wave vibration has a uniform wavelength and a uniform amplitude over the entire circumference of the piezoelectric element 23 and loci of rotational movements generated on the surface of the elastic member 10 are uniform.
FIG. 8 shows yet another embodiment of the present invention.
A piezoelectric element 24 shown in FIG. 8 has an electrode pattern on one side that is different from those of the piezoelectric elements 21 and 23 shown in FIGS. 2 and 7 . Twenty-two electrodes are formed on the one side of the piezoelectric element 24 .
The one side of the piezoelectric element 24 is also divided into two circles with different radiuses. In each circle, positive electrodes (+) and negative electrodes (−) are formed which are polarized while being alternately reversed in their thickness direction. In FIG. 8 , electrodes 600 to 604 on the upper outer circumference side and electrodes 610 to 615 on the lower inner circumference side form a first electrode group, and electrodes 700 to 705 on the lower outer circumference side and electrodes 710 to 714 on the upper inner circumference side form a second electrode group. When alternating voltages of an identical wavelength and an identical amplitude, whose phases are shifted by 90 degrees from each other, are applied to the first electrode group and the second electrode group, a fifth order standing wave vibration is generated in each of the first electrode group and the second electrode group.
The piezoelectric element 24 is different from the piezoelectric elements 21 and 23 in that positions where an inner circumference side and an outer circumference side on which the electrodes of each electrode group are formed change places (a position between the electrodes 600 and 700 , a position between the electrodes 610 and 710 , a position between the electrodes 604 and 705 and a position between the electrodes 614 and 715 ) are provided in positions to be nodes of a standing wave vibration such that it is possible to make a total area of electrodes large. Consequently, the number of slits between electrodes can be reduced and the total area of electrodes can be larger than that in the piezoelectric element 21 of FIG. 2 . Further, in the piezoelectric element 24 , a total area of the first electrode group and a total area of the second electrode group are also identical. Also, in this piezoelectric element 24 , a traveling wave vibration generated on the surface of the elastic member 10 also has a uniform wavelength and a uniform amplitude over the entire circumference of the piezoelectric element 24 and loci of rotational movements are uniform.
In addition, if an electrode pattern shown in FIG. 9 is formed as piezoelectric element for generating a third order standing wave vibration, a total area of electrodes can be larger than that in the electrode pattern shown in FIG. 6 due to the same reason as the electrode pattern shown in FIG. 8 .
Further, although a first electrode group and a second electrode group are formed on a piezoelectric element in the above-described embodiment, the present invention is not limited to this. For example, a front surface of a piezoelectric element may be divided into three circles with different radiuses to form a first electrode group, a second electrode group and a third electrode group or to form more electrode groups. In these cases, it is sufficient to form the electrode groups such that the number of electrodes in each electrode group, a total area of each electrode group and an arrangement pattern of each electrode group are equal.
As described above, electrode groups for generating different standing wave vibrations are provided in a plurality of areas of a concentric circle shape with different radiuses, whereby unevenness of traveling wave vibrations generated in the elastic member 10 can be reduced.
Next, another configuration of a piezoelectric element for reducing unevenness of traveling wave vibrations generated in an elastic member will be described.
FIG. 10A shows an electrode pattern on a front surface of a piezoelectric element 26 and FIG. 10B shows an electrode pattern of a rear surface of the piezoelectric element 26 . The electrode pattern shown in FIG. 10A is identical with the electrode pattern shown in FIG. 14 A. As it can be seen from FIGS. 10A and 10B , the electrode patterns on the front surface and the rear surface are formed such that their shapes and phases are completely identical. With this configuration, as shown in FIG. 12 , all directions of electric fields applied to the part between the electrode pattern on the front surface and the electrode pattern on the rear surface at the time of polarization are in parallel with a thickness direction of the piezoelectric element 26 , and a polarization direction becomes uniform. Therefore, since an elastic modulus of the piezoelectric element 26 becomes uniform, unevenness of traveling wave vibrations generated when an alternating voltage is applied can be reduced.
FIG. 11A shows an electrode pattern on a front surface of a piezoelectric element 27 and FIG. 11B shows an electrode pattern on a rear surface of the piezoelectric element 27 . The electrode pattern shown in FIG. 11A is for generating two standing wave vibrations of a wavelength λ and is formed at a pitch for one electrode of λ/4. In the electrode pattern, positive electrodes (+) for generating an A phase standing wave vibration, positive electrodes (+) for generating a B phase standing wave vibration, negative electrodes (−) for generating an A phase standing wave vibration and negative electrodes (−) for generating a B phase standing wave vibration are arranged in the peripheral direction in this order. When alternating voltages of an identical wavelength and an identical amplitude, whose phases are shifted by 90 degrees from each other, are applied to a first electrode group for generating an A phase standing wave vibration and a second electrode group for generating a B phase standing wave vibration, a traveling wave vibration is generated in the piezoelectric element 27 .
The electrode pattern on the rear surface shown in FIG. 11B is formed such that its shape and phase are completely identical with those of the electrode pattern on the front surface. With this configuration, as shown in FIG. 12 , all directions of electric fields applied to the part between the electrode pattern on the front surface and the electrode pattern on the rear surface at the time of polarization are in parallel with a thickness direction of the piezoelectric element 27 , and a polarization direction becomes uniform. Therefore, since an elastic modulus of the piezoelectric element 27 becomes uniform, unevenness of traveling wave vibrations generated when an alternating voltage is applied can be reduced.
As described above, electrode patterns whose shapes and phases are both identical with each other are provided on a front surface and a rear surface of a piezoelectric element, whereby unevenness of traveling wave vibrations generated in the elastic member 10 can be reduced.
In addition, electrode patterns are not limited to those shown in FIGS. 10A , 10 B, 11 A and 11 B. For example, the electrode patterns shown in FIGS. 1 to 9 may be provided on both sides of a piezoelectric element.
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The present invention has been devised in order to raise driving efficiency of the vibration wave driving apparatus. A vibration member of a vibration wave driving apparatus of the present invention comprises the vibration member constituted of an elastic member and an electro-mechanical energy conversion element, and a rotor contacting the vibration member, and the vibration member generates a travelling wave in the elastic member when an alternating signal is applied to the electro-mechanical energy conversion element, in which an electrode film provided on a surface of the electro-mechanical energy conversion element of the vibration member is divided into a plurality of circular areas with different radiuses and each circular area is divided into a plurality of electrodes along its peripheral direction.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a divisional application of U.S. patent application Ser. No. 10/391,425 filed Mar. 18, 2003 now U.S. Pat. No. 7,013,784, which claims priority from U.S. Provisional application Ser. No. 60/365,999 filed Mar. 19, 2002; the disclosures of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Technical Field
This invention relates to rotary saw blades, and more particularly circular saw blades for use on circular saws or the like. Specifically, the invention is directed to a variable tooth saw blade that cuts faster and smoother while reducing harmonic vibrations.
2. Background Information
Circular saw blades are readily available for use in cutting wood and other materials using a portable, hand-held circular saw, or a fixed table or radial saws, or other like saws. The saw blades are formed of flat, circular discs made of steel or other like metals. As is well known in the art, circular saw blades include a peripheral edge from which a plurality of circumferentially-spaced teeth project radially outwardly for cutting.
Users continually desire to purchase blades that allow for faster cutting without negative effects such as “burning” of the blade, dulling of the teeth, or jamming of the saw. The ability of the teeth to efficiently cut the material and thus maintain the blade speed is critical. As a result, users continue to desire improved blades providing for faster and/or more efficient cutting.
Users also desire smooth cuts. Often the speed of a cut is inversely correlated to the smoothness of the cut, that is, the faster the user cuts, the rougher is the end cut, and vice versa. As a result, users continue to desire improved smoothness coupled with faster cutting.
Users further desire reduced noise. The high speed at which blades rotate often causes high levels of harmonic vibration leading to excessive noise, undesirable saw or saw blade vibration, and if the vibration is significant, a less than desirable cut. Users thus desire, and often government agencies require, blades providing for reduced noise and thus reduced harmonic vibration.
Consequently, there is a need for an improved saw that cuts faster and smoother while also reducing noise and harmonic vibration.
SUMMARY OF THE INVENTION
The present invention provides a saw blade comprising a flat, circular disc having a peripheral outer edge and a center hole; a plurality of circumferentially-spaced teeth each having a cutting edge and projecting radially outwardly from the peripheral outer edge; a first group of the cutting edges defining a first circumferential width between each adjacent pair of the cutting edges in the first group; a second group of the cutting edges defining a second circumferential width between each adjacent pair of the cutting edges in the second group; the second circumferential width differing from the first circumferential width; and a third group having at least one cutting edge defining a third circumferential width as one of the distance between adjacent cutting edges in the third group and, the distance between the at least one cutting edge in the third group and the adjacent cutting edge in the adjacent group; the third circumferential width differing from the first and second circumferential widths.
The invention further provides a saw blade comprising a flat, circular disc having a peripheral outer edge and a center hole, the disc being divided into a first half and a second half, each half being a copy exact of the other half positioned in a diametrically opposite manner; a plurality of circumferentially-spaced teeth each having a cutting edge and projecting radially outwardly from the peripheral outer edge; a first group in each half having five cutting edges including a first cutting edge and a last cutting edge defining therebetween a first group circumferential width of approximately sixty degrees; a second group in each half having three cutting edges including a first cutting edge and a last cutting edge defining therebetween a second group circumferential width of approximately forty degrees; a third group in each half having one cutting edge and having a third group circumferential width defined between the one cutting edge of the third group and the last cutting edge of the second group, the third group circumferential width being approximately thirty-six degrees; a first circumferential space being between the first and second groups in each half and having an approximately twenty-degree circumferential width; and a second circumferential space being between the third group in each half and the first group in the respective other half and having an approximately twenty-four-degree circumferential width.
The invention further provides a saw blade comprising a flat, circular disc having a peripheral outer edge and a center hole, the disc being divided into a first half and a second half, each half being a copy exact of the other half positioned in a diametrically opposite manner; a plurality of circumferentially-spaced teeth each having a cutting edge and projecting radially outwardly from the peripheral outer edge; a first group in each half having seven cutting edges including a first cutting edge and a last cutting edge defining a first group circumferential width therebetween which is approximately thirty-six degrees; a second group in each half having six cutting edges including a first cutting edge and a last cutting edge defining a second group circumferential width therebetween which is approximately forty-five degrees; a third group in each half having three cutting edges including a first cutting edge and a last cutting edge defining a second group circumferential width therebetween which is approximately thirty degrees; a fourth group in each half having two cutting edges defining a second group circumferential width therebetween which is approximately twenty degrees; a first circumferential space being between the first and second groups in each half and having an approximately nine-degree circumferential width; a second circumferential space being between the second and third groups in each half and having an approximately ten-degree circumferential width; a third circumferential space being between the third and fourth groups in each half and having an approximately ten-degree circumferential width; and a fourth circumferential space being between the fourth group in each half and the first group in the respective other half and having an approximately twenty-degree circumferential width.
BRIEF DESCRIPTION OF THE DRAWINGS
Preferred embodiments of the invention, illustrative of the best modes in which the applicant has contemplated applying the principles, are set forth in the following description and are shown in the drawings and are particularly and distinctly pointed out and set forth in the appended claims.
FIG. 1 is a side view of a first embodiment of the saw blade of the present invention;
FIG. 2 is the same side view of the first embodiment of the saw blade as in FIG. 1 with the sections clearly marked;
FIG. 3 is an enlarged view of a few teeth from the saw blade of the first embodiment in FIGS. 1–2 ;
FIG. 4 is a side view of a second embodiment of the saw blade of the present invention;
FIG. 5 is the same side view of the second embodiment of the saw blade as in FIG. 4 with the sections clearly marked; and
FIG. 6 is an enlarged view of a few teeth from the saw blade of the second embodiment in FIGS. 4–5 .
DESCRIPTION OF THE PREFERRED EMBODIMENT
The improved saw blade of the present invention is shown in two embodiments in the Figures although other embodiments are contemplated as is apparent to one of skill in the art. Specifically, the first embodiment of the improved saw blade is indicated generally at 20 as shown in FIGS. 1–2 , while a second embodiment of the improved saw blade is indicated generally at 120 as shown in FIGS. 4–5 .
The first embodiment is saw blade 20 embodied as a standard seven and one quarter inch diameter saw blade although it may be of any other diameter used or contemplated by those of skill in the art. The saw blade whether embodied as blade 20 or 120 is a flat, circular disc 22 , made of steel or other like metals, with a center arbor hole 24 as is well known in the art. The disc 22 includes a peripheral edge 30 with a plurality of circumferentially-spaced teeth projecting radially outwardly therefrom for cutting and generally referred to as 32 . Each tooth 32 has a cutting edge 44 and is more fully described below.
In accordance with one of the features of the invention, the blade is divided into an even number of groups or sections, and in more detail the blade 20 in the first embodiment is divided into two halves of six sections while the blade 120 in the second embodiment is divided into two halves of eight sections. Each section along the peripheral edge has a matching or copy exact section diametrically opposite thereto such that a symmetry-like line divides the blade into two halves of a repeating pattern.
In further accordance with one of the features of the invention, the sections in each half do not have the same number of teeth or teeth of the same size as the other sections. More particularly, there are a different number of cutting edges 44 in each section in each half and the circumferential width between each of the adjacent cutting edges 44 within a given section is different than that of each other section in a given half.
Preferably in accordance with another feature of the invention, the size of the teeth remains the same and/or decreases in each section from a largest size to a smallest size in the direction of cutting (or vice versa), while the number of teeth increases or remains the same in each section in the direction of cutting (or vice versa respectively). More particularly, the circumferential width between each adjacent pair of cutting edges 44 remains the same and/or decreases in each section from largest to smallest in the direction of cutting (or vice versa), while the number of cutting edges 44 increases or remains the same in each section in the direction of cutting (or vice versa respectively).
Each tooth 32 includes a tooth body 40 defined as a sloped face or land 42 culminating in outwardly extending cutting edge 44 . On the opposite side of cutting edge 44 from land 42 is a notch or void 54 which communicates with the land 42 of an adjacent tooth 32 . Notch 54 thus separates the cutting edge 44 of one tooth 32 from the land 42 of an adjacent tooth 32 . More specifically, notch 54 includes a radial face 46 extending inwardly toward hole 24 adjacent cutting edge 44 of one tooth 32 into a bend 56 which communicates with land 42 of an adjacent tooth 32 . Land 42 may include an optional additional cutting or finishing edge 52 in the middle thereof for reducing kick-back and providing smoother cuts, whereby such land 42 in the embodiment shown includes a first steep tapered section 48 and a second slightly tapered section 50 separated by the additional cutting edge 52 although other configurations are contemplated including only one tapered section of a constant taper or a gradually changing taper. Specifically, land 42 may be any form of a surface behind tooth 32 that transitions into notch 54 . Cutting edge 44 may be a sharpened edge, or, as in the embodiments, an L-shaped seat 60 in which an insert such as a carbide or diamond tip 62 is seated and secured. The insert has a cutting face 64 . Where an insert is used, cutting edge 64 becomes the cutting edge of a tooth 32 and thus the term “cutting edge” includes “cutting face” in that scenario.
In accordance with yet another feature of the invention, the hook angle a of each tooth is most preferably between 15° (fifteen degrees) and 25° (twenty-five degrees). The hook angle a is specifically the angle between the tangent to the cutting face 44 and a radius line through hole 24 .
In more detail as to the first embodiment of the blade referred to as 20 , teeth 32 are arranged in a unique eighteen-tooth design that is divided into two copy exact sections, namely a first side 70 A and a second side 70 B divided by axis 72 . Since the blade as shown in FIGS. 1–2 has a right and left copy exact side (sides 70 A and 70 B respectively), only the right side will be described below (except where necessary to refer to the other or left side where transitions occur). The first side 70 A includes nine teeth, namely teeth 32 A, 32 B, 32 C, 32 D, 32 E, 32 F, 32 G, 32 H, and 32 I separated by voids 54 .
In accordance with another feature of the invention, the nine teeth 32 A, 32 B, 32 C, 32 D, 32 E, 32 F, 32 G, 32 H, and 32 I of each side 70 A and 70 B are not all identical in size and spacing. Specifically in the embodiment shown, first side 70 A is divided into three sections 80 , 82 and 84 (and thus the saw blade 20 has six sections over sides 70 A and 70 B) of varying circumferential distance with differing number of teeth and size of teeth in each.
Section 80 includes cutting edges 44 of five teeth 32 , namely teeth 32 A, 32 B, 32 C, 32 D, and 32 E, and these cutting edges define a first circumferential width between each adjacent pair of the cutting edges. Section 80 also includes the trailing components of four teeth 32 , namely teeth 32 B, 32 C, 32 D, and 32 E, so that those four teeth are fully within section 80 , and those teeth within section 80 are substantially identical to one another. These trailing components include land 42 having tapered sections 48 and 50 , and optional additional cutting edge 52 . Thereafter, section 82 includes cutting edges 44 of three teeth, namely teeth 32 F, 32 G and 32 H, and these cutting edges define a second circumferential width between each adjacent pair of the cutting edges that is different from the first circumferential width. Section 82 also includes the trailing components of two teeth, namely teeth 32 G and 32 H, so that those two teeth are fully within section 82 , and those teeth within section 82 are substantially identical to one another. Further thereafter, section 84 includes cutting edge 44 of one tooth, namely tooth 32 I, along with its trailing components, so that tooth 32 I is fully within section 84 .
Each of sections 80 , 82 and 84 is specifically measured as the circumferential group width from the cutting edge 44 of the first tooth 32 of a section to the cutting edge 44 of the last tooth in the same section except where a section has only one tooth 32 and thus its circumferential group width is defined from the cutting edge 44 of the last tooth 32 of the previous section to the cutting edge 44 of the only tooth 32 in the section. Specifically, section 80 is the circumferential group width from the cutting edge 44 of the first tooth 32 A of the section 80 to the cutting edge 44 of the last tooth 32 E in the same section 80 , which is defined as angle b. Section 82 is the circumferential group width from the cutting edge 44 of the first tooth 32 F of the section 82 to the cutting edge 44 of the last tooth 32 H in the same section 82 , which is defined as angle c. Section 84 with only one tooth is the circumferential group width from the cutting edge 44 of the last tooth 32 H of the previous section 82 to the only cutting edge 44 of the only tooth 32 I in the section 84 , which is defined as angle d. The previous section for the first section is the last section, which would mean the last section of the other side where the blade has two copy exact sides, or simply the last section in the case where the sections span the entire circumference of the blade. For example, the section previous to section 80 of side 70 A is section 84 of side 70 B.
In between each of the sections are transitions or circumferential spaces 90 , 92 , and 94 . Specifically, transition 90 is the space between sections 80 and 82 , transition 92 is the space between sections 82 and 84 but since the section 84 has only one tooth then no transition exists as section 84 and transition 92 have the same definition, and transition 94 is the space between sections 84 and 80 of the next side (the left side). This space is defined as the circumferential width from the cutting edge 44 of the last tooth of a section to the cutting edge 44 of the first tooth in the next section. Specifically, transition 90 is the circumferential width from the cutting edge 44 of the tooth 32 E of section 80 to the cutting edge 44 of the tooth 32 F in the next section 82 , which is defined as angle e. Transition 92 does not exist due to the one-tooth nature of section 84 . Transition 94 is the circumferential width from the cutting edge 44 of the tooth 32 I of section 84 to the cutting edge 44 of the tooth 32 A in the next section 80 (which is on the other side or left side in this case), which is defined as angle f.
In accordance with one of the features of the invention, the section angle b is 60°, the section angle c is 40°, the section angle d is 36°, the transition angle e is 20°, and the transition angle f is 24°. The effect is a design where section 80 has cutting edges 44 for five teeth, section 82 has cutting edges 44 for three teeth, and section 84 has cutting edges for one tooth, with uneven transitions between sections 80 and 82 , and between 84 and 80 of the other side (the left side). Although it is noted above that no transition 92 exists between sections 82 and 84 because the definition of transition 92 is the same as section 84 , nonetheless, it is also seen that what might be considered as transition 92 also differs from either of transitions 90 and 94 .
In more detail as to the second embodiment of the blade referred to as 120 , teeth 32 are arranged in a unique thirty-six tooth design that is divided into two copy exact sections, namely a first side 170 A and a second side 170 B by axis 172 . Since the blade as shown in FIGS. 4–5 has a right and left copy exact side (sides 170 A and 170 B respectively), only the right side will be described below (except where necessary to refer to the left side). The first side 170 A includes eighteen teeth, namely teeth 132 A, 132 B, 132 C, 132 D, 132 E, 132 F, 132 G, 132 H, 132 I, 132 J, 132 K, 132 L, 132 M, 132 N, 132 O, 132 P, 132 Q, and 132 R.
As with the first embodiment and in accordance with one of the features of the invention, the eighteen teeth 132 A, 132 B, 132 C, 132 D, 132 E, 132 F, 132 G, 132 H, 132 I, 132 J, 132 K, 132 L, 132 M, 132 N, 132 O, 132 P, 132 Q, and 132 R of each side 170 A and 170 B are not all identical in size and spacing. Specifically in the embodiment shown, first side 170 A is divided into four sections 180 , 182 , 184 and 186 (and thus saw blade 120 has eight sections) of varying circumferential distance with differing number of teeth and size of teeth in each. Section 180 includes cutting edges 44 of seven teeth, namely teeth 132 A, 132 B, 132 C, 132 D, 132 E, 132 F, and 132 G, and these cutting edges define a first circumferential width between each adjacent pair of the cutting edges; Section 180 also includes the trailing components of six teeth, namely teeth 132 B, 132 C, 132 D, 132 E, 132 F and 132 G, so that those six teeth are fully within section 180 , and those teeth within section 180 are substantially identical to one another. As noted above, the trailing components include land 42 including tapered sections 48 and 50 , and optional additional cutting edge 52 . Thereafter, section 182 includes cutting edges 44 of six teeth, namely teeth 132 H, 132 I, 132 J, 132 K, 132 L and 132 M, and these cutting edges define a second circumferential width between each adjacent pair of the cutting edges that is different from the first circumferential width; Section 182 also includes the trailing components of five teeth, namely teeth 132 I, 132 J, 132 K, 132 L and 132 M, so that those five teeth are fully within section 182 , and those teeth within section 182 are substantially identical to one another. Further thereafter, section 184 includes cutting edges 44 of three teeth, namely teeth 132 N, 132 O and 132 P, and these cutting edges define a third circumferential width between each adjacent pair of the cutting edges that is different from the first and second circumferential widths. Section 184 also includes the trailing components of two teeth, namely teeth 132 O and 132 P, so that those two teeth are fully within section 184 , and those teeth within section 184 are substantially identical to one another. Finally thereafter, section 186 includes cutting edges 44 of two teeth, namely teeth 132 Q and 132 R, along with the trailing components of tooth 132 R, so that tooth 132 R is fully within section 186 .
In the same manner as described above with reference to the first embodiment, each section is specifically measured as the group circumferential width from the cutting edge 44 of the first tooth of a section to the cutting edge 44 of the last tooth in the same section except where a section has only one tooth 132 and thus its group circumferential width is defined from the cutting edge 44 of the last tooth 132 of the previous section to the cutting edge 44 of the only tooth 132 in the section. Specifically, section 180 is the group circumferential width from the cutting edge 44 of the first tooth 132 A of the section 180 to the cutting edge 44 of the last tooth 132 G in the same section 180 , which is defined as angle g. Section 182 is the group circumferential width from the cutting edge 44 of the first tooth 132 H of the section 182 to the cutting edge 44 of the last tooth 132 M in the same section 182 , which is defined as angle h. Section 184 is the group circumferential width from the cutting edge 44 of the first tooth 132 N of the section 184 to the cutting edge 44 of the last tooth 132 P in the same section 184 , which is defined as angle j. Section 186 is the group circumferential width from the cutting edge 44 of the first tooth 132 Q of the section 186 to the cutting edge 44 of the last tooth 132 R in the same section 186 , which is defined as angle k.
In between each of the sections are transitions or circumferential spaces 190 , 192 , 194 and 196 . Specifically, transition 190 is the space between sections 180 and 182 , transition 192 is the space between sections 182 and 184 , transition 194 is the space between sections 184 and 186 , and transition 196 is the space between sections 186 and 180 of the next side (the left side). This space is defined as the circumferential width from the cutting edge 44 of the last tooth of a section to cutting edge 44 of the first tooth in the next section. Specifically, transition 190 is the circumferential width from cutting edge 44 of tooth 132 G of section 180 to cutting edge 44 of tooth 132 H in the next section 182 , which is defined as angle l. Transition 192 is the circumferential width from cutting edge 44 of tooth 132 M of section 182 to cutting edge 44 of tooth 132 N in the next section 184 , which is defined as angle m. Transition 194 is the circumferential width from cutting edge 44 of tooth 132 P of section 184 to cutting edge 44 of tooth 132 Q in the next section 186 , which is defined as angle q. Transition 196 is the circumferential width from cutting edge 44 of tooth 132 R of section 186 to cutting edge 44 of tooth 132 A in the next section 180 (which is on the other side or left side in this case), which is defined as angle s.
In accordance with one of the features of the invention, the circumferential width or section angle g is 36.015°, the section angle h is 44.985°, the section angle j is 30.015°, the section angle k is 20°, the transition angle l is 9°, the transition angle m is 9.985°, the transition angle q is 10°, and the transition angle s is 20°.
In accordance with yet one more feature of the invention, it has been discovered that alternating the number of teeth in adjacent sections from odd to even provides additional benefits including noise reduction.
Accordingly, the improved saw blade of the above embodiments is simplified, provides an effective, safe, inexpensive, and efficient device which achieves all the enumerated objectives, provides for eliminating difficulties encountered with prior devices, and solves problems and obtains new results in the art.
In the foregoing description, certain terms have been used for brevity, clearness and understanding; but no unnecessary limitations are to be implied therefrom beyond the requirement of the prior art, because such terms are used for descriptive purposes and are intended to be broadly construed.
Moreover, the description and illustration of the invention is by way of example, and the scope of the invention is not limited to the exact details shown or described.
Having now described the features, discoveries and principles of the invention, the manner in which the improved saw blade is constructed and used, the characteristics of the construction, and the advantageous, new and useful results obtained; the new and useful structures, devices, elements, arrangements, parts and combinations, are set forth in the appended claims.
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An apparatus for cutting materials and more specifically an improved saw blade includes a plurality of variable teeth thereon. The variable tooth saw blade cuts faster and smoother while reducing harmonic vibrations. Specifically, the teeth on the saw blade are grouped into sections with differing circumferential widths and differing spacing between the sections.
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TECHNICAL FIELD
The present invention relates to viscous creamy scouring compositions, which are substantially free of terpene-solvents, are stable and show excellent cleaning and shine performance.
These compositions, which comprise an abrasive, contain a binary system represented by a water-insoluble hydrocarbon solvent and a long-chain fatty-alcohol.
BACKGROUND
It is well known to formulate scouring compositions, in liquid or creamy form, containing solvents.
In particular, creamy scouring compositions containing an abrasive and a binary solvent system constituted of terpenes and polar solvents have been disclosed in European Patent Application 126,545 published on Nov. 28, 1984. In these compositions, the terpenes in addition to their cleaning abilities, contribute among others to emulsification. Their removal will therefore result in a significant decrease in viscosity which could only be prevented by addition of excessively high levels of thickener: the formulation of viscous scouring cleansers which are substantially free of terpene solvents was known to be difficult.
It has now been found that remarkably effective viscous creamy scouring cleanser compositions which are substantially free of terpene solvents can be formulated; In more detail, the combination, of a long-chain fatty alcohol with a particular water-insoluble hydrocarbon solvent in specific weight ratios, provides superior cleaning, allows excellent component emulsification and yields a creamy consistency.
The water-insoluble hydrocarbon solvents useful herein are selected from the group of C 8 -C 20 paraffin oils and C 10 -C 22 alkyl benzenes.
Paraffin oils have already been used as grease-removal solvents, and linear alkyl benzenes of upto C 9 alkyl chain length as well.
In European Patent Application 137,616, published Apr. 17, 1985, fatty acids/soaps are used in combination with a grease-removal solvent, both species at levels above 5% by weight of the total composition, to provide an emulsion.
It is an object of the present invention to provide viscous creamy cleanser compositions which are substantially free of terpene solvents.
It is a further object of the present invention to provide a cleanser composition with excellent cleaning and shine performance.
SUMMARY OF THE INVENTION
The present invention relates to viscous creamy scouring compositions being substantially free of terpene solvents, containing a surface active agent, an abrasive, and an organic solvent and if desired conventional additives, characterized in that the solvent contains a binary system represented by
from 0.1% to 5% by weight of a water-insoluble hydrocarbon solvent selected from C 10 -C 22 alkyl benzene and C 8 -C 20 paraffin oils and;
from 0.1% to 5% by weight of a fatty alcohol having from 8 to 20 carbon atoms,
the weight ratio of water-insoluble hydrocarbon solvent to fatty alcohol being in the range from 3:1 to 1:4.
DETAILED DESCRIPTION OF THE INVENTION
The surface-active agents, the abrasives, the solvent system and the optical ingredients are described in more detail hereinafter.
Unless indicated to the contrary, the %-indications stand for "%-by weight".
SURFACE ACTIVE AGENTS
Water-soluble detersive surfactants useful herein include well-known synthetic anionic, nonionic, amphoteric and zwitterionic surfactants and mixtures thereof. Typical of these are the alkyl benzene sulfates and sulfonates, paraffin sulfonates, olefin sulfonates, alkoxylated (especially ethoxylated) alcohols and alkyl phenols, amine oxides, sulfonates of fatty acids and of fatty acid esters, and the like, which are well-known in the detergency art. In generaly, such detersive surfactants contain an alkyl group in the C 10 -C 18 range; the anionic detersive surfactants are most commonly used in the form of their sodium, potassium or triethanolammonium salts. The nonionics generally contain from 3 to 17 ethylene oxide groups per mole of hydrophobic moeity. Especially preferred in the compositions of the present invention are: C 12 -C 16 alkyl benzene sulfonates, C 12 -C 18 paraffin-sulfonates and the ethoxylated alcohols of the formula RO(CH 2 CH 2 O) n , with R being a C 12 -C 15 alkyl chain and n being an number from 6 to 10.
Anionic surfactants are frequently present at levels from 0.3 to 8% of the composition. Nonionic surfactants, are used at levels between 0.1% to 6% by weight of the composition. Mixtures of the like surfactants can also be used.
Abrasive--the abrasives employed herein are selected from water-insoluble, non-gritty materials well-known in the literature for their relatively mild abrasive properties. It is highly preferred that the abrasives used herein not be undesirably "scratchy". Abrasive materials having a Mohs hardness in the range of about 7, or below, are typically used; abrasives having a Mohs hardness of 3, or below, can be used to avoid scratches on aluminum or stainless steel finishes. Suitable abrasives herein include inorganic materials, especially such materials as calcium carbonate and diatomaceous earth, as well as materials such as Fuller's earth, magnesium carbonate, China clay, attapulgite, calcium hydroxyapatite, calcium orthophosphate, dolomite and the like. The aforesaid inorganic materials can be qualified as "strong abrasives". Organic abrasives such as urea-formaldehyde, methyl methacrylate melamine-formaldehyde resins, polyethylene spheres and polyvinylchloride can be advantageously used in order to avoid scratching on certain surfaces, especially plastic surfaces. When such "soft abrasives" are used, it can be desirable to include a builder in the composition.
Typically, abrasives have a particle size range of 10-1000 microns and are used at concentrations of 5% to 30% in the compositions. Thickeners are frequently added to suspend the abrasives.
SOLVENT SYSTEM
The solvent of the compositions herein contain a binary system represented by a water-insoluble solvent, and a long-chain fatty alcohol.
The term "water-insoluble" as used in the present specification, means that the solubility in water must be less than 5%.
The hydrocarbon solvents useful herein do not contain any other atom then C and H and are not cyclic. These solvents are selected from the group of C 8 -C 20 paraffin oils and C 10 -C 22 alkyl benzenes. Preferably, isoparaffins are used herein. C 10 -C 14 isoparaffins are especially preferred.
Suitable iso-paraffin oils for use in the compositions of the invention are available under the trade names ISOPAR® G, H, and L, sold by ESSO.
The alkyl benzenes can have a linear or branched alkyl chain. Preferred are linear alkyl benzenes, especially those having an alkyl chain-length between C 12 and C 20 .
The water-insoluble solvent is present in amounts from 0.1% to 5%, preferably from 0.5% to 2.5%.
The long-chain fatty alcohols useful herein have 8 to 20, preferably 12 to 18, carbon atoms in the alkyl chain. They may be saturated or unsaturated species.
The alcohol is used at levels of from 0.1% to 5%, preferably 0.5% to 2.5%. The weight ratio of water-insoluble hydrocarbon to fatty alcohol is in the range from 3:1 to 1:4, preferably from 2:1 to 1:2.
In a preferred embodiment, the solvent system contains, in combination with the aforesaid binary system, a water-soluble solvent. Suitable water-soluble solvents useful herein are benzyl alcohol and 2-Ethyl-1,3 hexanediol. The water-soluble solvent can also be selected from the water-soluble CARBITOL® solvents and water-soluble CELLOSOLVE solvents. Water-soluble CARBITOL® solvents are compound of the 2-(2-alkoxyethoxy)ethanol class wherein the alkoxy group is derived from ethyl, propyl or butyl; a preferred water-soluble Carbitol is 2-(2-butoxyethoxy)ethanol also known as butyl carbitol. Water-soluble CELLOSOLVE® solvents are compound of the 2-alkoxyethoxy ethanol class, with the butyl cellosolve being preferred. The water-soluble solvent can be used in levels ranging from 0.1 to 5% of the composition.
Optional Ingredients--The compositions herein can contain other ingredients which aid in their cleaning performance. For example, it is highly preferred that the compositions contain a detergent builder and/or metal ion sequestrant. Compounds classifiable and well-known in the art as detergent builders include the nitrilotriacetates, (NTA), polycarboxylates, citrates, water-soluble phosphates such as tri-polyphosphate and sodium ortho- and pyro-phosphates, silicates, and mixtures thereof. These builders are preferably not used in combination with strong abrasives like calcium carbonate, but are recommended in combination with soft organic abrasives like polyvinylchloride.
Metal ion sequestrants of lower metal sequestration constant can advantageously be used in combination with strong or soft abrasives.
Those metal ion sequestrants include ethylene diamine tetraacetate (EDTA), iminodiacetade materials like N(2-hydroxyethyl)iminodiacetate (HEIDA), amino-polyphosponates (DEQUEST) and phosphates. Preferred builders/sequestrants for use in the present invention are NTA, EDTA, and HEIDA and mixtures of EDTA and HEIDA.
The builders/sequestrant will be present at levels of from 1% to 15%.
Soaps can also be present in the compositions of the invention, in order to provide suds control. Soap prepared from coconut oil fatty acids is preferred.
Soaps are used in amounts ranging from 0.05% to 3% by weight of the composition.
Thickeners will preferably be included in the compositions of the invention, mainly in order to suspend the abrasive; high levels of thickeners are detrimental to the performance because they are difficult to rinse from the cleaned surfaces. Accordingly, the level will be kept under 2%, preferably from 0.2% to 1.5%. Common thickeners such as the polyacrylates, xanthan gums, carboxymethyl celluloses, swellable smectite clays, and the like, can be used herein.
Optional components are also represented by ingredients typically used in commercial products to provide aesthetic or additional product performance benefits. Typical ingredients include pH regulants, perfumes, dyes, optical brighteners, soil suspending agents, detersive enzymes, gel-control agents, freeze-thaw stabilizers, bactericides, preservatives, and the like.
Another optional ingredient for use herein is represented by conventional detergent hydrotropes. Examples of suitable hydrotropes are urea, monoethanolamine, diethanolamine, triethanolamine and the soliudm potassium, ammonium and alkanol ammonium salts of xylene-, toluene-, ethylbenzene- and isopropyl-benzene sulfonates. It is a particular feature of the present invention, however, that stable formulations can be prepared without the need for hydrotropic materials of this kind.
The compositions herein typically contain up to about 90% water as a carrier. By way of example the water-level can vary in the range from e.g. 50% to 80%. Water-alcohol (e.g., ehtanol, isopropanol, butanol, etc.) mixtures can also be used. Alkylated polysaccharides can be used to increase the stability and performancce characteristics of the compositions.
The compositions herein are preferably formulated in the alkaline pH range, generally in the range of pH 8-11, preferably about 10-10.8. Caustics such as sodium hydroxide and sodium carbonate can be used to adjust and buffer the pH as desired.
The following examples are given by way of illustrating the compositions herei, but are not intended to be limiting of the scope of the invention.
ABBREVIATIONS
NaPS: Sodium C 13 to C 16 paraffin sulfonate
LAS: Sodium salt of linear C 11 -C 8 alkyl benzene sulfonate
LAB: Linear C 10-22 Alkyl Benzene
Lutensol®A07: Condensate of 1 mole C 12 -C 14 fatty alcohol with 7 moles of ethylene oxide
Dobanol®45/7: C 14 -C 15 oxoalcohol with 7 moles of ethylene oxide per mole of alcohol
HC n FA: Narrow cut, hardened, coconut fatty acid.
NTA: Sodium nitrilotriacetate
EDTA: Ethylene Diamine Tetraacetate
HEIDA: N-(2-hydroxyethyl)imino diacetate
CaCO 3 : Calcium Carbonate
Sokalan®PHC 25: Crosslinked polyacrylate thickener
ETHD: 2-Ethyl-1,3-hexanediol
Liquid cleansers were prepared by mixing the listed ingredients in the stated proportions (% by weight).
______________________________________ Comp Ex Ex Ex Ex ExIngredients A I II III IV V______________________________________NaPS 3.0 3.0 3.0 3.0 3.0 3.0LAS 0.6 0.6 0.6 0.6 0.6 0.6Lutensol ® A07 0.3 0.3 0.3 0.3 0.3 0.3Na.sub.2 CO.sub.3 3.0 3.0 3.0 3.0 3.0 3.0HC.sub.n FA 0.2 0.2 0.2 0.2 0.2 0.2Benzyl Alcohol 1.3 -- -- -- -- --Butyl Carbitol -- 4.0 4.0 4.0 4.0 4.0Orange Terpenes 1.9 -- -- -- -- --Isopar ® G -- 1.6 1.6 .13 -- --C.sub.12 LAB -- -- -- -- 1.6 1.6Dodecanol -- 1.6 1.6 1.3 1.6 1.6NTA -- -- 3.0 3.0 3.0 3.0CaCO.sub.3 30 30 30 -- 30 --PVC -- -- -- 1O -- 10Sokalan ® PHC25 0.65 0.5 0.5 0.5 0.5 0.5Water up to 100______________________________________
The compositions of Examples I to V showed a high viscosity and an excellent stability.
The above compositions were comparatively tested on synthetic soils representative of typical hard surface household soils. The test-soils were prepared as follows.
(a) HBTS soil: is composed of 250 ml isopropyl alcohol, 75 g. calcium stearate powder and 0.5 g. carbon black. It is applied on an enamel-coated metal plate (cleaned with a detergent and then with alcohol) with a paint roller, and the plates are baked at 180° C. for 20 minutes.
(b) KD soil: is composed of 25% HSW® soil with carbon black (2), 37.5% Crisco® (1) oil, 37.5% Puritan® (1) oil. This soil is rolled onto stainless steel plates (beforehand cleaned with a detergent and then with alcohol) using a paint roller. A very thin uniform layer is needed since the soil is difficult to cure. The plates are placed in the oven at 115° C. ("soft soil") or 170° C. ("hard soil") for 2 hours and then allowed to age at least 1 day.
(1) commercial cooking oil sold by The Procter & Gamble Company.
(2) commercial soil sold by Chem Pack Inc., U.S.A.
The testing conditions were as follows:
All test were run with the aid of an Erichsen washability machine. A sponge of approximately 9.5×5×4 cm was used after being carefully washed under hot running water and squeezed through drying rolls. 5 g of the undiluted cleanser to be tested was spread over one side of the sponge. The number of strokes of the cleaning machine varied with the type of soil. Performance readings were done as soon as visible cleaning differences became noticeable. The gradings were done visually by three judges working independently. The performance benefits were estblished via a paired comparison with duplicates as follows. A 0-4 scale was used whereby: 0 means no difference; 1=probable difference; 2=consistent difference; 3=clear difference; 4=big difference.
The testing results were as listed below. Prior art composition A was the reference against which compositions of examples I, II, III, IV and V were compared.
______________________________________soil Comp A Ex I Ex II Ex IV Ex III Ex V______________________________________KD"Hard" Ref +2 +2 +2"Soft" Ref +1 +1 +1HBTS Ref +1 +2.5 +2.5 +2.5 +2.5______________________________________
The above test clearly confirms the significant performance benefits derivable from the inventive compositions vs. related art composition.
In addition, the following compositions are prepared:
______________________________________ Ex. Ex. Ex. Ex.Ingredients Ex. VI VII VIII IX X Ex. XI______________________________________NaPS 3.0 3.0 3.2 3.2 3.5 2.5LAS 0.6 0.6 0.4 0.4 0.3 1.0Lutensol ® A07 0.3 -- 0.2 -- 0.3 --Dobanol ® 4S/7 -- 0.3 -- 0.2 -- 0.4NaCO.sub.3 3.0 3.0 3.0 3.0 3.0 3.0HC.sub.n FA 0.2 0.2 0.2 0.2 0.2 0.2Benzylalcohol 2.0 3.0 -- -- 2.0 --Butyl carbitol -- -- 4.0 2.0 2.0 --ETHD -- -- -- 2.0 -- 4.0Isopar ® G 0.6 -- 1.0 -- 1.0 --C.sub.12 L.A.B. -- 0.6 -- 1.0 -- 1.0Dodecanol 0.6 0.6 1.0 1.0 1.0 1.0NTA -- 3.0 -- -- -- --EDTA -- -- 1.0 -- 4.0 --HEIDA -- -- 4.0 4.0 -- 3.0CaCO.sub.3 30.0 30.0 -- -- -- --PVC -- -- 10.0 10.0 10.0 10.0Sokalan ® PHC25 0.5 0.5 0.5 0.5 0.5 0.5Water balance to 100______________________________________
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Viscous creamy scouring compositions substantially free of terpene solvents are disclosed. These compositions contain a binary system represented by a water-insoluble hydrocarbon solvent and a long-chain fatty alcohol.
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BACKGROUND OF THE INVENTION
Generally, in the automotive field, especially with regard to trucks, indicator lamp assemblies are employed to indicate, by their respective energization, that certain selected functions or vehicular operating parameters are in an unacceptable condition. For example, as in a truck, such indicator lamp assemblies may be operatively connected to related sender units which are, in turn, responsive to indicia of: engine oil level; engine temperature; loss of engine coolant; generator or alternator output level; actuation or operation of anti-skid mechanism; air pressure in truck air tanks; headlamp selection (whether high or low beam) or parking brake engagement.
Since trucks represent a comparatively high financial investment and since the only way that a profitable return of such investment can be assured is to keep such trucks in use for as long as possible with as little "down-time" (the time during which the truck is taken out of productive use such as, for example, for maintenance or inspection) as possible, great care is taken to prevent operation of a truck when all important conditions of such truck are judged to be not up to standard as well as to achieve engine shut-down as quickly as possible after the occurrence of a related failure. Such engine shut-down may be called for merely as a preventive or safety measure as, for example, for the prevention of possible damage to the engine or, for example, a progressive loss of air pressure in a truck employing pneumatically actuated brakes.
The truck industry has, heretofore, employed one or more indicator lamp assemblies to thereby create, upon energization thereof, a visual signal to the truck operator that a particular parameter is exhibiting less than satisfactory conditions thereby enabling the operator to take corrective action.
Usually a plurality of such indicator lamp assemblies are employed and mounted as on the vehicular instrument panel. Further, provision is often made so that upon the operator turning the ignition key toward the engine cranking or "start" position, all of the electrical circuits leading to the indicator lamp assemblies are closed thereby causing energization of the lamp assemblies. It is at this time that the operator can see whether all of the lamp assemblies are still functioning or if any bulb replacement is required.
However, various problems have arisen because of the prior art indicator lamp assemblies. For example, certain of the prior art indicator lamp assemblies employ bulbs of a shank length different from the shank length of bulbs employed in other prior art indicator lamp assemblies. This means that in order to provide for all contingencies, the various truck service centers, as well as the truck operator, must carry a supply of all sizes of bulbs since it is possible that bulbs of differing shank sizes will have to be replaced. Obviously, times occur when the particular size of bulb is not available and because of the reluctance of the operator to operate the truck without being assured that the particular related sensed condition is acceptable, additional "down-time" is created in order to properly inspect the related structure.
Further, since energization of an indicator lamp assembly can occur for reasons other than bulb failure, additional problems have been experienced with the prior art indicator lamp assemblies. That is, such non-energization can be the result of a failure within the bulb socket assembly or the electrical conductors leading from the socket assembly to the related source of electrical potential. Because the prior art employed various designs of socket assemblies and because a particular truck instrument panel was effective to receive only one particular design of socket assembly, it has heretofore been necessary that truck service centers (often referred to as "truck stops") maintain a large inventory in order to be able to provide whatever design of socket assembly may be required by any particular truck having that need.
The prior art indicator lamp assemblies have created additional problems also resulting in increased costs. For example, generally it is well known that for various reasons it is desirable to make the cab portion (that part of the truck providing space for the operator and associated controls and instruments) as short in length as possible while still providing adequate space for the operator. Consequently, the space as between the instrument panel and, for example, the forward wall of the cab portion is kept at an absolute minimum with such space being filled with as much related operating equipment, controls, linkages and electrical conductors as is practicably possible.
Because of this compactness of construction of the cab it becomes difficult not only to service, for example, the replacement of bulbs which have failed in the indicator lamp assemblies but also in the actual construction of the cab by the truck builder. That is, almost exclusively the prior art indicator lamp assemblies are such as to require the removal and replacement of the bulb from the rear or underside of the instrument panel and, as already stated, such space is usually very limited.
Generally, the builders of trucks in their manufacturing procedures, more specifically, during assembly of the instrument panel and the subsequent assembling of the completed instrument panel to the cab, require that the indicator lamp assemblies be first assembled to the instrument panel as to comprise a portion of the completed instrument panel before such completed instrument panel is assembled to the cab. This enables the instrument panel to be completed as at a station which is not part of the final assembly of the vehicle.
According to the prior art, the lamp assemblies were thusly assembled. However, because such prior art lamp assemblies were, in the main, constructed of a body-like bulb socket with male type blade terminals carried directly thereby, the assembly of the completed instrument panel onto the cab required the use of intermediate wire harness assemblies which would at one end plug into or onto the blade terminals of the lamp assemblies and, at the other end, plug into terminal ends of a vehicular wiring system which could take the form of a second wiring harness. This meant that not only was the final assembly doubly difficult because of the requirement that each lamp assembly had to have two electrical connections made in order to complete a wiring system thereto, but also the fact that two such terminal sets were used for each lamp assembly doubled the possibility of failure at such terminal points. Also, because of the very small space behind or below the instrument panel, it is difficult to assure that proper connections are made to the prior art socket assembly because the terminals thereof are situated relatively closely to the rear or under-surface of the instrument panel.
Other problems also exist with respect to the prior art. For example, prior art indicator lamp assemblies often have a lens which is screwed onto the body of the lamp assembly. As is apparent, because of the thread lead, it becomes impossible to both tighten the lens onto the body and at the same time be assured that the lens will assume a particular desired position so that any legend or word (such as, for example, "HOT", "OIL", "AIR") carried by and on such lens is easily readable by the operator. With such prior art lamp assemblies, the lens would have to be tightened and then the lamp body-like socket assembly would have to be turned or rotated until the lens was in a proper attitude at which point the securing means would again be tightened. Such time-consuming operations did not totally correct the problem because even after the lens and body-like socket assembly were initially properly secured during manufacturing and assemblying of the vehicle, the vibrations caused during truck use and consequently experienced by the prior art lamp assembly usually results in the lens becoming loosened as well as the bodylike bulb socket assembly rotating within its cooperating mounting aperture in the instrument panel. As is apparent, such vibrations ultimately, and frequently, cause misalignment of the prior art lenses.
Accordingly, the invention as herein disclosed, described and claimed is primarily directed to the solution of such, as well as other related and attendant, problems.
SUMMARY OF THE INVENTION
Apparatus
According to the invention, a lamp housing comprises housing body means, deflectable means carried by said body means for enabling said body means to be detachably secured to associated support structure, said body means having a first end for receiving a lens, said body means having a second open end for detachably receiving therein a portion of an associated bulb socket assembly, and passage means formed in said body means between and interconnecting said first and second open ends, said passage means being adapted to receive therein at least a portion of a bulb operatively connected to and carried by said socket assembly.
Method
According to the invention a method of manufacturing a lamp housing assembly comprises the steps of molding a first longitudinal half of a generally tubular housing body, molding a second longitudinal half of a generally tubular housing body, forming a lens of at least translucent material, molding a lens retainer, securing said first longitudinal half to said second longitudinal half as to form a tubular housing body, placing said lens in juxtaposition with one end of said first and second longitudinal halves and in juxtaposition with said lens retainer, and securing said lens retainer to said first and second longitudinal halves.
Various general and specific objects, advantages and aspects of the invention will become apparent when reference is made to the following detailed description considered in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings, wherein for purpose of clarity certain details and/or elements may be omitted from one or more views:
FIG. 1 is a fragmentary perspective view of an interior of a truck cab having an instrument panel employing various indicator lamp assemblies including a lamp housing assembly embodying teachings of the invention;
FIG. 2 is an enlarged cross-sectional view, partly in phantom line, taken generally on the plane of line 2--2 of FIG. 1 and looking in the direction of the arrows;
FIG. 3 is a cross-sectional view of relatively reduced scale, of a portion of the structure of FIG. 2, taken generally on the plane of line 3--3 of FIG. 2 and looking in the direction of the arrows;
FIG. 4 is a view of relatively reduced scale, of a portion of the structure of FIG. 2, taken generally on the plane of line 4--4 of FIG. 2 and looking in the direction of the arrows;
FIG. 5 is an elevational view taken generally on the plane of line 5--5 of FIG. 4 and looking in the direction of the arrows;
FIG. 6 is an end elevational view of relatively reduced scale taken generally on the plane of line 6--6 of FIG. 2 and looking in the direction of the arrows;
FIG. 7 is an end elevational view of relatively reduced scale taken generally on the plane of line 7--7 of FIG. 2 and looking in the direction of the arrows;
FIG. 8 is a cross-sectional view taken generally on the plane of line 8--8 of FIG. 7 and looking in the direction of the arrows;
FIG. 9 is a view of relatively reduced scale, of a portion of the structure of FIG. 2, taken generally on the plane of line 9--9 of FIG. 2 and looking in the direction of the arrows;
FIG. 10 is an elevational view taken generally on the plane of line 10--10 of FIG. 9 and looking in the direction of the arrows;
FIG. 11 is an elevational view, of relatively reduced scale, of one of the elements of the structure of FIG. 2 taken generally on the plane of line 11--11 of FIG. 2 and looking in the direction of the arrows;
FIG. 12, is a view of relatively reduced scale taken generally on the plane of line 12--12 of FIG. 2 illustrating the panel mounting aperture of FIG. 2;
FIG. 13 is a side elevational view of a bulb socket assembly, fragmentarily illustrated in phantom line in FIG. 2, employable with the invention;
FIG. 14 is a generally exploded view of the elements shown in preceding Figures and somewhat simplified, illustrating, in part, a method of manufacturing the lamp housing assembly.
FIG. 15 is a view similar to that of FIG. 2 and illustrating a further embodiment of the invention;
FIG. 16 is a view somewhat similar to that of FIG. 3, taken on the plane of line 16--16 of FIG. 15 and looking in the direction of the arrows;
FIG. 17 is a view illustrating, in effect, a fragmentary portion of the structure shown in FIG. 15 and a further modification thereof;
FIG. 18 is a view taken generally on the plane of line 18--18 of FIG. 17, looking in the direction of the arrows and illustrating a possible outer configuration of the structure of FIG. 17; and
FIG. 19 is a view similar to that of FIG. 18 and illustrating another possible outer configuration.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now in greater detail to the drawings, FIG. 1 illustrates the interior of a truck cab 10 as being comprised of, for example, a driver's or operator's seat assembly 12, steering wheel and column assembly 14, windshield 16, operator's foot actuated levers and pedals 18, 20 and 22, and instrument panel assembly 24 comprising a panel-like support 25 and an array of gauges 26, 28, 30, 32 and 34, controls 36, 38 and a plurality of indicator lamp and housing assemblies 40, 42, 44, 46 and 48.
In FIG. 2, the indicator lamp and housing assembly 40 is illustrated as being comprised of a main body or housing 50, lens 52, lens retainer or bezel 53, bulb socket assembly 54 and cooperating bulb 56, all being suitably secured to and carried as by panel or support 25 of the instrument panel assembly 24.
Referring in particular to FIG. 2, 3, 4, 5 and 6, in the preferred embodiment of the invention, body or housing 50 is preferably generally tubular having a tubular wall 57 comprised as of an outer generally cylindrical surface 58 of relatively large diameter and an inner generally cylindrical surface 60 of relatively smaller diameter. Formed integrally with the wall 57 are oppositely disposed resiliently deflectable detent like latching arms 62 and 64 respectively joined as at 66 and 68 to wall 57 and, respectively, having free ends 70 and 72. The right-most (as viewed in FIGS. 2, 3 and 5) or forward ends of arms 62 and 64 are provided with generally radially outwardly extending cam-like or ramp-like surface means 74 and 76 as well as oppositely inclined cam-like or ramp-like surface means 78 and 80, respectively. Such oppositely inclined surfaces may join each other as at, for example, respective apexes 82 and 84. As generally depicted by FIGS. 2 and 5, arms 62 and 64 are respectively situated generally within slot-like clearances 86 and 88 formed in the wall 57 of housing body 50.
The left end (as viewed in FIGS. 2, 3 and 5) of body or housing 50 terminates as in an axial end surface 90 formed as on a transverse extending wall 92 through which an aperture or passage 94 is formed. The relative dimensions of passage 94 and inner surface 60 are preferably such as to result in a stepped or flange-like annular surface 96. In the preferred embodiment, the aperture or passage 94 may be tapered as to thereby present a relatively larger opening at the inner-most side of wall 92 while presenting a relatively smaller opening at the outermost side of wall 92.
The right-most or forward end of housing or body means 50 is formed as to terminate in end surfaces 98 and 100 which are further defined as by a relatively enlarged bezel or lens retainer mounting portions 102 and 104, respectively. When viewed as in FIGS. 4 or 6, the portions 102 and 104 define a generally square configuration with rectilinear mounting surfaces 106, 108 and 110 formed on portion 102 and rectilinear mounting surfaces 112, 114 and 116 formed on portion 104. Mounting or head-like portions 102 and 104 extend generally axially or longitudinally and terminate as in wall-like surfaces 118, 120, 122 and 124. As depicted in FIGS. 2, 3, 4 and 5, mounting surfaces 106, 108, 110, 112, 114 and 115 are preferably inclined with respect to each other as to generally be closer to the axis 126 the more nearly such surfaces approach end surfaces or faces 98 and 100. In the preferred embodiment surfaces or end faces 98 and 100 are substantially coplanar with each other and opposed end faces or surfaces 118, 120, 122 and 124 are also substantially coplanar with each other.
In the preferred embodiment, the housing is comprised of plastic material such as, for example, short glass fiber filler nylon type 66. (Nylon 66 is a condensation product of adipic acid and hexamethylenediamine. Adipic acid is obtained by catalytic oxidation of cyclohexane.)
Referring now in greater detail to FIGS. 2, 7, 8, 9 and 10, the bezel 53 is illustrated as comprising a generally rectangular or square frame-like body 126 with an inner opening 128 defined as by surfaces 130, 132, 134 and 136 which, at the forward most ends, terminate in the forward or end face surface 138 of body 126. The outer periphery of body 126 is defined as by rectilinear surfaces 140, 142, 144 and 146 which extend from the forward-most end surface 138 to the rearward-most end surface 148. The body 126 is further provided with internal rectilinear surfaces 150, 152, 154 and 156 which, at their respective inner-most ends, terminate as in a transverse wall portion 158 and, at their respective other ends, terminate in end surface 148. As depicted in each of FIGS. 2, 8 and 9 the inner surfaces 150, 152, 154 and 156 are inclined with respect to each other as to be at angles complementary to the inclinations of surfaces 108, 106-112, 114 and 116-110, respectively, of mounting portions 102 and 104 of housing body 50.
Also, in the preferred embodiment, at least surfaces 142 and 146 are respectively provided with textured surface portions 164 and 166 as to thereby further enhance the gripping qualities thereof, as will be more fully described.
The lens 52, shown in FIGS. 2, 7 and 11, in its preferred embodiment, comprises translucent polycarbonate sheet-like material and has its forward-most or outer face 160 treated as to be of a generally frosted surface. Further, preferably, a suitable legend such as, for example, "ENG HOT", is formed on or carried by the rear or inner face of 162 of the lens. The legend, in FIG. 7, is depicted in hidden line since, in the preferred embodiment, because of the frosted forward or outer surface 160, the legend would normally not be visible until such time as the bulb 56 is energized.
As best seen in FIG. 11, the lens 52 is also preferably of a square configuration. The lens 52 is received generally within bezel or lens retainer means 53 in a manner whereby a generally outer portion of forward or outer surface 160 of lens 53 is in abutting engagement with abutment or wall surface 158 of bezel 53. The bezel 53 and lens 52 are then assembled onto and suitably secured to housing body 50, as generally depicted in FIG. 2, resulting in lens 52 being axially contained as between end surfaces 98 and 100 of body means 50 and wall or abutment surface means 158 of bezel or retainer means 53. The retainer means 53 may be operatively secured to portions 102 and 104 of housing means 50 by any number of suitable securing means. However, in the preferred embodiment, once the bezel means 53 and lens means 52 are assembled onto housing means 50, the retainer means 53 is secured to housing means 50 by sonic welding as through those portions of retainer means 53 disposed generally between surface 140 and surface 108 of portion 102 and generally between surface 144 and surface 114 of portion 104. Obviously, in view of the teachings, it should be apparent that such attachment may be accomplished as with suitable adhesives, cements and even mechanical interlock means.
In any event when the lens retainer means or framing means 53 is suitably secured to housing 50, the resulting assembly 40 may be inserted as into an aperture 41, formed in panel or support 25, as by first introducing the left-most end of housing means 40 into aperture 41, and progressively pushing and moving the housing means 40 to the left (as viewed in FIG. 2). Such progressive leftward movement causes the surface of aperture 41 to first engage ramp surfaces 78 and 80 of arms 62 and 64 causing such arms 62 and 64 to be progressively deflected inwardly toward the axis 126 as viewed, for example, in FIG. 3. Such deflection of arms 62 and 64 continues until such time as when the housing means 40 is moved to the left sufficiently to cause the apexes 82 and 84 of arms 62 and 64 to pass beyond the confines of aperture 41. When this happens, further leftward movement of housing means 40 results in arms 62 and 64 moving, resiliently, outwardly with such outward movement being determined by the continuing engagement between aperture 41 and ramp or cam surfaces 74 and 76. When the housing means 40 is moved sufficiently leftward, end or wall surfaces 118, 120, 122 and 124 abut against panel or support 25 and prevent further leftward movement of housing assembly 40. At this time, the resilient force of arms 62 and 64 along with the inclinations of surfaces 74 and 76 become sufficient to hold the housing assembly 40 in its mounted or assembled condition with respect to panel 25, as generally depicted in FIG. 2. In the preferred embodiment, the effective axial length of retainer or bezel means 53 is such that the surface 148 thereof is forwardly of or coplanar with surfaces 118, 120, 122 and 124. If any excessive loads, forces or impacts are to be experienced, it is preferred that such be transmitted into the body portions 102 and 104 directly through surfaces 118, 120, 122 and 124 and not into surface 148 and through body 138.
The preferred embodiment of the invention also comprises gating or indexing means. Such gating or keying means 170 may be comprised of a generally longitudinally extending slot or groove 172 formed, generally, as in the inner surface 154 of retainer or frame means 53 (FIGS. 2, 8 and 9) and a cooperating key-like extension 174 formed on or carried by housing body 50 (FIGS. 2, 3, 4, 5 and 6). Further, in the preferred embodiment, the lens 52 is also provided with a key-like portion or tang 176 which is also slidably received within the groove or guide 172 thereby limiting the relative position which lens 52 may assume when assembled to or received by the retainer 53.
As best depicted in FIG. 2, the effective length of the key portion 174 is substantially longer than the effective length of the coacting groove or slot 172 as to result in a portion 178 thereof extending beyond groove 172. FIG. 12, fragmentarily illustrates panel or support 25 with mounting aperture 41 formed therethrough. In some arrangements, such apertures are also provided with a key-like slot or recess 180 formed therein. In such instances the projecting or extending portion 178 of key portion 174 is received within key slot 180 and thereby provides a positive mechanical lock against any undesirable rotation of the lamp housing 40 within aperture 41. In those situations where the mounting aperture is not provided with a slot such as 180, and if the preferred embodiment of the invention is employed as the lamp housing, the lamp housing may be mounted to such aperture by either of two expedients. That is, since the preferred embodiment is made of plastic material, it has been determined that the projecting portion 178 of key 174 can be cut or broken off as by, for example, grasping that portion with pliers or the like and simply twisting off such grasped portion thereby permitting the lamp housing 40 to be fully inserted into the cooperating mounting aperture to a position as depicted in FIG. 2. The other expedient comprises the use of a suitable spacer which could approximate the projected configuration of surface 148 (FIG. 9) and be of a length generally equal to or slightly greater than the length of the projecting portion 178 of key 174. If such a spacer were employed, it would be slipped over housing body 50 and against surface 148 prior to lamp housing 40 being introduced into the mounting aperture.
FIG. 13 illustrates, by way of example, a bulb socket assembly 54 employable in the invention. The main portion of the structure of FIG. 13 is of plastic or other suitable electrically non-conductive material. Socket assembly 54 comprises a plurality of resiliently deflectable circumferentially situated arcuate latching members or portions 182, 184, 186 and 188, which may be integrally formed with main body portion 190, and a plurality of extending electrical conductors 192 and 194, with respective terminal members 196 and 198, comprising the wiring harness as to achieve, for example, a remote electrical circuit connection.
As is well known in the art and as already implied, the body or housing 190 of socket assembly 54 may be formed of electrically non-conductive plastic material with a suitable centrally located cylindrical recess formed therein adapted to receive therein the male plug-in portion of the related bulb 56. Further, by way of example, the said male plug-in portion may be of the bayonet lock type wherein a tab carried at the side thereof becomes locked against an electrically conductive member within the bulb-receiving recess while a spring loaded contact at the end of the recess engages the end of the said plug-in portion to thereby complete a circuit with and through bulb 56.
As should now be apparent, when bulb socket assembly 54 is in a disconnected state from housing body 50 all that needs to be done to affect operative connection therebetween is to push the socket assembly 54 against the rear or left open end of housing body 50. In so doing, the forward inclined portions of latching arms or portions 182, 184, 186 and 188 operatively engage the surface of aperture 94 and, upon continued applied force, will resiliently deflect radially inwardly as to thereby generally pass through aperture 94. Once such passage is affected, under their own inherent resilient force, the latching or detent portions or arms 182, 184, 186 and 188 move radially outwardly thereby causing the rearwardly disposed inclined portions or surfaces thereof to respectively engage the effective annular step created internally of housing body 50 by virtue of the shoulder or annular surface 96. The dimensions and configurations of the respective cooperating elements is such as to preferably cause forward end surface 200 of body 190 to be in abutting engagement with housing body end surface 90 prior to latching arms 182, 184, 186 and 188 dissipating all of the inherent resilient force thereby assuring a sound latched engagement as between housing body 50 and socket assembly 54.
The invention enables, for example, the bulb 56 to be changed from either the front or the rear of the support or instrument panel 24. If removal of the bulb 56 is to be affected from the rear, all that has to be done is to exert a slight, preferably oblique, force against the bulb socket assembly 54 and directed generally away from body 50 thereby causing the socket body assembly 54 to become disengaged from housing body 50 while still retaining the bulb 56 in such socket assembly. The bulb can then be replaced in the socket assembly and such again latched to the housing body 50 as previously described. If removal of the bulb is to be affected from the front, the housing assembly 40 is withdrawn, as by manually grasping the opposed textured surfaces 164 and 166 of the forward portion or bezel means 53 and, as viewed in FIG. 2, pulling the assembly 40 rightward out of the mounting aperture 41. In so doing, the bulb socket assembly 54 will also be drawn through and out of aperture 41 thereby enabling disconnection of the socket assembly 54 (and attendant replacement of the bulb carried thereby) to be made in front of the panel or support 25. Thereafter, the socket assembly is again latched to the housing body 50 of assembly 40 and together they are re-introduced into mounting aperture 41 and operatively secured thereto in the manner previously described.
The lamp housing assembly of the invention may be manufactured in any of a number of ways. However, it has been discovered that a particularly beneficial manner or method of manufacture comprises the steps of molding or otherwise forming the several elements and then joining them together into an assembly. More particularly, especially with reference to FIGS. 2,3,4 and 14, it is contemplated that the housing body 50 be actually comprised of first and second longitudinally extending molded halves 202 and 204 as to result in, so to speak, a parting or juncture line or plane being the plane of the drawing in FIG. 2 and, in FIG. 4, the vertically extending trace 206 being the parting or juncture plane. The halves 202 and 204 may then be joined to each other as along juxtaposed longitudinal surfaces 208 and 210 and along juxtaposed longitudinal surfaces 212 and 214. The lens 52 may be cut or otherwise formed from suitable material and brought into juxtaposition with end 98 of halves 202 and 204 as well as into juxtaposition with separately molded plastic lens retainer means 53 which, in turn, would be operatively secured to, for example, portions 102 and 104 of the halves 202 and 204.
Further, it has been discovered that such manufacture and assembly can be easily and readily performed by the following steps comprising molding a first longitudinal half, such as 202, of the generally tubular housing 50; molding a second longitudinal half, such as 204, of the generally tubular housing 50; forming a lens, such as 52, of at least translucent material; molding a lens retainer, such as 53; placing the retainer 53 in a suitable fixture as to, for example, be situated having its surface 148 upwardly disposed; placing the lens 52 within the retainer 53 as to rest, for example, against surface 158 thereof; placing the said first longitudinal half 202 into said retainer as to cause surfaces 108, 106, 112 and 114 thereof to be in juxtaposition with surfaces 150, 152 and 154 of retainer 53 while surface portion 98 of half 202 is in juxtaposition with lens 52; placing the said second longitudinal half 204 into said retainer as to cause surfaces 108, 110, 116 and 114 thereof to be in juxtaposition with surfaces 150, 156 and 154 of retainer 53 while surface portion 98 of half 204 is in juxtaposition with lens 52; operatively engaging the sections 202 and 204 as near the swingable ends of arms 62 and 64 and urging such away from each other to assure maximum contact as between juxtaposed surfaces 108, 106, 112, 114, 110, 116 and surfaces 150, 152, 154 and 156; applying sonic wave producing means as to surface 138 of retainer 53 and as to end surface 90; energizing said sonic wave producing means to cause sonic welding as between juxtaposed surfaces of said first and second halves and as between juxtaposed surfaces of said first and second halves and said retainer.
Thus far the invention has been disclosed as having a body with a generally squared or rectillinear end to which a squared or rectilinear retainer is secured. It should be made clear that the invention is not so limited and, among other things, it is specifically contemplated that such end (as comprised of portions 102 and 104) may have any suitable outer configuration as, for example, circular or arcuate, and that the retainer 53 may likewise have a circular outer configuration and/or circular inner configuration.
FIGS. 15, 16, 17, 18 and 19 illustrate yet another embodiment of the invention. Generally, those elements in FIGS. 15-19 which are like or functionally similar to those of FIGS. 1-14 are identified with like reference numerals provided with a suffix "a".
As can be seen in FIGS. 15 and 16, formed integrally with wall 57a are oppositely disposed resiliently deflectable detent like latching arms 62a and 64a respectively joined, at their one ends, to wall 57a as at portions 66a and 68a and similarly respectively joined, at their opposite ends, to wall 57a as at portions 70a and 72a. The right-most (as viewed in FIGS. 15 and 16) or forward ends of arms 62a and 64a are provided with generally radially outwardly extending cam-like or ramp-like surface means 74a and 76a as well as generally rearwardly disposed oppositely inclined cam-like or ramp-like surface means 78a and 80a, respectively. As generally depicted, in the preferred form of the embodiment of FIG. 15, arms 62a and 64a are respectively situated between opposite slot-like clearances 86a and 88a formed in the wall 57a of housing 50a.
The right-most or forward end of housing or body means 50a is provided with a generally enlarged body portion 53a for carrying a related lens 52a. As can be seen, preferably, passage 60a terminates as in a transversely or radially extending and generally circumscribing surface 250 against which the cooperating lens 52a can be operatively placed. As also illustrated, an opening 252 is provided as from the right or forward-most surface 254 to enable the reception therein of said lens 52a and consequently enable the operative mounting thereof. In the preferred embodiment, opening 252 has its general peripheral surface 256 generally inclined with respect to axis 126a in a manner as to generally be disposed further away from such axis 126a the closer such surface approaches the forward end 254. Also, preferably, the outer surface means 258 of enlarged end portion 53a is tapered or inclined, with respect to axis 126a in a direction generally opposite to said inner surface means 256.
The left-most or rearward end of enlarged portion 53a is provided with a generally transverse wall 148a which serves as an axial abutment against the associated support 25a. As best seen in FIGS. 15 and 16, the guide or keying means 174a is formed integrally with wall 57a and enlarged portion 53a and serves the same purpose in the same manner as described with reference to FIGS. 1-14.
The lens 52a may be operatively secured to housing means 50a in any suitable manner as, for example, by adhesives or sonic welding.
In FIGS. 17 and 18 all elements which are like or similar to those of FIGS. 15 and 16 are identified with like reference numerals and suffixes, if any. The modification of FIGS. 17 and 18 contemplates the provision of additional bezel-like or lens retaining means 260 which, as illustrated, may have a generally outer surface complementary to inner surface 256. The retainer means may be situated as to mechanically retain the lens 52a in an assembled condition and the retainer means 260, itself, may be suitably secured to the housing enlarged portion 53a as by, for example, adhesives, sonic welding or any other means, as for example, a mechanical interlock. The inner surface 262 of retainer means 260 may be as to form a general continuation of passage 60a; however, both the retainer means 260 and inner surface 262 need not be so limited. That is, FIG. 18 depicts the enlarged portion 53a as being generally arcuate or circular with the retainer means 260 and its inner surface 262 also being circular; however, the enlarged portion 53a may have any other outer configuration such as, for example, rectilinear or generally squared as depicted in FIG. 19 (wherein elements which are like or functionally similar to those of FIGS. 15-18 are identified with like reference numerals and suffixes, if any). In a configuration as depicted in FIG. 19, if a retainer means 260 were to be employed, the outer surface thereof would be complementary to inner surface 256 of FIG. 19 and yet the inner surface 262 of that retainer could be similarly of a square-like configuration or circular as depicted in FIG. 18.
In the preferred form of the embodiment of FIGS. 15-19, the housing means 50a would be molded of plastic material and, if desired, it could be molded in opposed halves which would be joined to each other generally in accordance with the method set forth and described with regard to FIG. 14.
Although only a preferred embodiment and a select number of modifications of the invention have been disclosed and described, it is apparent that other embodiments and modifications of the invention are possible within the scope of the appended claims.
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A lamp housing for a lamp assembly, such as, for example, an indicator type, has a main body portion detachably connectable to an associated support, as, for example, an instrument panel of a related vehicle, with such body portion enabling the easy connection thereto of an associated bulb socket structure; a pair of resiliently deflectable arm-like members carried by the body portion cooperate with a flange portion of the housing to contain the associated support therebetween.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. application Ser. No. 13/950,312 filed Jul. 25, 2013, now pending. U.S. application Ser. No. 13/950,312 filed Jul. 25, 2013, now pending, is a continuation-in-part of International Patent Application No. PCT/CN2011/002131 with an international filing date of Dec. 19, 2011, designating the United States, now pending, and further claims priority benefits to Chinese Patent Application No. 201110035241.6 filed Jan. 29, 2011. The contents of all of the aforementioned applications, including any intervening amendments thereto, are incorporated herein by reference. Inquiries from the public to applicants or assignees concerning this document or the related applications should be directed to: Matthias Scholl P. C., Attn.: Dr. Matthias Scholl Esq., 245 First Street, 18th Floor, Cambridge, Mass. 02142.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention relates to the field of building materials, and more particularly to a joint structure for assembling wood floorboards or composite floorboards.
[0004] 2. Description of the Related Art
[0005] Typical joints used in floorboards include: a round tenon and round mortise joint, and a rectangular tenon and rectangular mortise joint. Assembly process of the round tenon and round mortise joint includes: rotating the round tenon to place the round tenon in the round mortise, placing the floorboards to a horizontal level so as to interlock the round tenon and the round mortise. The round tenon and round mortise joint is sealed and water-proof on a surface of the stitching line, however, seams cannot be sealed if errors occurs, and a base of the assembled joint is not water-proof or damp-proof. Assembly process of the rectangular tenon and rectangular mortise joint includes: inserting pins obliquely downwards from the rectangular mortise to fix a floorboard, and leaving an expansion joint for inserting a mounting piece. The assembly process for the rectangular tenon and rectangular mortise joint has tremendous and complicated procedures, but low assembly efficiency. Besides, the assembled floorboards cannot be recycled after being disassembled, so that the rectangular tenon and rectangular mortise joint tends to be discarded.
SUMMARY OF THE INVENTION
[0006] In view of the above-described problems, it is one objective of the invention to provide a joint structure for a floorboard that has simple assembly, rigid connection, and high strength, and is water-proof and damp-proof in top and bottom surfaces of the joint.
[0007] To achieve the above objective, in accordance with one embodiment of the invention, there is provided a joint structure comprising a first floorboard and a second floorboard. The first floorboard and the second floorboard each comprises: a top surface; a bottom surface; a first side surface; a second side surface; a third side surface; a fourth side surface; a first beveled tenon, the first beveled tenon comprising a first tenon face facing upwards; a first beveled mortise, the first beveled mortise comprising a first mortise face facing upwards; a second beveled tenon, the second beveled tenon comprising a second tenon face facing downwards; and a second beveled mortise, the second beveled mortise comprising a second mortise face facing downwards. The top surface is disposed substantially parallel to the bottom surface. The first side surface, the second side surface, the third side surface, and the fourth side surface are disposed substantially perpendicular to the bottom surface. The first side surface is disposed opposite to the second side surface; the third side surface is disposed opposite to the fourth side surface; the third side surface connects between the first side surface and the second side surface; and the fourth side surface connects between the first side surface and the second side surface. The first beveled tenon is disposed in parallel with the bottom surface and is disposed on the first side surface at approximately half a height of the first floorboard or the second floorboard; and the first beveled mortise is disposed at an inner side of the first beveled tenon. The second beveled tenon is disposed on the second side surface at approximately half the height of the first floorboard or the second floorboard; and the second beveled mortise is disposed at an inner side of the second beveled tenon. The first beveled tenon is adapted to fit with the second beveled mortise; and the second beveled tenon is adapted to fit with the first beveled mortise. An outer side of the first beveled tenon of the first floorboard and an inner side of the second beveled mortise of the second floorboard form a first interlock mechanism; and an outer side of the second beveled tenon of the first floorboard and an inner side of the first beveled mortise of the second floorboard form a second interlock mechanism. In assembling, the first beveled tenon and the first beveled mortise of the first floorboard match with the second beveled mortise and the second beveled tenon of the second floorboard, respectively; and the first floorboard and the second floorboard are further interlocked by the first interlock mechanism and the second interlock mechanism.
[0008] In accordance with another embodiment of the invention, there is provided a joint structure comprising a first floorboard and a second floorboard. The first floorboard and the second floorboard each comprises: a top surface; a bottom surface; a first side surface; a second side surface; a third side surface; a fourth side surface; a first beveled tenon, the first beveled tenon comprising a first tenon face facing outwards; a first beveled mortise, the first beveled mortise comprising a first mortise face facing outwards; a second beveled tenon, the second beveled tenon comprising a second tenon face facing outwards; and a second beveled mortise, the second beveled mortise comprising a second mortise face facing outwards. The top surface is disposed substantially parallel to the bottom surface. The first side surface, the second side surface, the third side surface, and the fourth side surface are disposed substantially perpendicular to the bottom surface. The first side surface is disposed opposite to the second side surface; the third side surface is disposed opposite to the fourth side surface; the third side surface connects between the first side surface and the second side surface; and the fourth side surface connects between the first side surface and the second side surface. The first beveled tenon is disposed in perpendicular to the bottom surface and is disposed on the first side surface at approximately half a height of the first floorboard or the second floorboard; and the first beveled mortise is disposed at an inner side of the first beveled tenon. The second beveled tenon is disposed on the second side surface at approximately half the height of the first floorboard or the second floorboard; and the second beveled mortise is disposed at an inner side of the second beveled tenon. The first beveled tenon is adapted to fit with the second beveled mortise; and the second beveled tenon is adapted to fit with the first beveled mortise. An outer side of the first beveled tenon of the first floorboard and an inner side of the second beveled mortise of the second floorboard form a first interlock mechanism; and an outer side of the second beveled tenon of the first floorboard and an inner side of the first beveled mortise of the second floorboard form a second interlock mechanism. In assembling, the first beveled tenon and the first beveled mortise of the first floorboard match with the second beveled mortise and the second beveled tenon of the second floorboard, respectively; and the first floorboard and the second floorboard are further interlocked by the first interlock mechanism and the second interlock mechanism.
[0009] In accordance with still another embodiment of the invention, there is provided with a joint structure for a floorboard, comprising: at least one first curved tenon, the first curved tenon comprising a tenon face facing outwards; a first curved mortise, the first curved mortise comprising a mortise face facing outwards; at least one second curved tenon, the second curved tenon comprising a tenon face facing outwards; and a second curved mortise, the second curved mortise comprising a mortise face facing outwards. The first curved tenon is disposed inclined to a surface of the floorboard at a right edge approximately half a height of the floorboard. The first curved mortise is disposed at an inner side of the first curved tenon. The second curved tenon is disposed at a left edge approximately half the height of the floorboard. The second curved mortise is disposed at an inner side of the second curved tenon. The first curved tenon matches with the second curved mortise. The second curved tenon matches with the first curved mortise. An outer side of the first curved tenon and an inner side of the second curved mortise form a first interlock mechanism. An outer side of the second curved tenon and an inner side of the first curved mortise form a second interlock mechanism. In assembling, the first curved tenon and the first curved mortise of a first floorboard match with the second curved mortise and the second curved tenon of a second floorboard, respectively; and the two floorboards are further interlocked by the first interlock mechanism and the second interlock mechanism.
[0010] In a class of this embodiment, the second interlock mechanism is formed by arranging tooth-shaped tenons respectively on the inner side of the first beveled mortise and the outer side of the second beveled tenon, allowing a tooth top line and a tooth bottom line of each of the tooth-shaped tenons to be in parallel with the surface of the floorboard, and engaging the two tooth-shaped tenons with each other. The first interlock mechanism is formed by arranging tooth-shaped tenons respectively on the outer side of the first beveled tenon and the inner side of the second beveled mortise, allowing a tooth top line and a tooth bottom line of each of the tooth-shaped tenons to be in parallel with the surface of the floorboard, and engaging the two tooth-shaped tenons with each other.
[0011] In a class of this embodiment, the second interlock mechanism is formed by arranging a first trapezoidal blind mortise on the inner side of the first beveled mortise and a first trapezoidal tenon on the outer side of the second beveled tenon, respectively, and matching the first trapezoidal blind mortise and the first trapezoidal tenon with each other. The first interlock mechanism is formed by arranging a second trapezoidal tenon on the outer side of the first beveled tenon and a second trapezoidal blind mortise on the inner side of the second beveled mortise, respectively, and matching the second trapezoidal blind mortise and the second trapezoidal tenon with each other.
[0012] In a class of this embodiment, a first deformation structure is formed between the first trapezoidal tenon and corresponding side surface of the floorboard; and a second deformation structure is formed between the second trapezoidal tenon and corresponding side surface of the floorboard. Each of the first deformation structure and the second deformation structure comprises: a triangular ridge comprising a sharp edge and two additional edges, or a rectangular ridge comprising a sharp edge and three additional edges. The sharp edge leans against a beveled line of the first trapezoidal blind mortise or the second trapezoidal blind mortise so as to form a line contact. An expansion joint is formed between the two additional edges of the triangular ridge or the three additional edges of the rectangular ridge for avoiding contact.
[0013] Because the expansion joint is designed, it is not required to insert a sandwich piece, thereby saving the assembly time. Besides, the beveled tenon-and-mortise joint provides the floorboard with a highly integrative structure, so that the fixation by inserting pins are avoided, which further saving the time and the production cost. The deformation structure is designed for solving problems resulting from the natural expansion of the floorboard.
[0014] The interlock mechanism is not limited to the above structures, it is a structure comprising a rectangular tenon and a rectangular blind mortise, or a structure comprising a miter tenon and a rectangular corner.
[0015] In a class of this embodiment, the floorboard comprises: a front edge comprising a straight tenon on an upper part and a straight blind mortise on a lower part; and a rear edge comprising a straight blind mortise on an upper part and a straight tenon on a lower part.
[0016] In the process of assembling the floorboards, dovetail tenon-and-mortise joint are added on two ends that are intersected with the ends provided with the beveled tenon-and-mortise joint so as to increase the strength in a direction in perpendicularity to a grain. Dovetail mortises are arranged on the upper part and the lower part of each of the front edge and the rear edge of the first floorboard and the second floorboard; and each of the dovetail mortise is provided with the dovetail tenon strip.
[0017] In a class of this embodiment, the first beveled tenon and the second beveled tenon have the same slope. One or more beveled tenon-and-mortise joints are provided.
[0018] To assemble floorboards employing the joint structure and using the tooth-shaped tenon or the trapezoidal tenon-and-blind mortise as the interlock mechanism, place the beveled tenon of the first floorboard in the beveled mortise of the second floorboard, push the beveled tenon from a relatively wide beveled mortise to a relatively narrower beveled mortise so as to fix the beveled tenon inside the beveled mortise; meanwhile, further interlock the two floorboards by the interlock mechanism of the he tooth-shaped tenon or the interlock mechanism of the trapezoidal tenon-and-blind mortise so as to effectively prevent the boards from splitting in the joint part. Because the base of the joint part overlaps with one another, the base is damp-proof. Floorboards of such structure are capable of forming a rigid integrative structure and preventing the floorboards from falling apart. The up-down connected part is sealed, thereby being damp-proof. No swell and few contraction of the floorboard will happen after long term use. The joint has a simple structure, convenient assembly, which is very suitable for assembling wood floorboards and composite floorboards.
[0019] Advantages of the invention are as follows:
1) when used in decorative wall panels, the assembly process using the joint structure is simple and time saving; the assembled decorative wall panels has completely sealed stitching lines, high integration, no nail holes or exposed screws, and seam splitting resulting from retraction of the floorboard is prevented. 2) when used in light weight building walls, the use of the joint structure is capable of saving a large amount of keels for fixing internal joints. 3) when used in water proof wall panels used in wooden building. The joint structure of the invention is capable of largely increasing the air impermeability (energy saving) and the strength of the integrative structure (wind resistant and shock resistant). 4) A paint treatment on the joint position can prevent the formation of the joint splitting. 5) The use of the joint of the invention is suitable to cut panels of large area into small pieces so as to save packing materials and the transporting space, which meets the requirements of environmental protection. 6) The joint structure of the invention decreases the use of the pins and assembly process thereof, and meanwhile the gluing is saved. 7) When the joint structure is used in furniture, the use of the hardware and glue can be largely decreased. The integrative structure is transformed from a conventional point stress structure into a line stress structure, thereby improving the duration of the whole furniture, omitting the gluing process, simplifying the assembly and disassembly, and meeting the requirements of environmental protection.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] The invention is described hereinbelow with reference to the accompanying drawings, in which:
[0028] FIG. 1 is a structure diagram of a floorboard comprising a tenon-and mortise-joint in accordance with one embodiment of the invention;
[0029] FIG. 2 is a structure diagram of a floorboard comprising a tenon-and mortise-joint in accordance with one embodiment of the invention;
[0030] FIG. 3 is an axonometric drawing of hardwood floorboards comprising a plurality of beveled tenon-and-mortise joints in accordance with one embodiment of the invention;
[0031] FIG. 4 is an enlarged view of a deformation structure of assembled hardwood floorboards of FIG. 3 in accordance with one embodiment of the invention;
[0032] FIG. 5 is an axonometric drawing of softwood floorboards comprising a plurality of beveled tenon-and-mortise joints in accordance with one embodiment of the invention;
[0033] FIG. 6 is an enlarged view of a deformation structure of assembled softwood floorboards of FIG. 5 in accordance with one embodiment of the invention;
[0034] FIG. 7 is an axonometric drawing of two floorboards to be assembled in accordance with one embodiment of the invention;
[0035] FIG. 8 is a laterally sectional view of two floorboards to be assembled in accordance with one embodiment of the invention;
[0036] FIG. 9 is a cross sectional view of a floorboard end comprising a lower straight tenon and an upper straight mortise in accordance with one embodiment of the invention;
[0037] FIG. 10 is a cross sectional view of a floorboard end comprising a lower straight mortise and an upper straight tenon in accordance with one embodiment of the invention;
[0038] FIG. 11 is a laterally sectional view of two assembled floorboards in accordance with one embodiment of the invention;
[0039] FIG. 12 is a top view of a floorboard in accordance with one embodiment of the invention;
[0040] FIG. 13 is a top view of assembled floorboards in accordance with one embodiment of the invention;
[0041] FIG. 14 is an axonometric drawing of veneers comprising beveled tenon-and-mortise joints before assembly in accordance with one embodiment of the invention;
[0042] FIG. 15 is a structure diagram of planks comprising beveled tenon-and-mortise joints before assembly in accordance with one embodiment of the invention;
[0043] FIG. 16 is a structure diagram of planks comprising beveled tenon-and-mortise joints after assembly in accordance with one embodiment of the invention;
[0044] FIG. 17 is a top view of planks comprising beveled tenon-and-mortise joints after assembly in accordance with one embodiment of the invention;
[0045] FIG. 18 is a structure diagram of floorboards comprising beveled tenon-and-mortise joints in perpendicularity to the floorboards before assembly in accordance with one embodiment of the invention;
[0046] FIG. 19 is a structure diagram of floorboards comprising beveled tenon-and-mortise joints in perpendicularity to the floorboards after assembly in accordance with one embodiment of the invention;
[0047] FIG. 20 is a structure diagram of floorboards comprising beveled tenon-and-mortise joints at an angle of 45° to the floorboards before assembly in accordance with one embodiment of the invention;
[0048] FIG. 21 is a structure diagram of floorboards comprising beveled tenon-and-mortise joints at an angle of 45° to the floorboards before assembly in accordance with one embodiment of the invention;
[0049] FIG. 22 is a structure diagram of a tooth-shaped tenon in accordance with one embodiment of the invention;
[0050] FIG. 23 is a front view of a tooth-shaped tenon of FIG. 1 in accordance with one embodiment of the invention;
[0051] FIG. 24 is a lateral view of a tooth-shaped tenon of FIG. 1 in accordance with one embodiment of the invention;
[0052] FIG. 25 is a structure diagram of a connecting member comprising a groove fitting with a tooth-shaped tenon in accordance with one embodiment of the invention;
[0053] FIG. 26 is a structure diagram of another connecting member comprising a groove fitting with a tooth-shaped tenon in accordance with one embodiment of the invention;
[0054] FIG. 27 is a structure diagram of connecting members of FIGS. 25-26 assembled by a tooth-shaped tenon of FIG. 22 in accordance with one embodiment of the invention;
[0055] FIG. 28 is a structure diagram of a dovetail beveled tenon in accordance with one embodiment of the invention;
[0056] FIG. 29 is a lateral view of a dovetail beveled tenon of FIG. 7 in accordance with one embodiment of the invention;
[0057] FIG. 30 is a front view of a dovetail beveled tenon of FIG. 7 in accordance with one embodiment of the invention;
[0058] FIG. 31 is a structure diagram of a connecting member comprising a groove fitting with a dovetail beveled tenon in accordance with one embodiment of the invention;
[0059] FIG. 32 is a structure diagram of another connecting member comprising a groove fitting with a dovetail beveled tenon in accordance with one embodiment of the invention;
[0060] FIG. 33 is a structure diagram of connecting members of FIGS. 31-32 assembled;
[0061] FIG. 34 is a an axonometric drawing of connecting members comprising a plurality of tenons and mortises before assembly in accordance with one embodiment of the invention;
[0062] FIG. 35 is a top view of two connecting members comprising reversed straight angle tenons in assembly in accordance with one embodiment of the invention;
[0063] FIG. 36 is a op view of two connecting members comprising reversed straight angle tenons in assembly in accordance with one embodiment of the invention;
[0064] FIG. 37 is a structure diagram of a floorboard combined with a curved tenon-and-mortise joint 12 and a tapered tenon-and-mortise joint 13 in accordance with one embodiment of the invention;
[0065] FIG. 38 is a structure diagram of floorboards comprising a tapered tenon-and-mortise joint before assembly in accordance with one embodiment of the invention;
[0066] FIG. 39 is a structure diagram of floorboards comprising a tapered tenon-and-mortise joint after assembly in accordance with one embodiment of the invention;
[0067] FIG. 40 is a cross section view of an assembled tapered tenon-and-mortise joint;
[0068] FIG. 41 is a first installation diagram of floorboards comprising a curved tenon-and-mortise joint in accordance with one embodiment of the invention;
[0069] FIG. 42 is a second installation diagram of floorboards comprising a curved tenon-and-mortise joint in accordance with one embodiment of the invention;
[0070] FIG. 43 is a second installation diagram of floorboards comprising a curved tenon-and-mortise joint in accordance with one embodiment of the invention;
[0071] FIG. 44 is a structure diagram of a curved tenon-and-mortise joint before assembly in accordance with one embodiment of the invention;
[0072] FIG. 45 is a cross section view of a curved tenon-and-mortise joint after assembly in accordance with one embodiment of the invention;
[0073] FIGS. 46-50 are structure diagrams of milling cutters of different shapes for machining a curved tenon-and-mortise joint; in accordance with one embodiment of the invention;
[0074] FIG. 51 is a machining path of a milling cutter of shape E in accordance with one embodiment of the invention;
[0075] FIG. 52 is a structure diagram of different milling cutters shaping different positions of a curved tenon-and-mortise joint in accordance with one embodiment of the invention;
[0076] FIG. 53 is a structure diagram of a finished curved tenon-and-mortise joint in accordance with one embodiment of the invention; and
[0077] FIG. 54 is a structure diagram of a curved tenon-and-mortise joint with specific dimensions in accordance with one embodiment of the invention.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0078] For further illustrating the invention, experiments detailing a joint structure for assembling floorboards are described below. It should be noted that the following examples are intended to describe and not to limit the invention.
[0079] As shown in FIGS. 1-3 , a joint structure for a floorboard, comprises: at least one first beveled tenon 11 , the first beveled tenon 11 comprising a tenon face facing upwards; a first beveled mortise 12 , the first beveled mortise 12 comprising a mortise face facing upwards; at least one second beveled tenon 13 , the second beveled tenon 13 comprising a tenon face facing downwards; and a second beveled mortise 14 , the second beveled mortise 14 comprising a mortise face facing downwards. The first beveled tenon 11 is disposed in parallel to a surface of the floorboard at a right edge approximately half a height of the floorboard. The first beveled mortise 12 is disposed at an inner side of the first beveled tenon 11 . The second beveled tenon 13 is disposed at a left edge approximately half the height of the floorboard. The second beveled mortise 14 is disposed at an inner side of the second beveled tenon 13 . The first beveled tenon 11 matches with the second beveled mortise 14 . The second beveled tenon 13 matches with the first beveled mortise 12 . An outer side of the first beveled tenon 11 and an inner side of the second beveled mortise 14 form a first interlock mechanism. An outer side of the second beveled tenon 13 and an inner side of the first beveled mortise 12 form a second interlock mechanism. In assembling, the first beveled tenon 11 and the first beveled mortise 12 of a first floorboard 1 match with the second beveled mortise 14 and the second beveled tenon 13 of a second floorboard 2 , respectively; and the two floorboards are further interlocked by the first interlock mechanism and the second interlock mechanism.
[0080] As shown in FIG. 1 , the second interlock mechanism is formed by arranging tooth-shaped tenons 15 a , 16 a respectively on the inner side of the first beveled mortise 12 and the outer side of the second beveled tenon 13 , allowing a tooth top line and a tooth bottom line of each of the tooth-shaped tenons 15 a , 16 a to be in parallel with the surface of the floorboard, and engaging the two tooth-shaped tenons 15 a , 16 a with each other. The first interlock mechanism is formed by arranging tooth-shaped tenons 16 b , 15 b respectively on the outer side of the first beveled tenon 11 and the inner side of the second beveled mortise 14 , allowing a tooth top line and a tooth bottom line of each of the tooth-shaped tenons 15 b , 16 b to be in parallel with the surface of the floorboard, and engaging the two tooth-shaped tenons 15 b , 16 b with each other. The first beveled tenon 11 and the first beveled mortise 12 of the first floorboard 1 match with the second beveled mortise 14 and the second beveled tenon 13 of the second floorboard 2 , respectively; and the two floorboards are further interlocked and clamped by the first interlock mechanism and the second interlock mechanism.
[0081] As shown in FIG. 2 , the second interlock mechanism is formed by arranging a trapezoidal blind mortise 17 a on the inner side of the first beveled mortise 12 and a trapezoidal tenon 18 a on the outer side of the second beveled tenon 13 , respectively, and matching the trapezoidal blind mortise 17 a and the trapezoidal tenon 18 a with each other. The first interlock mechanism is formed by arranging the trapezoidal tenon 18 b on the outer side of the first beveled tenon 11 and a trapezoidal blind mortise 17 b on the inner side of the second beveled mortise 14 , respectively, and matching the trapezoidal blind mortise 17 b and the trapezoidal tenon 18 b with each other. The first beveled tenon 11 and the first beveled mortise 12 of the first floorboard 1 match with the second beveled mortise 14 and the second beveled tenon 13 of the second floorboard 2 , respectively; and the two floorboards are further interlocked and clamped by the first interlock mechanism and the second interlock mechanism.
[0082] To avoid swell phenomenon between the trapezoidal blind mortise 17 a , 17 b and the trapezoidal tenon 18 b , 18 a , a deformation structure is designed. The deformation structures is formed between the trapezoidal tenon 18 b , 18 a arranged on the outer side of either the first tenon 11 or the second tenon 13 , and corresponding edge of the floorboard. A deformation structure comprises: a triangular ridge 18 c comprising a sharp edge 18 e (as shown in FIGS. 3-4 ), or a rectangular ridge 18 d comprising a sharp edge 18 e (as shown in FIGS. 5-6 ). The sharp edge 18 e leans against a beveled line 17 c of the trapezoidal blind mortise 17 b so as to form a line contact. An expansion joint is formed between the other two sides of the triangular ridge 18 c or the other three sides of the rectangular ridge 18 d for avoiding contact.
[0083] In the process of assembly the floorboards, dovetail tenon-and-mortise joint are added on two ends that are intersected with the ends provided with the beveled tenon-and-mortise joint so as to increase the strength in a direction in perpendicularity to a grain. As shown in FIG. 7 , dovetail mortises 23 are arranged on the upper part and the lower part of each of the front edge and the rear edge of the first floorboard 1 and the second floorboard 2 ; and each of the dovetail mortises 23 is provided with the dovetail tenon strip 24 .
[0084] The interlock mechanism can be other structures, such as a structure comprising a rectangular tenon and a rectangular blind mortise, and a structure comprising a sharp corner-tenon and a rectangular sharp corner.
[0085] One or more beveled tenons and beveled mortises matched with each other can be designed. As shown in FIG. 3 , the invention comprises a plurality of beveled tenons and corresponding mortises that have the same slope. The structure comprising the trapezoidal blind mortise and the trapezoidal tenon is employed.
[0086] FIG. 8 is a lateral view of assembled two floorboards.
[0087] As shown in FIGS. 9-10 , the floorboard comprises: a front edge comprising a straight tenon 19 on an upper part and a straight blind mortise 21 on a lower part; and a rear edge comprising a straight blind mortise 21 on an upper part and a straight tenon 19 on a lower part.
[0088] FIG. 11 is a laterally sectional view of two assembled floorboards.
[0089] FIG. 12 is a top view of a floorboard.
[0090] FIG. 13 is a top view of assembled floorboards.
[0091] The joint of the invention can used to assemble veneers, an axonometric drawing of veneers comprising beveled tenon-and-mortise joints before assembly is shown in FIG. 14 .
[0092] The joint of the invention can also used to assemble planks, a structure diagram of planks comprising beveled tenon-and-mortise joints before assembly is shown in FIG. 15 . FIG. 16 is a structure diagram of planks comprising beveled tenon-and-mortise joints after assembly. FIG. 17 is a top view of planks comprising beveled tenon-and-mortise joints after assembly.
[0093] Another joint structure for a floorboard, comprises: at least one first curved tenon 29 , the first curved tenon 29 comprising a tenon face facing outwards; a first curved mortise 30 , the first curved mortise 30 comprising a mortise face facing outwards; at least one second curved tenon 29 , the second curved tenon 29 comprising a tenon face facing outwards; and a second curved mortise 30 , the second curved mortise 30 comprising a mortise face facing outwards. The first curved tenon 29 is disposed inclined to a surface of the floorboard at a right edge approximately half a height of the floorboard; the first curved mortise 30 is disposed at an inner side of the first curved tenon 29 . The second curved tenon 29 is disposed at a left edge approximately half the height of the floorboard; the second curved mortise 30 is disposed at an inner side of the second curved tenon 29 . The first curved tenon 29 matches with the second curved mortise 30 . The second curved tenon 29 matches with the first curved mortise 30 . An outer side of the first curved tenon 29 and an inner side of the second curved mortise 30 form a first interlock mechanism. An outer side of the second curved tenon 29 and an inner side of the first curved mortise 30 form a second interlock mechanism. In assembling, the first curved tenon 29 and the first curved mortise 30 of a first floorboard 1 match with the second curved mortise 30 and the second curved tenon 29 of a second floorboard 2 , respectively; and the two floorboards are further interlocked by the first interlock mechanism and the second interlock mechanism.
[0094] Herein a composite floorboard (as shown in FIG. 37 ) comprising the curved tenon-and-mortise joint 12 and a tapered tenon-and-mortise joint 13 are described.
[0095] The curved tenon-and-mortise joint as shown in FIG. 44 comprises: a curved tenon 29 and a curved mortise 30 , auxiliary matching structures comprising a stitching tenon 16 and a stitching mortise 15 , and a curved corner 28 .
[0096] The tapered tenon-and-mortise joint 13 (as shown in FIG. 38 ) comprises: a tapered tenon 23 , 25 and a tapered mortise 24 , 26 , and an auxiliary matching structure comprising a stitching tenon 16 a and a stitching mortise 15 b.
[0097] Floorboards employing the two kinds of joints are superior to those employing the same tenon-and-mortise joints but totally different from those conventional ones employing different tenon-and-mortise joints. The curved tenon-and-mortise joint as shown in FIG. 44 has a smaller space of 5 mm compared to the conventional joints of 12 mm. The finished product rate exceeds two times of that of the conventional ones, thereby largely improving the finished product rate of the floorboards. Furthermore, the floorboards after being assembled have sealed joints and high integration and strength. Because the two floorboards have the same tenon-and-mortise joints on the same side, the assembly and disassembly of the floorboards are very convenient.
[0098] The tapered tenon-and-mortise joint as shown in FIGS. 38-39 is assembled by a method of unilateral axis rotating, which obviously different from the conventional stitching principles. The assembly of the tapered tenon-and-mortise joint is realized by slight deformation. The tapered tenon-and-mortise joint of the invention has a much simpler structure, no obvious grooves, and high integration and strength.
[0099] Process for assembling composite floorboard comprising the curved tenon-and-mortise joint 12 and the tapered tenon-and-mortise joint 13 is as follows: place the curved tenon 29 of a first floorboard into the curved mortise 30 of another floorboard. Move the two floorboards in opposite directions along a stitching line to match with each other. Move in horizontal direction after being lifted by two curved corners 28 , control a horizontal movement within a range of the curved tenon 29 (that is, a width of a conventional expansion joint of floor corner is approximately 5 mm) Process for joint the curved tenon and the curved mortise are shown in FIGS. 41-43 . Match the tapered tenon-and-mortise joint while moving, using the matching curved tenon-and-mortise joint as an axis to lifting the curved tenon-and-mortise joint of an opposite end. The match of the curved tenon-and-mortise joint realizes the stitching of the stitching tenon 16 and the stitching mortise 15 during which the tapered tenon-and-mortise joint moves downwards to realize the stitching of the stitching tenon 16 a and a stitching mortise 15 b , as shown in FIGS. 38-39 . Thus, the assembling composite floorboard comprising the curved tenon-and-mortise joint 12 and the tapered tenon-and-mortise joint 13 are finished.
[0100] FIGS. 46-50 are structure diagrams of milling cutters of different shapes for machining a curved tenon-and-mortise joint. FIG. 52 is a structure diagram of different milling cutters shaping different positions of a curved tenon-and-mortise joint. A machining path of a milling cutter of shape E is shown in FIG. 51 . Machining paths of other milling cutters of different shapes (such as shape A, shape B, shape C, and shape D) are straight lines. FIG. 53 is a structure diagram of a finished curved tenon-and-mortise joint. FIG. 54 is a structure diagram of a curved tenon-and-mortise joint with specific dimensions.
[0101] While particular embodiments of the invention have been shown and described, it will be obvious to those skilled in the art that changes and modifications may be made without departing from the invention in its broader aspects, and therefore, the aim in the appended claims is to cover all such changes and modifications as fall within the true spirit and scope of the invention.
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A joint structure includes a first floorboard and a second floorboard. The first floorboard and the second floorboard each includes: a top surface; a bottom surface; a first side surface; a second side surface; a third side surface; a fourth side surface; a first beveled tenon, the first beveled tenon including a first tenon face facing upwards; a first beveled mortise, the first beveled mortise including a first mortise face facing upwards; a second beveled tenon, the second beveled tenon including a second tenon face facing downwards; and a second beveled mortise, the second beveled mortise including a second mortise face facing downwards. The top surface is disposed substantially parallel to the bottom surface. The first side surface, the second side surface, the third side surface, and the fourth side surface are disposed substantially perpendicular to the bottom surface.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is related to and claims all available benefit of international application PCT/GB2010/000611 filed Mar. 29, 2010, which in turn claims benefit to British application GB0905663.1 filed Apr. 1, 2009.
BACKGROUND
This invention relates to the methods of and apparatus for the installation of columns/piles and more particularly submerged columns/piles.
In particular, the present invention is concerned with the installation of upstanding columns/piles that are intended to serve as supports for the mounting of installations above or below a water surface. Such installations can be of many forms or purposes, such as for example, supporting submerged water driven turbine installations, and/or wind driven turbine installations.
It is convenient to note that methods and apparatus for generating power from sources other than the combustion of hydrocarbon materials are known and in particular the generation of power from sea and rivers water flows together with the development of power from the movement of air by the use of wind turbines with both involving the mounting of the associated wind or water driven turbine/rotor assembly upon a column/pile upstanding from a sea or river bed.
Whether or not a submerged water driven turbine or an air driven turbine is involved in such power generation the column/pile upon which it is mounted needs to be very firmly anchored in its upstanding position so as to be able to withstand forces that may be imposed upon the column/piles by water and air flows.
It will be clear that in the case of the mounting of columns/piles in water presents considerable operational difficulties.
SUMMARY
Whilst the above observations have been made in relation to the mounting of columns/piles in relation to power generation it is convenient to note that, for example, water submerged columns/piles may be used in connection with other forms of installation such as support columns, for example, for bridges. Broadly according to a first aspect of the invention there is provided a method of mounting one or more a column/pile in an upstanding position on a supporting surface formed by a lake, sea or river bed comprising the steps of lowering the column/pile to be installed from a support vessel into contact with the supporting surface, using the lower/toe end of the column/pile as a drill such upon rotation of the column/pile a bore is formed in the supporting surface into which the lower region of the column/pile is to be located and leaving the column/pile in situ in the thus formed bore after the completion of a drilling operation.
If desired, a reverse fluid circulation is used during the drilling operation such that drill cutting debris is discharged into the water at the head of the column/pile by using a flow of compressed air derived from the support vessel by way of a flexible umbilical.
Also if desired a forward fluid circulation can be used during the drilling operation such that drill cutting debris is discharged into the water at the bed of the water within which drilling takes place using a flow of fluid supplied from the support vessel by way of a flexible umbilical.
Preferably a submersible drilling machine is used for mounting one or more columns/piles to be inserted in the supporting surface, and deploying the machine from the surface support vessel so that it rests on the supporting surface, remotely operating from the support vessel one or more drilling mechanisms by way of one or more flexible umbilicals for delivering power to and for controlling the operation of the drilling machine, and following a required drilling operation recovering the drilling machine by the support vessel to leave one or more columns/piles upstanding from the supporting surface.
Conveniently when installing one or more foundation columns/piles in a lake, river or sea bed, a submersible drilling machine can incorporate one or more drilling mechanisms the machine being deployable with the aid of a surface support vessel so as to be able to rest on the lake, river, or sea bed as to be fully supportable by the lake, river or sea bed, means for remotely operating from the support vessel said one or more drilling mechanisms by way of one or more flexible umbilicals for delivering power to and for controlling the machine, and mains whereby following a required drilling operation the machine recoverable by the support vessel thereby to leave one or more columns/piles upstanding from the lake, river or sea bed.
Preferably the machine incorporates telescopic legs or otherwise articulated members whereby the operational position of the drilling machine is positionally adjustable relative to the support surface in such manner as to level the machine so that its drilling mechanisms are able to produce a vertical bores in the supporting surface.
If desired the machine incorporates position adjustment actuators such as hydraulic cylinders, pneumatic cylinders, bags or bladders or the like.
In a preferred construction each column/pile to be installed is cylindrical it includes at its lower/toe end rock or soil cutters in such manner that on rotation of the column/pile about its longitudinal axis the column/pile effectively acts as a rotary drill, and wherein the machine incorporates means for rotating the column/pile thereby to perform a drilling operation.
In a further preferred construction the machine includes means for enabling the drilling means of the machine to be positionally indexed from the site of a drilling operation to a site for the next following drilling operation without bodily moving the machine, the arrangement being such that a predetermined pattern of column/piles can be established without moving the entire machine.
In a preferred further construction the drilling machine is recoverable to the support vessel whereby the machine can be equipped with a further column/pile and returned to a different location of the machine the arrangement being such as to allow a multiplicity of columns/piles to be installed in a predetermined pattern without moving the entire machine. In a further aspect of the construction of the apparatus the machine is provided with a plurality of drilling mechanisms whereby the drilling of a prearranged installation pattern of the columns/piles is facilitated.
In a further construction of the apparatus the machine includes means such as hydrofoils for utilizing the flow of water in the vicinity of the machine to create a net force that assists gravity in holding the machine onto the lake, river or sea bed.
Preferably the machine incorporates telescopic legs or otherwise articulated members whereby the operational position of the drilling machine is positionally adjustable in such manner as to level the machine so that its drilling mechanisms are able to produce a vertical bore in the lake, river or sea bed. Conveniently, the machine incorporates position adjustment actuators such as hydraulic cylinders, pneumatic cylinders, bags or bladders or the like.
BRIEF DESCRIPTION OF THE DRAWINGS
For a better understanding of the invention and to show how the invention may be carried into effect reference will now be made to the accompanying drawings in which:—
FIGS. 1 a to 1 h schematically illustrate successive stages in the positioning and locating of a first embodiment of apparatus for installing and mounting a column/pile upon a lake, sea or river bed.
FIGS. 2 a and 2 b schematically illustrate a second embodiment of apparatus for installing and mounting a column/pile upon a lake, sea or river bed and
FIG. 3 . schematically illustrates a further embodiment of the apparatus for installing and mounting a column/pile upon a lake, sea or river bed.
DESCRIPTION OF PREFERRED EMBODIMENTS
Referring now to the drawings and in particular to FIG. 1 a . This Figure schematically illustrates a surface vessel 1 positioned in the vicinity of a location 2 of a sea/river bed 3 at which it is required to install an upstanding columns/pile 4 .
As illustrated in the Figure the surface vessel 1 carries a column/pile 4 or several columns/piles 4 to be mounted in the sea/river bed 3 . In the Figure such columns/piles are shown as being located at the stern end 5 of the vessel 1 . A derrick/crane installation 6 is located at the stem end 7 of the vessel supports a drilling machine 8 which incorporates a main platform section 9 mounting a plurality of telescopic legs 10 having profiled feet 11 that are intended to engage with the lake, sea or river bed 3 in the vicinity of the required location 2 . The drilling machine 8 is suspended for deployment into the water by means of a cable 12 and an associated winch assembly 13 .
At this stage a column/pile 4 to be installed in the sea/river bed 3 is shown as being vertically positioned on the drilling machine 8 in its drilling position. In other words a column/pile 4 is pre-installed on the drilling machine 8 .
The drilling machine 8 incorporates equipment for rotating the column/pile 4 carried thereby in order to carry out an installing operation. Arrangements for operating the drilling machine are provided in the form of flexible umbilical connections 15 , 16 operationally connected between the drilling machine 8 and associated control equipment (not shown) provided on the vessel 1 .
The vessel 1 is maintained in its required operational position throughout a drilling operation by appropriate vessel positioning arrangements such as mooring cables and/or a dynamic vessel positioning systems (not shown)
It will be appreciated that during travel of the vessel 1 to the required column/pile installation position 2 the drilling machine 8 would be positioned by the winch assembly 13 inboard of the vessel and once the required position 2 of the lake, sea or river bed 3 at which it is required to install the column/pile 4 has been reached the drilling machine 8 is moved by the winch assembly 13 to a positional setting at in which it can be lowered by the winch assembly 13 down to the sea machine bed 3 to the position as shown in FIG. 1 b.
At this stage of the installation of the drilling it will be noted that since the lake, sea or river bed is uneven the drilling machine 8 is not level, and that the weight of the drilling machine 8 is totally supported by the fact of its resting on the lake, sea or river bed 3 . In this situation the winch assembly cable 12 is arranged to be slack as are the umbilical connections 15 / 16 . This situation accommodates possible displacement and heave movements of the vessel 1 arising from the action of wind, tide, and wave motions on the vessel. It will be understood that during such deploying of the drilling machine 8 the vessel is positioned to ensure that the drilling machine 8 is deposited upon the lake, sea or river bed as accurately as possible to the required site 2 of the column/pile to be mounted.
This accuracy of positioning, in practice, is a matter of importance particularly where more than one column/pile 4 is involved in the mounting of a base support unit for a larger column/pile or installation.
Once the drilling machine 8 is resting upon the lake sea or river bed 3 it is necessary to adjust the leveling of the drilling machine platform 9 such that it is horizontal and that the column/pile 4 to be inserted into the sea bed is positioned immediately above the required mounting position. This leveling is achieved by appropriate adjustments to the lengths of the telescopic legs 10 projecting beneath the platform 9 .
This leveling operation is discussed in relation to FIG. 1 c from which it will be noted that the drilling rig platform 9 has been set to a horizontal operational setting by appropriate height adjustment of the legs 10 together with any lateral positional adjustment to position the column/pile above the lake, sea or riverbed location 2 at which it is to be positioned and to ensure that the platform 9 is positionally stable. As mentioned this positional adjustment of the drilling machine 8 may be effected by using hydraulic or electrical actuators (not shown) controlled from the vessel 1 by way of the umbilical connections 15 / 16 .
In practice lateral forces exerted upon the drilling machine by the action of currents and waves are reacted through the legs 10 into the sea/river bed by means of friction.
In the embodiment shown the socket/bore 17 for receiving the column/pile is created by a rotary drilling operation using the lower/toe end 18 of the column/pile 4 as a drill bit. For this purpose the lower end/toe 18 of the column/pile 4 is equipped with cutters 19 regarded as being suitable for the expected lake, sea or river bed conditions. The required rotational drilling torque is applied to the column/pile by a rotary drill drive. The required force necessary to move the column/pile downwards during the drilling rotation is supplied by the weight of the column/pile. If, in practice, this is found not to be sufficient the column/pile can be ballasted by the application of weight to the column/pile. If necessary, additional force can be obtained from hydraulic cylinders 21 .
A guide tube 22 within which the column/pile 4 is located whilst on the drilling machine serves to maintain the column/pile 4 in a vertical position during the drilling operation. In practice, power for the drilling operation and the control of the actual drilling operation is derived from the vessel 1 by way of the umbilicals 15 and 16 . Furthermore other services to the column/pile such as compressed air for the removal of drilling debris/cuttings can be supplies by way of the umbilicals 15 and 16 between the vessel 1 and the drilling machine 8 .
Referring now to FIG. 1 d , this Figure schematically illustrates the stage at which the column/pile 4 has been advanced to a required depth in the lake, sea or river bed 3 . At this stage the annulus 17 A that has been produced by the drilling operation around inserted part of the column/pile 4 needs to be filled with grout to ensure that the column/pile 4 is firmly secured in position. This grout can be mixed on the vessel 1 and can be fed to the annulus 17 A by the umbilical 15 used for the pumping in of air. Once the annulus 17 has been filed the umbilicals 15 , 16 can be released and recovered to the surface vessel.
In situations in which it is required to insert into the lake, sea or river bed 3 more than one column/pile 4 , for example, in close relationship to each other the drilling unit 20 and in particular the column/pile guide 22 , the torque drive and associated hydraulic cylinders 21 can be moved to the required location for the next column/pile 4 to be inserted in the lake, sea or river bed.
This displacement can be achieved in many different ways, for example, by using a yaw drive to move the drilling unit 20 to a new position as is illustrated in FIG. 1 e . A new column/pile 4 can then be lowered into the guide tube 22 from the vessel 1 . It is to be noted that the first column/pile 4 to be installed could be separate from the deploying of the drilling machine 8 to the lake, sea or river bed. In this case the drilling machine can be deployed without the column/pile 4 being in place In particular as may be seen from FIG. 1 e once the displacement of the drilling machine 8 has been effected that is the guide tube 22 has been set above the position 2 in which the next column/pile 4 is to be inserted into the lake, sea or river bed 3 the next column/pile 4 to be inserted is lowered from the vessel 1 and entered into the guide tube 22 .
As is indicated in FIG. 1 e this is shown as being located to the right of the position shown in FIGS. 1 c and 1 d . In other words the guide tube 22 and associated drill unit 20 can be displaced relative to the drilling machine platform 9 by a drive unit 23 which is such as to displace the guide tube 22 to a selected one of a number of possible operational positions relative to the platform 9 .
FIG. 1 f illustrates an installation stage in which the first column/pile 4 has been inserted and the guide tube 22 has been moved to the next required position and the next column/pile 4 to be mounted in the lake, sea or river bed has been installed in a manner as discussed in relation to FIGS. 1 c and 1 d and grout has been or is being inserted into the annulus 17 produced in the lake, sea or river bed by the drilling operation.
The above discussed process is repeated for each column/pile 4 to be positioned in the lake, sea or river bed 3 .
Once the drilling pile installation has been completed the machine 8 is withdrawn by the winch assembly to be repositioned onto the vessel. This is illustrated in FIG. 1 g.
It will be noted from FIG. 1 g that a series of columns/piles 4 are upstanding from the lake, sea or river bed. FIG. 1 h illustrates very schematically the mounting of a turbine and rotor installation 25 being mounted to the columns/piles previously inserted as herein before described in relation to the previously discussed FIGS. 1 a to 1 g.
Referring now to FIGS. 2 a and 2 b which illustrate a second embodiment of a drilling machine apparatus 35 in which the platform of the previous Figures is effectively replaced by arrangement of sealed ballast tanks 26 which when filled with air are able to float in water so that they drilling machine can be moved to a required drilling position by being towed by the control vessel 1 .
With this embodiment once the drilling machine 8 has been positioned in the required position for inserting a column/pile 4 , the ballast tanks 26 are partially flooded with water to an extent that the ballast tanks and the associated drilling machine 8 exhibits a slightly negative buoyancy so that the drilling machine 8 can be lowered to the lake, sea or river bed 3 by the winch assembly 13 . Once the drilling machine 8 is at the lake, sea or river bed 3 and the drilling machine 8 has been leveled so the drilling machine platform 9 is horizontal and the guide tube 22 is vertical the ballast tanks 26 are fully flooded with water thereby maximizing the submerged weight of the drilling machine 8 and therefore its frictional engagement with the lake, sea or river bed 3 . After the required number of columns/piles 4 have been inserted into the lake, sea or river bed 3 , the water is exhausted from the ballast tanks 26 to cause the drilling machine 8 to be readily liftable back to the vessel 1 .
FIG. 3 schematically illustrates a further embodiment of a drilling machine 8 which is such that weight required to stabilize the drilling machine whilst on a lake, sea or river bed 3 is reduced. For this purpose the machine is provided with positionally adjustable hydrofoils settable such that down force is produced by tide or river flows, thereby increasing the requisite friction between the machine feet 11 and the lake, sea or bed 3 thereby helping to counteract water flow drag on the drilling machine.
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A method and apparatus for mounting a column/pile in an upstanding position on a supporting surface comprising the steps of lowering the column/pile to be installed from a support vessel into contact with the supporting surface, using the lower/toe end of the column/pile as a drill such as to form a bore in the supporting surface into which the lower region of the column/pile is to be located and leaving the column/pile in situ in the bore after the completion of a drilling operation.
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CROSS REFERENCE TO RELATED APPLICATION
This application claims the benefit of the filing date of U.S. Provisional Patent Application No. 61/008,790 filed Dec. 21, 2007, the disclosure of which applications is hereby incorporated herein by reference.
BACKGROUND OF THE INVENTION
The present invention relates to a method for the cooling or heating of aircraft cabin air, or to an aircraft cabin wall comprising an outer skin and a sidewall panel that is suitable for this method.
SUMMARY OF THE INVENTION
An aircraft cabin wall usually comprises an outer skin and a sidewall panel. In this arrangement the sidewall panel is the inner delimitation to the cabin interior. The cabin interior must be insulated by the aircraft cabin wall, in particular against cooling. In this arrangement, insulation is achieved in that insulating material is affixed between the outer skin and the sidewall panel. Usually, primary insulation is arranged on the outer skin, while a second insulation, the secondary insulation, is arranged on the sidewall panel. In this arrangement the two insulations, namely the primary insulation and the secondary insulation, are arranged in the space between the outer skin and the sidewall panel. Insulation must ensure a predetermined minimum surface temperature of the sidewall panel. This is achieved by a corresponding thickness of the primary insulation and of the secondary insulation. Since the insulation of the aircraft cabin wall needs to be designed for the worst case, i.e. for the largest possible assumed temperature gradient between the outer skin and the sidewall panel, the thicknesses of the insulations must be designed correspondingly.
The temperature of the air in the aircraft cabin, the aircraft cabin air, should be within a range that is convenient to passengers. Passengers themselves contribute to the heating of the cabin air over time. For this reason cooling of the cabin air is required in order to ensure constant travel comfort. Cooling of the aircraft cabin air normally takes place with the use of cold fresh air. The cold fresh air is mixed, in a mixing chamber, with the already present aircraft cabin air, as a result of which mixing the temperature of the mixture is reduced compared to that of the original aircraft cabin air and kept constant over time respectively. The mixing chamber and its inlet and outlet lines result in an increase in weight and furthermore take up considerable space within the aircraft.
It is an object of the invention to provide a method and a device for more economical and lighter-weight insulation of an aircraft cabin and for the cooling or heating of aircraft cabin air.
This object is met by a method for insulating an aircraft cabin, respectively for the cooling or heating of aircraft cabin air, by an aircraft cabin wall that is suitable for this, by a corresponding aircraft, and the use of an aircraft cabin wall that is suitable for this, according to the independent claims.
Further advantageous embodiments of the invention are stated in the dependent claims.
The method according to the invention for insulating an aircraft cabin or for the cooling or heating of aircraft cabin air comprises the steps of: introducing the aircraft cabin air into an aircraft cabin wall; guiding this aircraft cabin air along a section of this aircraft cabin wall; and leading this aircraft cabin air out of the aircraft cabin wall. After the aircraft cabin air has passed through the gap, it is again fed to the air conditioning system of the aircraft. The aircraft cabin wall according to the invention comprises an outer skin and a sidewall panel and is designed to accomplish the method according to the invention.
In flight, outside the aircraft the temperatures are usually very low, which temperatures must be insulated against the aircraft interior in which the passengers are accommodated. On the other hand as a result of the body heat of passengers the aircraft cabin air is heated up over time and needs to be cooled. The method according to the invention causes a heat exchange. To this effect, aircraft cabin air is introduced into the aircraft cabin wall and then flows along the aircraft cabin wall. This results in a heat exchange because the aircraft cabin wall is heated and the aircraft cabin air is cooled. The cooled aircraft cabin air is then led out of the aircraft cabin wall again and can be transported back into the passenger compartment.
This active insulation of an aircraft cabin results in that the dimensioning of the insulation requires a smaller installed volume. In this way it is either possible to reduce the external diameter of the aircraft fuselage and thus the aircraft's drag in flight. Or it is possible to enlarge the aircraft cabin interior, as a result of which passenger comfort is enhanced, and more passengers can be accommodated respectively.
In order to cool the aircraft cabin air the aircraft cabin air is mixed with fresh air in a mixing chamber. As a result of cooling, according to the invention, of the aircraft cabin air, the temperature of the fresh air can be selected so as to be higher so that the energy requirement for conditioning the fresh air can be reduced, which results in lower operating costs.
From the point of view of thermodynamics, large exergy losses arise during mixing of airstreams with large temperature differentials. Furthermore, the arising exergy losses are small if the temperature differentials of the airstreams are small. As a result of the cooling, according to the invention, of the aircraft cabin air, the temperature difference between fresh air and aircraft cabin air is reduced. Therefore, advantageously, less exergy losses result during further cooling of the aircraft cabin air as a result of mixing with fresh air.
In the same manner as described above, heating of the aircraft cabin air can be achieved, e.g. while the aircraft is on the ground. In this case it may be necessary to heat the passenger compartment and to cool the aircraft cabin wall.
Advantageously, the aircraft cabin wall comprises insulation between the outer skin and the sidewall panel, which insulation usually comprises a material of low thermal conductivity.
Particularly advantageous is the arrangement of a layer of insulation on the outer skin and of a further layer of insulation on the sidewall panel, wherein between the two layers of insulation a region remains along which the aircraft cabin air can flow.
It is particularly advantageous if between these two layers of insulation the spacing remains the same, so that turbulences of the flowing aircraft cabin air can be avoided.
An embodiment according to the invention provides for an aircraft with an aircraft cabin wall according to the invention. In this arrangement it is particularly advantageous if the aircraft according to the invention comprises a device for draining off water.
The aircraft cabin air is cooled within the aircraft cabin wall, as a result of which water can condense. Over time this water can accumulate in the aircraft cabin wall and can result in an increase of weight of the aircraft and in a reduction of insulation effect. The drained condensation water can either be collected and removed from the aircraft in a targeted manner, or it can be used again for enriching aircraft cabin air in order to increase the humidity of the air within the aircraft cabin, thus ensuring thermal comfort. The drainage system thus prevents the above-described increase of weight of the aircraft. Furthermore, as a result of the removal of the condensation water the insulation function of the aircraft cabin wall is ensured even over an extended service life, and corrosion damages are prevented.
BRIEF DESCRIPTION OF THE DRAWINGS
Below, for further explanation and to provide a better understanding of the present invention exemplary embodiments are explained in more detail with reference to the enclosed drawings. In the following:
FIG. 1 shows part of a diagrammatic cross-sectional view of an aircraft cabin wall according to the state of the art;
FIG. 2 shows a diagrammatic cross-sectional view of a part of an aircraft cabin wall according to the invention; and
FIG. 3 shows a further diagrammatic cross-sectional view of a part of an aircraft cabin wall according to an exemplary embodiment of the invention.
DETAILED DESCRIPTION
In the following drawings the same reference characters are used for identical or similar elements.
FIG. 1 shows a diagrammatic cross-section of a part of an aircraft cabin wall according to the state of the art. In this arrangement, the aircraft cabin wall 6 comprises an outer skin 1 and a sidewall panel 5 . In this arrangement the insulation is provided by two materials 2 and 4 that have been applied, wherein material 2 is arranged on the outer skin 1 , and material 4 is arranged on the sidewall panel 5 . In this arrangement the materials 2 and 4 have low thermal conductivity. The arrangement of the insulating materials 2 and 4 can result in a gap 3 . This gap varies as a result of production-related factors, or it can be absent altogether. The insulating materials 2 and 4 have to be designed such that they ensure a correspondingly good insulation between the interior region of the aircraft and the exterior region even in the worst case, in other words under the worst conditions to be assumed. This requires correspondingly large thicknesses of the insulating materials 2 and 4 .
FIG. 2 shows the aircraft cabin wall according to the invention. It also comprises an outer skin 1 and a sidewall panel 5 on which insulating materials 2 and 4 are arranged. In this design the insulating material 2 is arranged on the outer skin 1 , while the insulating material 4 is arranged on the sidewall panel 5 . According to the invention, the insulating materials 2 and 4 are arranged such that a gap 3 , which is approximately uniform in width, is formed between the insulating materials 2 and 4 . In this arrangement the two insulating materials 2 and 4 can also be left out completely, and a gap can be formed directly between the outer skin and the aircraft cabin wall. Aircraft cabin air can be conveyed through this gap 3 . Said aircraft cabin air is, for example, fed in at an upper region of the aircraft cabin wall 6 and cools down as it flows through the aircraft cabin wall 6 . The cooled aircraft cabin air is removed from the aircraft cabin wall 6 in a lower region of the aircraft cabin wall 6 . In this process heat exchange between the aircraft cabin air and the aircraft cabin wall 6 takes place.
The degree of heat exchange between the aircraft cabin air and the aircraft cabin wall can be controlled by the quantity of aircraft cabin air that is fed in. In this arrangement, in the case of lower temperatures in the exterior of the aircraft, more aircraft cabin air can be fed through the aircraft cabin wall 6 . As a result of this active control the aircraft cabin wall can be designed so as to be thinner.
After the heat exchange the cooled aircraft cabin air can either be returned to the aircraft cabin region, or said cooled aircraft cabin air can be still further cooled with fresh air in a mixing chamber so that the desired interior temperature in the aircraft is attained. Because of the cooling action that has already taken place, lower exergy losses during mixing result.
When cooling the aircraft cabin air in the aircraft cabin wall 6 , condensation water may form. This condensation water can be drained from the aircraft cabin wall 6 by the arrangement of a drainage system in the aircraft. The condensation water can then be used for humidifying the air that is introduced into the aircraft cabin interior in order to increase the air humidity within the aircraft cabin and thus enhance thermal comfort.
FIG. 3 shows a further diagrammatic cross-sectional view of a part of an aircraft cabin wall according to an exemplary embodiment of the present invention. As shown in FIG. 3 , in the sidewall panel 5 and in the secondary insulation 4 an opening is provided into which an air line, for example a pipe 10 , has been inserted. This pipe 10 is connected to a fan 11 so that, by means of activation of the fan 11 , air can be blown into the gap in a targeted manner and, for example, as indicated by the arrows in FIG. 3 , a controlled circulation and a controlled flow of the aircraft cabin interior air in the gap can be generated. Furthermore, in this arrangement fan control can be provided that is linked to the air conditioning system 15 so that a cooperating system for air circulation can be generated so that, in coordination to the quantity of heat or the quantity of cool air required at any point in time by the air conditioning system, the correct quantity of air flowing in the gap can be set. The air cooled in the gap 3 can be conveyed to the air conditioning system 15 by a connection 16 , wherein said air conditioning system 15 , as described above, can be set in an optimized manner, by controlling the fan 11 in the sense of a closed-loop, optimized in respect of temperature conditions, for example when standing on a hot runway prior to takeoff, or when flying at high altitude or during extended cruising at high altitude, where the temperature input by the passengers accommodated in the cabin is not inconsiderable.
At a suitable position in the aircraft fuselage or in the aircraft cabin wall, for example in a lower region (in a bilge region), drainage 12 can be provided in order to drain away in a targeted manner any condensation water that may have formed in the gap 3 . This condensation water can be collected in a collection container 13 and can be conveyed to the air conditioning system 15 by a pipe connection 14 . This drained condensation water can be used in the air conditioning system 15 for the targeted rehumidification of the cabin air.
In order to simplify the outflow of condensation air from the primary insulation 2 or from the secondary insulation 4 , the surfaces of these two layers of insulation, which surfaces face the gap, can, for example, comprise a water-repellent material or a thin plastic coating so that any condensation water that might form can be fed more quickly and in a more targeted manner to the drainage container 13 . Likewise, such a coating can prevent any possible condensation water infiltration into the insulation layer, for example into the insulation foam, itself.
The aircraft cabin wall shown in FIGS. 2 and 3 can either be along the entire length of the cabin of an aircraft, or it can be provided only in certain sections or segments of the aircraft fuselage. Preferably, for example, a large gap width can be achieved without any problems in regions where it is precisely not the entire width of the aircraft outer skin 1 that needs to be utilized in order to accommodate as many passengers as possible beside each other. This is, for example, imaginable in more generously designed regions of a first class cabin or business class cabin of a passenger aircraft.
In contrast to conventional aircraft cabin insulation arrangements the above exemplary embodiments comprise an enlarged and defined gap through which, as is for example shown in FIG. 3 , already spent aircraft cabin air actively flows. In this context the term “defined gap” refers to a gap whose height (h) and width (b) respectively is as uniform as possible, of which gap in addition all the other geometric dimensions are known so that optimum circulation or an unhindered airflow can be achieved.
In order to be able to achieve an improved insulation effect, a multitude of fans or flow control means, for example air fins or flow grills, can be provided in order to design the flow in the gap so that it is as homogeneous as possible.
The design comprising an actively ventilated air gap makes it possible to minimize the thickness of the primary insulation layer and of the secondary insulation layer. The throughflow of warm cabin air results in energy input into the insulation layer, and the surface temperature of the sidewall panel can be kept above a determined minimum temperature even in the case of reduced thicknesses of the insulation layers.
Apart from the actual function of the insulation effect, the new insulation concept is associated with an advantage in that in flight the airstream that flows into the gap is cooled. In other words, the air that enters the mixing chamber of the air conditioning system is at a lower temperature. At a defined air temperature at the point of entry into the cabin this means that the temperature of the air flowing out of the air conditioning system (temperature of the fresh air entering the mixing chamber) can be higher, which results in reduced energy requirements of the air conditioning system, and is reflected directly in reduced energy consumption of the aircraft.
From a thermodynamic point of view this is advantageous because the mixing of air streams with great temperature differentials can be associated with very considerable losses of energy.
Since the temperatures in the gap can at times drop to very low levels, in the insulation shown above, i.e. in the above exemplary embodiments of aircraft walls, condensation can occur at times. However, as is shown, for example, in FIG. 3 , this can be controlled by drainage devices, where the condensation water does not remain in the insulating material (an effect which, as indicated above, could also be achieved by coating the insulating material), but the condensation water that arises can then be drained in a targeted manner. The collected condensation water can be fed to the cabin air in order to increase the humidity of the air within the aircraft cabin, thus enhancing the thermal comfort of the passengers.
In summary, a cabin wall system according to the above exemplary embodiments requires less space as a result of an equally good insulation effect despite a relatively large gap. The cooling and dehumidification of the cabin air can be controlled in a simple manner, and an uncontrolled condensation and water collection in the region of the insulation is prevented. Furthermore, reduced temperature differences between fresh air and recirculated cabin air in the mixing chamber can be achieved, which results in a minimization of energy losses.
In summary, in the present invention at least part of the aircraft cabin air is fed into a defined gap in the aircraft cabin wall. This can be achieved actively, for example by means of a fan.
By means of active ventilation, the air in the gap can, for example, also be introduced at pressure.
By providing air guidance fins or similar devices in combination with the fans, a homogeneous airstream is obtained. The aircraft cabin air is channeled, in the gap, along a section of this aircraft cabin wall. The aircraft cabin air is then led out of the aircraft cabin wall and can then be again conveyed to an air conditioning system of the aircraft.
In addition, it should be pointed out that “comprising” does not exclude other elements or steps, and “a” or “one” does not exclude a plural number. Furthermore, it should be pointed out that characteristics or steps which have been described with reference to one of the above exemplary embodiments can also be used in combination with other characteristics or steps of other exemplary embodiments described above. Reference characters in the claims are not to be interpreted as limitations.
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The present invention relates to a method for insulating an aircraft cabin 6 and for the cooling or heating of cabin air in an aircraft, respectively with the method comprising the steps of: introducing aircraft cabin air into an aircraft cabin wall 6 ; guiding this aircraft cabin air along a section of this aircraft cabin wall 6 ; and leading this aircraft cabin air away from the aircraft cabin wall 6.
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FIELD OF THE INVENTION
[0001] The present invention relates to the preparation of a novel insulin resistant cell based model system, to the use thereof, and to a method and device, respectively, for use in the model.
BACKGROUND OF THE INVENTION
[0002] Insulin resistance is frequently found in obese subjects and is an early hallmark in subjects prone to develop non-insulin-dependent diabetes (NIDDM). It can be defined as a diminution of the biological response to a given concentration of insulin. There are a number of factors that have been demonstrated to accelerate the development of insulin resistance in vivo. The most important among these are elevated blood levels of glucose and circulating free fatty acids. One major difficulty in attempts to study insulin resistance is that there is not yet any quantitative definition available. What is even more important is the fact that very little is known about pathogenesis of insulin resistance on molecular basis. During the last decades a number of methods have been developed using cellular systems to study pre-diabetic or diabetic states. In most of the cases induction of insulin resistance was achieved by using supra non-physiological concentrations of glucose (>25 μm) or/and insulin in cell culture media. These simplified approaches had several drawbacks such as lack of reproducibility and limitation of achieved effects depending on the cell type studied.
[0003] Schmitz-Peiffer, C., et al. (1999) J. Biol. Chem. 274, 24202-24210 discloses incubation of myoblasts with free fatty acids (FFA) of the concentration 0.2 to 2 mM to provide a model of lipid-induced skeletal muscle insulin resistance.
[0004] The use of insulin resistance models often involves the measurement of glucose and fatty acid oxidation rates. Usually, this has required complicated apparatus, common experimental set-ups using cells in suspension which is not satisfactory as many of the studied cell types are of an adherent type.
[0005] Ross, Philip, D., et al. (1981) Anal. Biochem. 112(2), 378-86, discloses a radiospirometer for continuous quantitation of 14 CO 2 release for specifically labeled substrates by intact cultured cells attached to plastic petri dishes. The petri dish is sealed with a cover, and a carrier gas is bubbled under the surface of the growth medium. Labeled CO 2 is removed from the carrier gas by trapping in an organic base and quantitated by liquid scintillation counting.
[0006] Mark van Epps-Fung et al. (1997) Endocrinology, Vol 188, Nr 10, 4338-4345, discloses incubation of adipocytes with 10 nM glucose and 1 mM fatty acid. Thus a very small amount of glucose was used for the measurement of glucose transport.
SUMMARY OF THE INVENTION
[0007] It is an object of the present invention to prepare a model for insulin resistance that overcomes the drawbacks of the prior art models. According to the invention, it has surprisingly been found that an excellent in vitro cellular model for insulin resistance in an animal (including humans) may be induced by long term incubation (usually from about eight hours or longer) of cell cultures in a cell culture medium medium containing moderately elevated, compared with normo-physiological levels, concentrations of glucose and free fatty acid (FFA).
[0008] In one aspect, the present invention therefore provides a method of inducing insulin resistance to an animal (including human) cell culture in a cell culture medium, which method comprises incubating the cell culture in the presence of glucose and at least one fatty acid, preferably a long-chain fatty acid, wherein the concentration of glucose is in the range of about 5 to about 25 mM and the concentration of fatty acid is less than about 2 mM.
[0009] Preferably, the concentration of glucose is in the range of about 10 to 20 mM and the concentration of fatty acid is in the range of about 120 PM to about 2 mM.
[0010] Preferred fatty acids are palmitic acid, oleic acid and linoleic acid.
[0011] The most preferred fatty acid for use in the method is palmitic acid.
[0012] The method of the invention may be applied to a variety of cells systems, including all cells affected in diabetes and obesity status. Exemplary cell systems are skeletal muscle cells, insulin secreting cells (i-like cells), adipocytes and hepatocytes.
[0013] In a second aspect, the present invention provides the use of the method for drug/target related studies, including, for example, screening of insulin releasing, insulin sensitizing or insulin mimetic compounds, metabolic pathway analysis, differential display analysis, signaling pathway analysis etc.
[0014] A third aspect of the invention relates to a method and device, respectively, for measuring carbohydrate and fatty acid oxidation rates by cultured cells in vitro, which method and device may be used with the model system prepared by the method of the invention as well as with other systems.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] [0015]FIG. 1A is a schematic sectional view of an illustrative device for the determination of glucose and fatty acid oxidation rates.
[0016] [0016]FIG. 1B is a schematic perspective view of the separate parts of a practical design of the device in FIG. 1A.
[0017] [0017]FIG. 2 is diagram showing the effects of increasing concentrations of glucose on insulin dependent glucose uptake.
[0018] [0018]FIG. 3 is a diagram showing the effect of increasing concentrations of palmitate in the presence of low glucose content (5.5 mM) on insulin stimulatable glucose uptake.
[0019] [0019]FIG. 4 is a diagram showing a comparison of glucose uptake rates under normal conditions versus insulin resistance induced conditions.
[0020] [0020]FIG. 5 is a diagram showing the effects of increasing concentration of palmitate on glucose oxidation rates.
[0021] [0021]FIG. 6 is a diagram showing the effects of increasing glucose concentrations on glucose oxidation rates, as well as the effect of the combination of different glucose concentrations with 480 μM palmitate on glucose oxidation rates.
[0022] [0022]FIG. 7 is a diagram showing an example of a practical application of established insulin resistant cell model in evaluation of effects of potential PPAR ligands on glucose uptake rates.
DETAILED DESCRIPTION OF THE INVENTION
[0023] The present invention is based on the fact that concentrations of glucose and circulating free fatty acids in blood from diabetic and obese patients are elevated. As mentioned above, the invention resides in the provision of a cellular based model of insulin resistance obtained by incubation of cell cultures in media containing only moderately elevated concentrations of both glucose and fatty acid, such as palmitic acid, compared with normal physiological levels. Thus, while most of the prior art studies within this area utilized one of the potential factors at a time, and at rather extreme and acute hyperglycemic and/or hyperinsulinemic conditions, which might influence insulin action, the present invention instead combines the glucose and fatty acid parameters during cell culture cultivation to reflect a chronically pre-diabetic state which in the end leads to fully developed insulin resistance.
[0024] By monitoring a number of metabolic read outs such as glucose uptake, glucose oxidation and fatty acid oxidation rates in response to action of insulin, the model prepared according to the invention permits a number of applications within the drug/target hunting area, such as metabolic pathway analysis, differential display analysis, signaling pathway analysis, as well as for screening of insulin releasers, insulin sensitizers, insulin mimetics, etc.
[0025] The invention will now be described in more detail in the following non-limiting Example. While the Example below describes exclusively a skeletal muscle system, the invention can, of course, be applied to other cellular systems, including all cells affected in diabetes and obesity states, such as e.g. insulin secreting cells, adipocytes and hepatocytes. One and each of the named cell types has its own specificity in terms of its specialized functions which in turn serve as a specific read out (insulin secretion, triglyceride synthesis, glucose production).
[0026] First, however, a device used in the Example will be described with reference to FIG. 1A.
[0027] The device comprises a cell culture flask, generally designated by reference numeral 1 . Mounted in the flask 1 is a tube 2 having a plurality of holes or apertures 3 in the tubular wall and adapted to receive a rolled up (liquid-soaked) filter paper (not shown) in the apertured section thereof, such that the filter paper is in contact with the atmosphere within the flask through the apertures 3 . The tube 2 has an end part 4 fitting through the flask opening and sealed by a septum 5 . An aperture 6 made in the tube wall near the flask opening permits the needle of a syringe which has pierced the septum 5 to be inserted into the interior of the flask 1 . In the illustrated case, the flask 1 contains a layer of adherent cells 7 and a culture medium 8 .
[0028] The device may be used for measuring the cellular oxidation rates of substances, or substrates, where one of the final products is carbon dioxide. To that end a substrate labeled by a radioactive carbon isotope, such as 14 C, is added to the flask containing adherent cells and culture medium. A filter paper soaked in a CO 2 -trapping agent, e.g. hyamine solution (hyamine is a strong base), is rolled up and placed in the tube 2 , and after a pre-determined incubation time, the incubation is stopped by adding e.g. sulfuric acid to the culture medium via a syringe, the needle piercing the septum 5 and extending through aperture 6 . After additional incubation, the filter paper is removed, cut into pieces and transferred to a scintillation vial and the radioactivity is measured.
[0029] [0029]FIG. 1B illustrates a practical design of the device in FIG. 1A. Corresponding parts are designated by the same reference numerals as in FIG. 1A. The culture flask 1 is of standard type and has a tubular inlet part 10 with an opening 11 and an external thread 12 . The support tube 2 for the filter paper, which tube is a separate part designed to be inserted into the flask 1 , has a fore part 13 slightly angled to a rear part 14 provided with a number of holes 3 and adapted to receive the rolled up hyamine-soaked filter paper (not shown). The fore end of the tube 2 is sealed, 15 . The insertable tube 2 is arranged to be inserted through the flask opening 11 and kept in position by a screw cap 16 (here shown on the tube 2 ) engaging with the thread 12 of the inlet part 10 and acting against an o-ring (not shown) which is secured on the tube 2 and abuts the edge of the flask opening 11 so that the system is closed.
EXAMPLE
[0030] Materials
[0031] Rat L6 cells were obtained from The American Type Culture Collection (ATCC). Bovine insulin, Dulbecco's Modified Eagle's medium (DMEM), Phosphate Buffered Saline (PBS), Foetal Calf Serum (FCS), Penicillin and Streptomycin (PEST) were bought from Gibco Laboratories. Tissue culture plates were purchased from Costar. Bovine Serum Albumin (BSA) and cytochalasin B were obtained from Sigma, USA. U- 14 C-glucose, 3 H-2-deoxy-glucose and U- 14 C-palmitate were from Du Pont NEN, Medical Scandinavia, Sweden. Whatman no. 1 filter paper was from Kebo Lab., Sweden, and Hyamine hydroxide from ICN, USA.
[0032] Methods
[0033] Cell Cultures
[0034] Rat L6 myoblasts were grown on culture flasks in Dulbecco's modified Eagle's medium (DMEM) containing 10% FCS and 2% PEST. To initiate differentiation, the media of sub-confluent cell cultures were replaced with DMEM supplemented with 1% FCS and 0.3 μM insulin as described in Klip, A., et al. (1984) Am. J. Physiol. 247, E291-E296; and Walker, P. S., et al. (1989) J. Biol. Chem. 264, 6587-6595.
[0035] Induction of Insulin Resistance
[0036] Differentiated skeletal muscle cells were incubated in serum free DMEM medium supplemented with 12 mM glucose and 480 μM palmitate bound to BSA in a molar ratio 5:1 for 20 hours in a standard cell culture incubator. For glucose uptake determinations the cells were seeded in 24-well plates and for substrate oxidation determinations cells were cultivated in T-25 flasks. One-hour prior to the measurement insulin was added at a concentration of 176 nmol/L.
[0037] Determination of Glucose Uptake Rate.
[0038] Glucose uptake was measured as described by Hundal H. S., Bilan P. J., Tsakiridis T., Marette A., Klip A. (1994.) Biochem. J., 297:289-295. Briefly, after incubation with hormones for 45 minutes, if not otherwise stated, cell monolayers were rinsed with glucose free PBS. Glucose uptake was quantified by incubating the cells in the presence of 1 μCi/ml 3 H-2-deoxy-glucose in PBS for 8 min. Non-specific uptake was determined by quantifying cell-associated radioactivity in the presence of 10 μM cytochalasin B. Uptake of 2-deoxy-glucose was terminated by rapidly aspirating the medium, followed by three successive washes of cell monolayers with ice cold PBS. The cells were lysed in 0.5 M NaOH, followed by liquid scintillation counting. Rates of transport were normalized for protein content in each well.
[0039] Determination of Glucose and Palmitic Acid Oxidation Rates By 14 CO 2 Trapping Method in Adherent Cells in Vitro.
[0040] In order to determine an efficiency by which glucose and free fatty acids (FFA) are converted into energy in cultured cells, a method for measuring rate of oxidative phosphorylation of these nutrients has been developed.
[0041] The principle of the glucose/FFA oxidation assay is based on the fact that one of the final products along metabolic pathways of these two substrates is carbon dioxide. Since the substrates are uniformly 14 C labeled, the radioactivity of carbon dioxide trapped in a carbon dioxide trap is a direct measure of the metabolic activity in studied cells (Rodbell, M. (1964), J. Biol. Chem. 239, 375-380).
[0042] The cells were cultivated until sub-confluence in T-25 Costar flasks. Prior to the experiment, the cells were deprived of serum for 6 hours in DMEM medium containing 5 mM glucose. 3 ml of medium supplemented with (U- 14 C)-glucose or (U- 14 C)-palmitic acid (0.2 μCi/ml of each) were added to each flask. A filter paper (1.5×5.5 cm) soaked in hyamine solution was rolled up, blotted on a paper towel to remove excess of fluid, and placed carefully into the tube ( 2 ) of the device illustrated in Figures 1 A and 1 B and described above. The tube was mounted in the flasks, the screw caps ( 16 ) were tightened and cells were incubated for indicated time periods.
[0043] Incubation was stopped by carefully piercing the septum of the device with a 21 G needle attached to a 1 ml syringe containing 0.4 ml of 2 M sulfuric acid. The sulfuric acid was added into medium and the cells were incubated for additional 60 min. at 37° C. After this time interval, the filter paper was removed, cut into small pieces and transferred to scintillation vials containing 10 ml of scintillation solution. Methanol (0.2 ml) was added to each counting vial to increase the solubility of hyamine-CO 2 in the scintillation fluid. Finally the radioactivity was measured.
[0044] The remaining cells were washed briefly with ice cold PBS, solubilized with 1 M KOH and the protein content was determined according to the Bradford method (Bradford, M. M. 1976, Anal. Biochem. 72, 248-254).
[0045] Calculations
[0046] General.
[0047] The rate of substrate oxidation was obtained by correcting the observed number of disintegrations per minute for counting efficiency, milligram of protein in the culture flask, trapping interval, and a specific activity of the substrate at time zero using the following equation:
R = ( D - B ) S × T × M
[0048] where
[0049] R=rate of substrate oxidation (μmol/min.×mg. prot.)
[0050] D=radioactivity on filter (dpm)
[0051] B=background (dpm)
[0052] S=specific radioactivity of substrate (dpm/μmol)
[0053] T=time (minutes)
[0054] M=protein content of the cultured cell plate/flask (mg. prot.)
[0055] Glucose Oxidation Rate;
[0056] Specific radioactivity was determined as follows. The radioactivity of a medium sample was measured (e.g. 100 μl gives approx. 40,000 dpm). Since the glucose concentration in medium was 5.5 mmol/l the specific radioactivity was calculated to 400,000 dpm/5.5 μmol (72,727 dpm/μmol).
[0057] Palmitic Acid Oxidation Rate;
[0058] Labeled palmitate added to the cultured cells was assumed to be the sole source of this substrate under the experimental conditions. For this reason the calculation of specific radioactivity differs from the above example. Specific radioactivity was determined by the manufacturer, in case of uniformly labeled palmitate it was 850 mCi/mmol. Since 0.2 μCi palmitate/ml medium are added, it was calculated that the palmitate concentration added is 0.2353 nmol/ml. Again, by measuring radioactivity of e.g. 100 μl medium the specific radioactivity expressed as dpm/nmol substrate was calculated.
[0059] Analyses
[0060] The effects of increasing concentrations of glucose on insulin dependent glucose uptake was studied with the model system described above, and the results are presented in FIG. 2. As can be seen in the figure, a maximal inhibitory effect is observed at a glucose concentration of 25 mM.
[0061] Also the effect of increasing concentrations of palmitate in the presence of low glucose content (5.5 mM) on insulin stimulatable glucose uptake was studied. The results are presented in FIG. 3. As shown, at the palmitate concentration of 480 μM the basal glucose uptake rate is slightly increased compared to control level, but the insulin effect is strongly inhibited.
[0062] A comparison of glucose uptake rates under normal conditions versus insulin resistance induced conditions was made. The results are presented in FIG. 4. As can be seen in the figure, the basal glucose uptake rate is not affected by treatment of cell cultures with 12 mM glucose and 480 μM palmitate but the insulin effect is completely abolished.
[0063] The effects of increasing concentrations of palmitate on glucose oxidation rates was also studied, and the results are illustrated in FIG. 5. Shown in the figure is a direct effect of increased palmitate concentration on a basal glucose oxidation rate as an effect of substrate preference. Also, an insulin dependent increase of glucose oxidation rates is decreased in a dose dependent mode. The glucose concentration was maintained at 5.5 mM throughout the experiment.
[0064] The results from a study of the effects of increasing glucose concentrations on the glucose oxidation rates are shown in FIG. 6. The figure also shows the effect of combination of different glucose concentrations with 480 μM palmitate on glucose oxidation rates.
[0065] Finally, an example of a practical application of the established insulin resistant cell model in the evaluation of effects of potential PPAR ligands on glucose uptake rates is shown in FIG. 7.
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A method of preparing a cellular in vitro model system for insulin resistance by inducing insulin resistance to an animal cell culture in a cell culture medium comprises incubating the cell culture in the presence of glucose and at least one fatty acid, preferably a long-chain fatty acid, wherein the concentration of glucose is in the range of about 5 to about 25 mM and the concentration of fatty acid is less than about 2 mM. A device that may be used in the method comprises a cell culture flask ( 1 ), and a support member ( 2 ) for a carbon dioxide absorbent body, which support member ( 2 ) is partially insertable into the culture flask ( 1 ) and fixable in the flask opening with the absorbent body extending into the flask.
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FIELD OF THE INVENTION
The present invention relates, in one aspect, to a process for producing (±)-3-alkyl-3,4-dihydro-2H-[1,4]benzoxazine derivatives and, in another aspect, to a process for producing optically active 3-alkyl-3,4-dihydro-2H-[1,4]benzoxazine derivatives, especially (S)-3-alkyl-benzoxazine derivatives.
BACKGROUND OF THE INVENTION
As processes for producing an optical isomer of compound (II) ##STR2## wherein X, Y and Z, which may be the same or different, each represents a hydrogen atom or a halogen atom and R represents a lower alkyl group having 1 to 6 carbon atoms, a process comprising converting compound (II) into an optically active proline derivative and isolating said product is known as described, for example, in EP-A-206,283. However, this procedure is disadvantageous in that the resolution reagent proline is expensive and is difficult to use again. Another known process involves the use of an asymmetric hydrolytic enzyme as described, for example, in JP-A-62-87577 (the term "JP-A" as used herein refers to a "published unexamined Japanese patent application") and EP-A-206,283.
SUMMARY OF THE INVENTION
The present invention relates, in a first aspect, to a process for producing a (±)-3-alkyl-3,4-dihydro-2H-[1,4]benzoxazine derivative of general formula (II) ##STR3## wherein X, Y and Z, which may be the same or different, each represents a hydrogen atom or a halogen atom and R represents a lower alkyl group having 1 to 6 carbon atoms, which comprises hydrogenating a 3-alkyl-2H-[1,4]-benzoxazine derivative of general formula (I) ##STR4## wherein X, Y, Z and R have the same meanings as defined above.
The invention further relates to a process for producing a (±)-3-alkyl-3,4-dihydro-2H-[1,4]benzoxazine derivative of general formula (II) which comprises: dehydrogenating an (R)-(+)-3-alkyl-3,4-dihydro-2H-[1,4]-benzoxazine derivative of general formula (III) ##STR5## wherein X, Y and Z, which may be the same or different, each represents a hydrogen atom or a halogen atom and R represents a lower alkyl group having 1 to 6 carbon atoms to give a 3-alkyl-2H-[1,4]benzoxazine derivative of general formula (I), wherein X, Y, Z and R have the same meanings as defined above; and hydrogenating the compound (I).
Further, this invention relates, in a second aspect, to the optical resolution of a (±)-3-alkyl-3,4-dihydro-2H-[1,4]benzoxazine derivative of general formula (II). Namely, the invention is directed to the salts of an (S)-3-alkyl-benzoxazine derivative and an (R)-(-)-camphor-10-sulfonic acid which has the general formula (V)' ##STR6## wherein X, Y and Z, which may be the same or different, each represents a hydrogen atom or a halogen atom and R represents a lower alkyl group having 1 to 6 carbon atoms; and it is also directed to a process for producing an optically active benzoxazine derivative which comprises subjecting a (±)-3-alkyl-3,4-dihydro-2H-[1,4]-benzoxazine compound of general formula (II) ##STR7## wherein X, Y and Z, which may be the same or different, each represents a hydrogen atom or a halogen atom and R represents a lower alkyl group having 1 to 6 carbon atoms, to an optical resolution using an optically active isomer of camphor-10-sulfonic acid (IV) as a resolution agent.
7,8-Difluoro-3-methyl-3,4-dihydro-2H-[1,4]-benzoxazine, which corresponds to the compound of formula (II) wherein X is a hydrogen atom, Y and Z each is a fluorine atom and R is a methyl group, is of value as an intermediate for the production of various compounds having potent antibacterial activity, such as ofloxacin (see, for example, Japanese Patent No. 1,444,043 and U.S. Pat. No. 4,382,892).
Furthermore, the resulting optically active compound is also useful as an intermediate for the production of, for example, (S)-(-)-9-fluoro-3-methyl-10-(4-methyl-1-piperadinyl)-7-oxo-2,3-dihydro-7H-pyrido-[1,2,3-de][1,4]benzoxazine-6-carboxylic acid (see, for example, JP-A-62-87577 and EP-A-206,283).
The present invention provides useful processes in that the optically active form of compound (II) can be produced with efficiency and high purity by the simple procedure of recrystallization employing less expensive optical resolution reagent and in that the optical resolution reagent can be used many times.
The present invention also provides a useful process of converting undesirable (R)-isomer of compound (II) into the racemic mixture. Through the combination of the optical resolution method of compound (II) and the racemization procedure of undesirable-isomer, the yield of useful (S)-isomer of compound (II) is increased.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWING
FIG. 1 is a recrystallization flow diagram.
DETAILED DESCRIPTION OF THE INVENTION
The first aspect of the present invention is described in detail below.
For the purpose of utilizing the undesirable (R)-isomer of compound (II), the present inventors found that compound (I) was obtained by the dehydrogenation of (R)-isomer of compound (II), and from this compound (I), racemic compound (II) was reprodicible through the hydrogenation.
The dehydrogenation reaction for conversion of compound (III) to compound (I) is carried out by treating compound (III) with a halogenating agent and a base in the presence or absence of a solvent at a temperature from about -100° C. to room temperature, preferably at -80° to 10° C., for a period of about 1 to 120 minutes.
The above-mentioned base may be organic or inorganic, and the preferred base is an aliphatic tertiary amine such as trimethylamine, triethylamine, tripropylamine, N,N-diisopropylethylamine and so on. The base may be used in virtually any desired proportion not less than equimolar with respect to compound (III) and may be used as a solvent of the reaction.
The halogenating agent may be virtually any known halogenating agent, such as chlorine, bromine, sulfuryl chloride, N-chlorosuccinimide (NCS), N-bromosuccinimide (NBS), N-bromoacetamide, hypochlorous acid, hypobromous acid, t-butyl hypochlorite and so on.
The amount of the halogenating agent is also any desired except that it must be at least equimolar to compound (III), and is preferably 1 to 10 mols per mol of compound (III).
Typical examples of the solvent that can be used in this reaction include various solvents which are insert to the reaction, such as esters (e.g., ethyl acetate, propyl acetate, etc.), amides (e.g., N,N-dimethylformamide, N,N-dimethylacetamide, etc.), ethers (e.g., tetrahydrofuran, 1,4-dioxane, etc.) and so on. The solvent is generally used in the range of 0 to 50 parts by weight with respect to compound (III).
The compound (I) which forms by the dehydrogenation of compound (III) can be isolated as pure crystals by the known procedures such as recrystallization, silica gel chromatography, etc., but the hydrogenation reaction may be conducted without isolating compoud (I).
The hydrogenation of compound (I) to compound (II) can be carried out by the known procedure per se, for example, by reduction using a metal hydride such as sodium borohydride, lithium borohydride, etc., or by catalytic hydrogenation using a catalyst such as palladium-on-carbon, platinum, Raney nickel, etc.
After completion of the hydrogenation, compound (II) can be isolated and purified by the known method such as extraction, redistribution, concentration, crystallization, chromatography and so on.
In the course of isolation and purification, the use of ordinary acid, such as hydrochloric acid, sulfuric acid, nitric acid, etc., in a proportion not less than equimolar with respect to compound (II) results in the direct crystallization and recovery of the corresponding salt of compound (II).
The optical purity (% e.e.) of compound (II) or compound (III) was determined by the following procedure. The "% e.e." is an abbreviation for % enantiomer excess, and is a measure of an optical purity of an optically active compound (see, for example, Asymmetric Synthesis, Vol. 1, p. 45, 60, Academic Press, N.Y. (1983), edited by J. D. Morrison et al.) For example, the "% e.e." is calculated as follows: ##EQU1## wherein (R) represents a molar ratio of (R)-isomer in percent, and (S) represents that of the (S)-isomer, when (R)+(S) is taken as 100%. Namely, in 0.5 ml of tetrahydrofuran was dissolved 20 mg of compound (II) or (III), followed by addition of 17 mg of pyridine and 54 mg of 3,5-dinirobenzoyl chloride, and the mixture was warmed at 30° to 40° C. for 30 minutes. A portion of the solution was taken and analyzed by high performance liquid chromatography (column: OA-4200 (Sumitomo Chemcal), 4.6 mm×250 mm; solvent: n-hexane/1,2-dichloroethane/ethanol =10:0.9:0.1; flow rate: 1.0 ml/min).
The second aspect of the present invention, which is concerned with the optical resolution of a (±)-3-alkyl-3,4-dihydro-2H-[1,4]benzoxazine derivative of general formula (II), is described in detail below.
The present inventors have conducted extensive investigations to develop a method for optical resolution of racemic compound (II). It is the characteristic feature of this method that the resolution reagent is less expensive and readily recovered.
As is apparent from the structure, both compounds (II) and (IV) have one asymmetric carbon in each melolecule. Compound (II) is composed of two enantiomeric isomers, and compound (IV) is also composed of two enantiomeric isomers. Four diastereoisomeric salts can be derived by combining the enantiomeric isomer of compound (II) and enantiomeric isomer of compound (IV). The present inventors found that two salts among these four salts were less soluble in organic solvents and readily precipitated from the solvents.
As a result, it has been found that only one of two optical isomers of compound (II) can be selectively precipitated in the form of a crystalline salt (V) according to the kind of camphor-10-sulfonic acid (IV), when a racemic mixture of compound (II) and one of the optically active compound (IV) is added in a solvent. ##STR8##
It was further found that the resolution reagent can be recovered in good yield and high purity.
When racemic compound (II) and one optical isomer of compound (IV) are dissolved thoroughly in a solvent of aqueous carboxylic acid, then a salt of one isomer of compounds (II) and (IV) is made to precipitate from the solution. On the other hand, when the other isomer of compound (IV) is used as the resolution reagent, the other isomer of compound (II) is precipitated in the form of salt. These facts show that the salts having the specific combination of optical isomers readily precipitate. The salts which readily precipitate have the following combination of the optical isomers of compounds (II) and (IV) as shown in Table 1 below.
TABLE 1______________________________________Combination of the Optical Isomers of (II)and (IV) Obtained as Precipitated SaltCompound (IV) Compound (II)______________________________________(R)-(-)-camphorsulfonic (S)--(-)-isomer of compoundacid (II)(S)--(+)-camphorsulfonic (R)-(+)-isomer of compoundacid (II)______________________________________
As shown in Table 1 above, for the purpose of isolating (S)-isomer of compoud (II), (R)-camphorsulfonic acid is the suitable resolution reagent, and for the isolation of (R)-isomer of compound (II), (S)-camphorsulfonic acid is suitable.
The optical purity of the precipitated salt is increased by repetition of recrystallization. The free optically active compound can be obtained by treating the isolated salt with a base and successive extraction with an organic solvent. The optical purity of the salt is maintained even after the treatment with a base. Moreover, the optical resolution reagent (IV) can be recovered in good yield and purity from the aqueous phase after treatment of salt (V) with a base.
The preparation of salt (V) is initiated either by adding the racemic compound (II) and specific optical isomer of compound (IV) to a solvent or by mixing a solution of racemic compound (II) dissolved in a carboxylic acid solvent with an aqueous solution of the specific isomer of compound (IV).
After the above mixing, the mixture is stirred at 70° to 100° C. for a period ranging from 30 minutes to 1 hour for the completion of dissolution and, then, further stirred under ice-cooling at 5° to 10° C. for 2 to 18 hours for crystallization of salt (V). For the repetition of recrystallization of salt (V), seed crystals may have to be added when hardly crystallized in an early stage but the crystallization becomes progressively easier as the recrystallization procedure is repeated.
In the above practice of the present invention, it is generally advantageous to mix compounds (II) and (IV) in equimolar ratio.
As for the solvent of this resolution method, carboxylic acid such as acetic acid, propionic acid and butyric acid are preferable. The most preferable one is acetic acid, and especially acetic acid with a water content of from 10 to 50% (v/v) is beneficial for the purpose.
The amount of the solvent is preferably in the range of 5 to 20 parts (v/w), and more preferably in the range of 10 to 20 parts (v/w), based on compound (II). The crystallized salt (V is collected by filtration, washed with a small quantity of the same solvent as used in the reaction or a different inert organic solvent such as ether, and dried.
The salt obtained can be simply treated with a base and extracted with an organic solvent to give the free optically active compound in high optical purity. The base may be organic or inorganic only if it is a stronger base compared with compound (II) and is preferably an inorganic base such as the hydroxides, carbonates and hydrogen carbonates of sodium, potassium and so on. As the solvent used for extraction, a halogenated hydrocarbon such as dichloromethane, chloroform, 1,2-dichloroethane, etc., are preferred.
The optical purity of the product can be determined by high performance liquid chromatography (HPLC) as described above (see, for example, EP-A-206,283 and JP-A-62-87577). The optical purity of compound (II) after 3 to 4 recrystallization runs was more than 98% e.e.
The yield of the optically active compound can be increased by recycling of the recrysallization mother liquid or the second crop of crystals and is not less than 30% based on starting compound (II).
The optical resolution reagent compound (IV) can be easily recovered in the following manner. The aqueous layer after isolation of the free optically active compound or the aqueous layer which may be obtained after extracting the benzoxazine compound (II) by the method as stated above from a salt mixture predominantly composed of undesired optical isomer of compound (II) is first acidified, concentrated if desired, and extracted with an organic solvent such as chloroform, 1,2-dichloroethane or the like. The compound (IV) thus recovered gave melting point, optical rotation and other physical values in agreement with the known values, indicating that the compound can be recovered in high purity. When the recovered compound (IV) was again used in the optical resolution procedure, no deterioration in the efficiency of resolution was observed at all.
The construction and effects of the present invention are now illustrated in greater detail with reference to specific examples, which are not to be construed as limiting the scope of the present invention.
EXAMPLE 1
7,8-Difluoro-3-methyl-2H-[1,4]benzoxazine (I, X=H, Y=Z=F, R=CH 3 ):
In a nitrogen stream, a solution of 2.11 ml of t-butyl hypochlorite and 2 ml of ethyl acetate were added dropwise to a mixture of 1.54 g of (R)-(+)-7,8-difluoro-3-methyl-3,4-dihydro-2H-[1,4]benzoxazine (optical purity: 71.7% e.e., (R)), 5.21 ml of triethylamine and 9 ml of ethyl acetate while keeping the internal temperature at -52° C. over a period of about 4 minutes, and the resulting mixture was further stirred at -60° to -50° C. for 30 minutes. The reaction mixture was washed twice with 10 ml portions of 5% aqueous solution of citric acid and further with 10 ml of dilute aqueous ammonia (concentrated aqueous ammonia:water=1:4 (v/v)) and the ethyl acetate layer was dried over anhydrous magnesium sulfate. The ethyl acetate was removed under reduced pressure and the oily residue was purified over silica gel (50 g) column chromatography using chloroform (the bottom layer after shaking with concentrated aqueous ammonia) as the eluent. The solvent was removed from the eluate under reduced pressure to yield 693 mg of 7,8-difluoro-3-methyl-2H-[1,4]benzoxazine as pale yellow crystals (yield: 60.8%).
Melting Point: 51.2° C. (Metler FP-61 automatic melting point meter, temperature increment: 1° C./minute)
Elemental Analysis for C 9 H 7 F 2 NO:
______________________________________Calc'd: C, 59.02; H, 3.85; N, 7.65Found: C, 58.91; H, 3.89; N, 7.49______________________________________
NMR (CDCl 3 )δ ppm:
2.12 (3H, s, --CH 3 ), 4,56 (2H, s, OCH 2 --), 6.5-7.2 (2H, m, benzene ring-H) MS (m/Z): 183 (M + )
EXAMPLE 2
7,8-Difluoro-3-methyl-3,4-dihydro-2H-[1,4]benzoxazine (II, X=H, Y=Z=F, R=CH 3 ):
A mixture of 641.3 mg of 7,8-difluoro-3-methyl-2H-[1,4]benzoxazine obtained in Example 1, 0.32 g of 5% palladium-on-carbon (50% aqueous) and 13 ml of ethanol was subjected to catalytic reduction in a hydrogen gas atmosphere at room temperature under atmospheric pressure. After completion of the reaction, the catalyst was filtered off and the ethanol was removed under reduced pressure. The residue was dissolved in 20 ml of ethyl acetate, washed with 5 ml of saturated aqueous solution of sodium chloride and dried over anhydrous magnesium sulfate. After the desiccant was filtered off, the solution was concentrated to approximately one-half of the initial volume and to the concentrate was added 0.31 ml of concentrated hydrochloric acid was stirring. After ice-cooling, the resulting crystals were collected by filtration and washed with cold ethyl acetate to give 554.5 mg of 7,8-difluoro-3-methyl-3,4-dihydro-2H-[1,4]-benzoxazine hydrochloride as colorless crystals (yield: 71.5%).
Melting Point: 180.7° C. (determined with a Metler FP-61 automatic melting point meter, temperature increment 1° C./minute)
Elemental Analysis for C 9 H 10 ClF 2 NO:
______________________________________Calc'd: C, 49.02; H, 4.61; N, 6.38Found: C, 48.77; H, 4.55; N, 6.32______________________________________
NMR (DMSO-d 6 )δppm: 1.45 (3H, d, --CH 3 ), 3.6-4.0 (1H, m, NCH<), 4.22, 4,56 (each 1H, q, OCH 2 --), 6.8-7.3 (2H, m, benzene ring-H)
Optical Purity: 0.5% e.e., (R), 3S:3R =0.99:1.00
EXAMPLE 3
7,8-Difluoro-3-methyl-3,4-dihydro-2H-[1,4]benzoxazine (II, X=H, Y=Z=F, R=CH 3 ):
A solution of 1.154 g of (R)-(+)-7,8-difluoro-3-methyl-3,4-dihydro-2H-[1,4]benzoxazine (optical purity: 71.7% e.e., (R)), 9 ml of ethyl acetate and 5.21 ml of triethylamine was cooled to -50° C. or less in a nitrogen gas stream. To this was added a solution of 2.11 ml of t-butyl hyopchlorite in 5 ml of ethyl acetate cooled to -50° C. or less over a period of about 20 seconds. The mixture was stirred at -60° to -50° C. for further an hour, then washed twice with 10 ml portions of cold 5% aqueous citric acid solution and 10 ml of cold dilute aqueous ammonia (the same as mentioned hereinbefore).
To the ethyl acetate layer were added 0.47 g of sodium borohydride and 2 ml of ethanol, and the mixture was stirred at room temperature for 2 hours. The reaction mixture was washed twice with 10 ml portions of 5% aqueous citric acid solution and once with 10 ml of dilute aqueous ammonia (the same as mentioned hereinbefore), and dried over anhydrous magnesium sulfate. The desiccant was filtered off and to the solution was added with 0.72 ml of concentrated hydrochloric acid with stirring. After cooling with ice-water, the resulting crystals were collected by filtration and washed with cold ethyl acetate to give 1.236 g of 7,8-difluoro-3-methyl-3,4-dihydro-2H-[1,4]benzoxazine hydrochloride as colorless crystals. Optical purity: 1.0% e.e., (S), 3S:3R =1.02:1.00. In 10 ml of chloroform was suspended 1.078 g of the above hydrochloride and to the suspension was added 10 ml of 5% aqueous sodium hydrogen carbonate solution with stirring. The chloroform layer was washed with water and dried over anhydrous magnesium sulfate. Then, the desiccant was filtered off and the solvent was distilled off under reduced pressure. The residue was dissolved in 1 ml of methanol, followed by addition of 5 ml of 50% aqueous methanol. After cooling with ice-water, the resulting crystals were collected by filtration to give 0.596 g of the title compound (yield: 60.9%).
Melting Point 51.0° C. (Metler FP-61 automatic melting point meter, temperature increment: 1° C./minute)
Elemental Analysis for C 9 H 9 F 2 NO:
______________________________________Calc'd: C, 58.38; H, 4.90; N, 7.56Found: C, 58.36; H, 5.06; N, 7.64______________________________________
EXAMPLE 4
7,8-Difluoro-3-methyl-3,4-dihydro-2H-[1,4]benzoxazine (II, X=H, Y=Z=F, R=CH 3 ):
A mixture of 1.154 g of (R)-(+)-7,8-difluoro-3-methyl-3,4-dihydro-2H-[1,4]benzoxazine (optical purity: 71.7% e.e., (R)), 5.21 ml of triethylamine and 5.8 ml of N,N-dimethylformamide was cooled to -60 to -50° C. under a nitrogen gas stream. To this solution was added 1.00 g of N-chlorosuccinimide (NCS) and the mixture was stirred at the same temperature for 35 minutes. Then, 047 g of sodium borohydride was added thereto and the mixture was stirred at room temperature for 20 minutes. The reaction mixture was diluted with 50 ml of ethyl acetate, washed twice with 10 ml portions of 5% aqueous citric acid solution and once with 10 ml of dilute aqueous ammonia (described hereinabove), and dried over anhydrous magnesium sulfate. The desiccant was then filtered off and the filtrate was concentrated to about 30 ml. To the concentrate was added 0.72 ml of concentrated hydrochloric acid and after cooling with ice-water, the resulting crystals were collected by filtration. The procedure gave 0.984 g of hydrochloride of the title compound (yield: 51.4%). Optical Purity: 7.6% e.e., (R), 3R:3S =1.00:0.86
EXAMPLE 5
To 10 ml of 20% aqueous acetic acid were added 1 g of (±)-7,8-difluoro-3-methyl-3,4-dihydro-2H-[1,4]-benzoxazine (hereinafter, referred to as "(±)-FBO") and 1.35 g of (R)-(-)-camphor-10-sulfonic acid monohydrate (hereinafter, referred to as "R-CSA"), and the mixture was stirred at 70° to 80° C. for dissolution. Then, the solution was further stirred under ice-cooling at 5° to 10° C. for 3 hours for crystallization. The procedure gave 1 g of crystals (yield: 46% based on (±)-FBO).
The above crystals were treated with aqueous sodium hydroxide solution and then extracted with dichloroethane. The extract was concentrated to dryness and the optical purity of the residue was determined by HPLC method. Optical purity: 49.2% e.e. The relationship of yield (based on (±)-FBO) and optical purity with the various water contents of the solvent is shown below in Table 2.
TABLE 2______________________________________The Relationship of yield and optical puritywith the water content of the solventWater Content of Solvent Yield Optical Purity(%) (%) (% e.e.)______________________________________10 73 15.620 46 49.230 60 27.5______________________________________
EXAMPLE 6
To 120 ml of 20% aqueous acetic acid solution were added 10 g of (±)-FBO and 13.5 g of R-CSA and the mixture was treated as in Example 5 to give crystals. The recrystallization procedure was repeated twice to yield 3.34 g of crystals.
Melting Point: 215°-218° C. [α] D -42.9° (c=1.0, methanol)
Elemental Analysis for C 19 H 25 F 2 NO 5 S;
______________________________________Calc'd: C, 54.66; H, 6.04; N, 3.35Found: C, 54.61; H, 6.22; N, 3.22______________________________________
The crystals obtained were treated with aqueous sodium hydroxide solution and extracted in the same manner as described above, and the extract was concentrated to give 1.48 g of oily residue. (Yield: 14.8% based on (±)-FBO). The physical data of this oily product, e.g., analytical data of IR, NMR, GC, TLC, etc., were identical to those reported in EP-A-206,283. The optical purity of the product was 98% e.e.
EXAMPLE 7
The procedure of Example 6 was repeated except that recrystallization was repeated 4 times, and the crystallization mother liquid (ML) and second crop of crystals were recycled to the next lot (see the flow diagram as shown in FIG. 1). As a result, (-)-FBO was obtained in Run 3 with a yield of 30% and an optical purity of 99% e.e.
EXAMPLE 8
To 9 ml of 20% aqueous acetic acid were added 0.74 g of (±)-FBO and 1.0 g of the recovered R-CSA, and the same crystallization procedure as described above was carried out to yield 0.9 g of crystals. The yield was 54%. This product was treated with aqueous sodium hydroxide solution and free compound was extracted in the same manner as in Example 5. After this procedure, the optical purity was 59.5% e.e., which was not low as compared with the purity obtained using a fresh lot of R-CSA.
EXAMPLE 9
To 13 ml of 15% aqueous acetic acid were added 555 mg of (±)-FBO and 750 mg of (S)-(+)-camphor-10-sulfonic acid monohydrate, and the same crystallization procedure as described above was followed to give 0.23 g of crystals (Yield: 17.6%).
Melting Point: 215°-218° C.
[α] D +43.3° (c=1.0, methanol)
The product obtained was treated with aqueous sodium hydroxide solution to give the corresponding free compound and its optical purity was determined. The optical purity as (+) compound was 50% e.e. This compound was further purified. By instrumental analyses including IR and NMR spectrometric determinations, the product was identified to be (R)-(+)-7,8-difluoro-3-methyl-3,4-dihydro-2H-[1,4]benzoxazine.
While the invention has been described in detail and with reference to specific embodiments thereof, it will be apparent to one skilled in the art that various changes and modifications can be made therein without departing from the spirit and scope thereof.
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The invention relates to a process for producing a (±)-3-alkyl-3,4-dihydro-2H-[1,4]benzoxazine derivate of formula (II) by stepwise racemization procedure. ##STR1## The invention further provides a process for optical resolution through the formation of a salt between a (±)-benzoxazine compound and an optically active form of camphor-10-sulfonic acid. Without requiring the conventional expensive resolution reagents, this process not only assures production of an optically active isomer of compound (II) in high purity but also permits reuse of the optical resolution reagent.
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FIELD OF THE INVENTION
[0001] The invention relates to design improvements in the construction of electrolytic cell receptacles for electrowinning and electrorefining processes of nonferrous metals, with a novel mold and molding method and to new formulations for three-layered polymer composite materials for the monolithic formation of the structural core with surface sealing coatings in the receptacles or containers of such cells.
BACKGROUND OF THE INVENTION
[0002] There are currently several known designs for cell-type receptacles or containers intended for electrolytic refining and winning used in the purification and recovery of nonferrous metals. In order to obtain high purity cathodic copper, there are currently two well-established industrial electrolytic processes: electrorefining of melted copper anodes dissolved in sulfuric acid electrolytes, and electrowinning cathodic copper directly from copper sulfate electrolytes previously recovered by hydrometallurgic processes by extraction of ore heaps or piles using lixiviated copper solvents. The receptacles for electrolytic cells used in both processes are similar, having a parallelepipedic geometry, being self-supporting, with suitable dimensions to lodge electrodes in the form of vertically positioned parallel laminar plates supported at each end at the upper edges of the side walls of the receptacle, and provided with means for electrolyte infeed and overflow. The design of the electrolytic cell receptacle itself is functional in order to accommodate the specific requirements of the corresponding electrolytic process. Currently, electrorefining cells typically operate with moderate electrolyte flows, at temperatures between 55° C. and 75° C., and the length/width ratio of the receptacle, in terms of the number of electrodes required for each cell, is generally <4; electrowinning cells, on the other hand, operate with much higher electrolyte flows, at lower temperatures, between 45° C. and 55° C., and their length/width ratio is typically >4. Recent technological efforts to improve productivity of both electrolytic processes have shown tendencies toward greater current densities per electrode, higher electrolytic temperatures, and a higher number of electrodes per cell, i.e., with a length/width ratio that is typically 5 or 6.
[0003] One of the receptacles for electrolytic cells of the current state of the art is discussed in (Chilean) Patent No. 38,151, which characterizes a corrosive electrolyte receptacle or container used in electrolytic processes, where said receptacle consists of a polymer concrete box with side walls, a pair of opposite end walls, and a bottom, and each of said end walls has an inner and outer surface where a formation has been molded onto the outer surface of the end wall that extends from its upper and lower ends and that is intermediate between the sides of the wall; a depression has been formed on the upper end of the formation, which opens toward the inner surface of said end wall; and below the upper edge of the wall a generally vertical first discharge passage has been formed at a certain distance from the outer surface of the formation on the outer surface of the end wall; the discharge passage has a first opening on the end of the formation and a second opening adjacent to the lower end of the formation in order to drain off the electrolytes from the upper part of the receptacle, characterized in that it has a second passage formed in the end wall and running through the lower part of the wall to drain off the electrolytes from the lower part of the receptacle, wherein electrolytes may be removed from both the upper and lower part of the receptacle.
[0004] It also describes a formation with a second passage on the inner surface of the other end wall and forming part of the wall, said second passage running from the upper end of said wall downward to a position adjacent to the lower end, with a channel formed in the end wall and in the inner surface, with a covering over the channel that is open at its upper and lower ends, all for the purpose of distributing the electrolytes entering the cell.
[0005] In addition, a corrosion-resistant layer has been applied, which includes a surface layer of a material selected from a group that consists of vinyl ester resin and polyester resin, and a lining layer that consists of an inorganic fiber saturated with a material selected from a group that includes vinyl ester resin and polyester resin.
[0006] Said lining layer is made of about 20-30 wt % fiber and about 70-80 wt % resin. The inorganic fiber is fiberglass in the form of a sheet or layer, said sheet being made up of threads that are 12.7-50.8 mm long. The surface layer has a thickness of about 0.0254.0.0508 mm.
[0007] The polymer concrete consists of 10-19 wt % resin selected from a group that includes thermosetting vinyl ester and polyester resin. The modified resin includes 80-90% resin selected from a group consisting of vinyl ester and polyester resin, and the balance is a thinning agent, inhibitors, promoters, and a catalyst.
[0008] Finally, it describes a method that includes the steps of applying to the surface of a mold a surface layer made of a material selected from a group consisting of vinyl ester resins and polyester resins; applied to said surface layer is a lining layer consisting of a sheet of Inorganic fiber saturated with a material selected from a group consisting of vinyl ester resins and polyester resins a thermosetting resin selected from a group consisting of polyester resin and vinyl ester resin and an aggregate are mixed together, the mixture being continuously emptied into an inverted mold in which said surface layer and lining define the bottom, end, and side walls, thereby permitting said molded mixture to set, wherein the surfaces of the receptacle shall conic into contact with the surfaces of the mold, which casts the smooth inner surfaces. Said layer is formed of threads that are 12.7-50.8 mm long and 0.0254-0.0508 mm thick. Said lining layer has about 20-30 wt % of fiber and about 70-80 wt % of resin. The aggregate includes a mixture that is 80-90 wt % of particles that are 6.35-0.79 mm in size; 10-15 wt % of particles taken from a group that consists of fine silica sand and fine silica powder and 0.9-5 wt % of particles from the group that consists of mica flakes whose approximate size is {fraction (1/64)} mm and of cut fiberglass threads 6.35-3.175 mm in length. In addition, the modified resin includes 80-90% resin selected from the group that consists of vinyl ester resin and polyester resin, and the balance is a thinning agent, inhibitors, promoters, and a catalyst.
[0009] Another (Chilean) Patent No. 35,466, refers to a compound material for use in molding containers or structures exposed to corrosive chemicals, particularly to corrosive acids, characterized in that it contains a plastic synthetic resin with an inert particulate filler composed of no less than 70 wt % of round particles whose diameter is on the order of less than 0.5 mm, with a total weight ratio of the particulate resin to the surrounding resin of 8:1 (that is, 11.1% resin content).
[0010] In the subordinate claims, the particulate material filler is described, which includes & fraction of about 40 wt % of the total filler of particles whose size ranges from 0.5-1 mm, and a fraction of about 15 wt % of the total filler of particles whose size varies between 14.75 mm and 1.75-3 mm.
[0011] Another receptacle for electrowinning or electrorefining nonferrous metals uses the concept of an inner container made of a two-layered polymer composite material, with the body of said container being preformed on an inverted mold by several successive applications of a first polymer composite material consisting of a base of fiberglass layers saturated with high corrosion-resistant polyester/vinyl ester resin contents. As the layers of polymer composite material closest to the surface of the mold cure, the thickness of the walls and bottom of the inner container imparts sufficient structural strength so that it may itself form the core mold for the electrolytic receptacle, which is then formed in a second phase of the manufacturing process. At the desired distance from the perimeter of the inverted inner container (acting as core mold), vertical molds are installed to vertically form the side and end walls and the thickness of the bottom of the electrolytic receptacle. The volume of the cavities defined by the molds so assembled is filled all around the inner container with a second polymer composite material based on a mixture of polyester/vinyl ester resin reinforced with particulate aggregate. The assembled receptacle is mechanically vibrated to compact the polymer concrete around the inner preformed container of fiberglass-reinforced polymer composite material. When the mass of the surrounding second polymer composite material cures, it does so joined to the outer layer of the first fiberglass-reinforced plastic material of the inner container/mold, thereby producing a chemical bond between the two polymer composite materials.
[0012] Although electrolytic cell receptacles constructed of polymer materials of the state of the art provide such advantages as improved ease of operation, productivity, and lower costs when compared to the cement concrete cells with corrosion resistant coatings of lead or plastic that they replaced, they still present significant disadvantages and technical shortcomings. The electrolytic cell receptacles of polymer concrete constructed according to the technology and the patents cited have experienced massive failures in various copper electrorefining and electrowinning plants in Chile, North America, and Europe. Defects persist in regard to both the absolute impermeability required of the cells while in operation, and significant variability in tolerances as to dimensions, structural strength, durability over time, as well as high manufacturing costs. The high costs result from the use of expensive polymer compound materials together with frequent and costly factory finishes, and from the higher volume of polymer concrete material applied in the construction of the receptacle than is strictly necessary, which makes them heavier than the receptacles for cells of the proposed design according to the invention. Other problems include defective or non-existent chemical barriers or surface seals, and poorly specified structural reinforcement on the polymer concrete of the receptacles, which significantly affect their impermeability, safety, and durability and makes them difficult to clean, maintain, and above all to successfully repair cracks, so as to be able to recover their impermeability reliably.
[0013] The most important defects that cause premature breakdown and, in general, low reliability in the performance of the current polymer concrete electrolytic cell receptacles maybe traced to such defects as. Non-homogeneity and inconsistencies in the structural polymer concrete. These defects may be directly attributed to insufficient specifications and lack of rigorous control over raw materials, to deficient formulations for the polymer composite materials with excess resin, to mixing processes that are not homogeneous, and curing that lacks uniformity or is defective in regard to excessive solidification contraction, porosity due to improper compacting of the mixture in the mold, cracks due to irregular contraction of the polymer composite materials, cracks caused by detective molds, etc.
[0014] Added to the above-mentioned defects in the material and In forming and molding processes are ineffective mold designs that consistently produce cell receptacles that present variable nominal measurements and often random deformed geometry as well, which makes it more difficult, costly, and time-consuming to install and level them on site. The current state of the art views molds as devices that merely impart shape and not as true chemical reactors, whose characteristics affect the curing, properties, and condition of the composite polymer material. As a consequence of the above, the internal stresses in the material of finished cells according to the current state of the art are unacceptably high, particularly because the finished cells are not post-cured, which leaves them more susceptible or disposed to early breakdown due to cracks developed in the material during handling, shipping, and installation of cell receptacles made of a characteristically fragile material.
[0015] To the foregoing, we can add cell receptacle designs that are characterized by a parallelepipedic geometry with excessively thick walls and bottoms, particularly on the front and bottom walls as compared to the side walls, formed on the basis of materials with high resin content, and above all with the forms of the receptacle walls and bottom characterized by horizontal and vertical intersections with acute edges. The distribution of the volume of the material in conventional parallelepipedic geometry with acute edges and vertices is not optimal for resisting the stresses to which cells are subjected, particularly thermal stresses caused by the contraction/expansion of the polymer concrete resulting from thermal gradients or differences between the temperatures of the inner surfaces in contact with hot electrolytes and the outer surfaces exposed to the outside environment or to contiguous cells. These thermal gradients, or their sudden changes, may often cause cracks or fissures in the polymer concrete of the stressed bottom or walls which travel through current inner coatings and seals, resulting in leaks of corrosive electrolytes; and defects in regard to the cells being securely supported by and attached to their foundations, in order to ensure good seismic resistance and to protect the integrity of the cells during significant seismic events.
[0016] Finally, the internal reinforcement of the polymer concrete structure is under-specified with categories of materials that are not sufficiently corrosion resistant to sulfuric electrolytes, and arc also defectively designed and installed merely to provide nominal protection to prevent disintegration of the cell material in the event of seismic catastrophes (catastrophes that, fortunately, have not yet occurred), and not for their primary function (in the event fissures in the material were to develop), which is to keep to a minimum the spreading of any fissures encountered in the material, so as to permit recovery of the structural integrity and impermeability of the cells by injecting liquid resin In the cracks. As the injected resin cures, it contracts and closes the fissure, adhering the material and sealing any leaks from the cells, thereby ensuring their impermeability the reinforcement material is often based on fiberglass, which has very low resistance to acid corrosion by sulfuric electrolytes (Class E), and this fiberglass is also improperly dosed or poorly applied, which contributes to the formation of fissures and the loss of impermeability of the cells in the medium term.
[0017] None of the above-mentioned problems or disadvantages are fully or coherently resolved by the current state of the art.
SUMMARY OF THE INVENTION
[0018] The advantages of the improved electrolytic cell receptacles according to the invention are as follows.
[0019] With the feedback of results and problems encountered in the past 10 years concerning some 14,000 polymer concrete cells in plants for the electrorefining and electrowinning of copper, it has been possible to determine that the greatest structural stress to which cells are subjected during operation is thermal in origin and is generated by the effect of the difference between the temperature of the electrolytes inside the cell and the temperature of its external surroundings, creating temperature gradients on the inner and outer surfaces of the walls and the bottom of the cell. The concentrations of typical tensile stresses in specific areas of the electrorefining cell are, for example, more severe (indicated by structural analysis using the finite element method and taking into consideration relatively higher operating temperatures—typically 58-75° C.), and are generated by these thermal gradients between the temperatures on different areas of the inner surfaces and between them arid the outer surfaces of the structural core of polymer concrete material of the walls and bottoms of the cells. In the invention, these arc significantly reduced or eliminated by three strategies applied individually or jointly:
[0020] A) introducing in the design of the receptacle wide radii of curvature in all intersections or vertices of the walls and between the walls and the bottom;
[0021] B) Introducing in the manufacture of the receptacle the application of at least two polymer composite materials in the monolithic construction of the core of three-layered polymer composite material, which are compatible while still presenting different properties; and
[0022] C) Introducing sealing layers of resin reinforced with fiber glass as continuous coatings on the inner and outer surfaces of the polymer concrete structural core of the receptacle, with at least three structural layers over all inner surfaces and, of course, also reinforced according to industry standards in specific areas or places as joints on overflow boxes or electrolyte feed systems.
[0023] In addition, the most important structural stresses to which empty cells are subjected result from point or concentrated overloads of a mechanical nature in their handling, shipping, storage, and installation, or of an accidental nature (drop of electrodes), as well as thermal overloads due to significant sudden and/or localized drops in temperature (thermal shock). The vulnerability of cells to such overloads increases in direct proportion to their length/width ratio.
[0024] The design of the improved electrolytic cell receptacles of the invention has been simultaneously optimized both structurally and in regard to corrosion resistance, with absolute impermeability and minimizing heat loss during operation. To achieve these four objectives, computer modeling and analysis according to the finite element method have been used, with temperature data obtained directly from electrolytic processes in Industrial operations. Such analysis establishes the essential conditions needed to achieve lightened stresses on the structural material workload with minimal concentrations of stresses during the working life of the receptacle, taking into account all the most severe real operating conditions that are typical in both processes of electrorefining and electrowinning as well as the normal service and handling of both types of empty cells. The optimization of the receptacle is generic and concerns the selection of a combination of such relevant parameters as geometric form, spatial distribution of the volumes of material in such geometric forms, and characteristics and stability of the properties of both the polymer concrete core material and that of the integrated seals that form the three-layered polymer composite material, in such a way as to combine together to significantly increase impermeability, ease of operation, safety, and durability of operation of cells for electrorefining and electrowinning copper and other nonferrous metals at lower cost.
[0025] As the only way to achieve improved reliability, ease of operation, and durability of the cells, only those raw materials shall be used that are certified as to their origin, specification, and compatibility, with proven mechanical and chemical suitability for application in cells with corrosive electrolytes; the certification of raw materials and other materials is fundamental to the application of quality assurance standards in all processes and instructions for manufacturing, storing, shipping, and handling.
[0026] The ratio of resin/aggregate content in the formulations for polymer concrete materials is reduced, which results in significant improvements in their mechanical properties at the same time as it reduces the cost of the structural core of the receptacle, particularly when we consider that the cost of resin represents at least 70% of the cost of the polymer concrete material.
[0027] Resistance to corrosion is significantly improved, and at the same time the absolute impermeability of the receptacles is more than insured over the long term.
[0028] Using a three-layered polymer composite material that incorporates monolithic continuous seals on both surfaces, inside and outside the structural core, and mesh reinforcement, all specifying fiberglass of the corrosion resistant class (E-CR or a must), designed and constructed according to international standards in force In the industry for receptacles of polymer composite materials with high resistance to chemical corrosion.
[0029] The formulation of the polymer composite material for the inner chemical barrier seal to insure the absolute impermeability of the receptacle is empirically determined so that the elongation and tensile strength of the multi-layered polymer composite material applied as an inner seal is significantly higher than the adherence of its interface with the polymer concrete material of the structural core, so that any crack that may occur in the polymer concrete structural core is never able to affect the continuity and integrity of the material of the inner seal of the receptacle, thereby Insuring absolute impermeability.
[0030] Elimination of all inserts, common in the current state of the art, which pass through the seals on the inner surface of the receptacle in contact with electrolytes.
[0031] The attachment of the cell to its supports is improved, with a design that ensures restricted movement in both senses in all three directions, without resorting to metal inserts, by incorporating a system based on a “fuse” component designed to collapse when subject to high stress during significant seismic events, thereby protecting the integrity of the cell.
[0032] Depending on which cross-sectional geometry of a conventional cell is used as a reference—for example, the one claimed in (Chilean) Patent No. 38,151-the application of the design of the invention having wide interior and exterior curves to the current horizontal and vertical intersections of the structural core also permits a reduction on the order of 18% in the overall volume of material applied in the new cell receptacle, and accordingly also reduces its weight when compared to the typical reference cell, again lowering costs.
[0033] Nevertheless, the overall reduction in the level of stresses (both mechanical and thermal) and the optimal distribution of the volume of the material by using radii at the Intersections to prevent the concentration of stresses significantly improve the safety features of the new cell under electrorefining and electrowinning operating conditions.
[0034] A basic design concept of the improved electrolytic cell receptacle of the invention is to avoid any concentration or localization of discrete volumes of polymer concrete so as to achieve a clean simple receptacle with uniform thicknesses, moderate transitions, and ample radii in order to thereby manage setting contractions and insure complete and homogeneous curing and easy removal from the mold, and to provide electrolytic cell receptacles for operation that are as relaxed or as free of internal stresses as possible.
[0035] In order to improve the distribution of stresses in the polymer concrete core, and above all, in order to be able to reliably repair any possible fissures in the structural core cells produced by catastrophic events, a pre-woven mesh is incorporated in the structural core in order to provide bidirectional reinforcement in the plane of the mesh. This pre-woven mesh for bi-directional reinforcement is preferably formed of a framework of fiberglass rods of the E-CR class resistant to acid corrosion, pultruded with vinyl ester resin, with a square or hexagonal cross section, twisted, or with a circular cross section and surface fibers applied in a spiral braiding, with predetermined spacing and points of contact between the rods of the pre-woven mesh adhered using vinyl ester resin. The pre-woven mesh is applied before applying the polymer concrete over the continuous coating seals on the surfaces of the core mold, onto the side and end walls and below the outer surface of the bottom. The spacing of the framework on the bottom plane is denser in order to help ensure the integrity of the bottom material of the cell receptacle during the solidification process of the already consolidated polymer concrete, so as to uniformly distribute contractions and to prevent the formation of cracks caused by setting contractions, which is typical of polymer concrete cells manufactured according to the state of the art,
BRIEF DESCRIPTION OF THE DRAWINGS
[0036] The improved characteristics of the construction of electrolytic cells with non monolithic overflow and electrolyte infeed systems, mold and molding method, and new formulations for three-layered polymer composites shall be better understood in descriptions with reference to the drawings that form an integral part of the invention:
[0037] [0037]FIG. 1 shows a side view of a receptacle for cells of the invention, without showing the means for electrolyte infeed and overflow/drainage.
[0038] [0038]FIG. 1A shows a longitudinal section of a cell for electrorefining processes, with electrolyte overflow/drainage system ( 1 A 1 ) and infeed system ( 1 A 2 ) oriented toward the inside of the end walls.
[0039] [0039]FIG. 1B shows a side view of a cell for electrowinning, and the detail of the design with a non monolithic overflow box on the receptacle, ( 1 B 1 ) draining toward the outside of an end wall.
[0040] [0040]FIG. 2 shows a bottom view of the electrolytic cell receptacle of the invention and the areas for seismic-resistance support.
[0041] [0041]FIG. 3 shows a detail of the support block and the attachment system with a fastener of the cell receptacles of the invention.
[0042] [0042]FIG. 4 shows a side view of the attachment system with a fastener of the cell receptacles of the invention.
[0043] [0043]FIG. 5A shows a perspective view of a cell of the invention for electrowinning, indicating each of its walls and vertices, the areas of seismic-resistance support, and a detail of the installation of the non monolithic overflow box on an end wall.
[0044] [0044]FIG. 5B shows a perspective view of a cell according to the invention for electrorefining and a detail of the installation of the overflow/drainage system with discharge tubing at two levels, the first for overflow and the second at a level for storing sludge, defined by a formation inside the bottom of the receptacle; and of the electrolyte infeed system, both systems being installed toward the inside of the end walls.
[0045] [0045]FIG. 6 shows the right side wall of the receptacle of the invention and its supports.
[0046] [0046]FIG. 7 shows a top view of the receptacle of the invention.
[0047] [0047]FIG. 8 shows a longitudinal section of the receptacle of the invention.
[0048] [0048]FIG. 9 shows the front overflow wall as seen from the outside of an electrowinning cell of the invention.
[0049] [0049]FIG. 10 shows the front electrolyte infeed wall as seen from the outside of a cell of the invention.
[0050] [0050]FIG. 11 shows a front overflow wall as seen from the inside of an electrowinning cell of the invention.
[0051] [0051]FIG. 12 shows a front electrolyte infeed wall as seen from the inside of an electrowinning cell of the invention. The section view shows the cross section at the supports.
[0052] [0052]FIG. 13 shows a core mold and its assembled side walls; visible on the core mold is the pre-woven bi-directional reinforcement mesh on the bottom and walls of the cell receptacle of the invention.
[0053] [0053]FIG. 14 shows two sections of the side walls, in other words, the part that gives rise to the straight sections of the side and end walls, and the part that gives rise to the lower outside perimetric curvature of a cell receptacle embodiment of the invention; also visible is the pre-woven bi-directionally reinforced mesh.
[0054] [0054]FIG. 15 shows how the two sections of the side walls of the mold are assembled together; also showing the continuity of the outer seal coating installed over the entire section of the wall; and a detail of the pre-woven mesh on the upper edge of the side and front walls of the cell of the invention,
[0055] [0055]FIG. 16 shows a cross-sectional view of a lower longitudinal vertex of a receptacle embodiment of the invention, formed by an inner radius and an outer radius.
[0056] [0056]FIG. 17 shows a cross-sectional view of a lower longitudinal vertex of a receptacle embodiment of the invention, whose inner and outer radii are formed by two or more different radii.
[0057] [0057]FIG. 18 shows a cross-sectional view of a lower longitudinal vertex of a receptacle of the invention, whose side wall and bottom are joined by means of three or more straight segments that generate regular segments.
[0058] [0058]FIG. 19 shows a new type of pre-woven bi-directionally reinforced mesh with pultruded, fiber reinforced polymer rods of circular cross section and with fibers with helicoidal twisted ribs, showing a section of the weave and an appropriate diameter of rod for the levels of stress required.
[0059] [0059]FIG. 20 shows a typical receptacle for an electrolytic cell of the invention, which may be equipped for either electrorefining or electrowinning, incorporating in each case corresponding typical electrolyte overflow/drainage and infeed systems on the end walls.
[0060] [0060]FIG. 20 a shows a detail of an overflow/drainage system With common tubing and discharge of the type of FIG. 58 of the electrorefining cell embodiment of the invention.
[0061] [0061]FIG. 20 b shows an inner end wall of an electrowinning cell with a non-monolithic overflow box as seen from inside.
DETAILED DESCRIPTION
[0062] With reference to FIGS. 1 - 20 b, electrolytic cell receptacle 1 for processes of electrowinning or refining nonferrous metals of the invention is composed of side wails ( 2 , 3 ), end or front walls ( 4 , 5 ), bottom ( 6 ), and support system ( 7 ), and non-monolithic overflow box ( 5 a ) installed after the receptacle has been molded and has hardened on end wall ( 5 ) or non-monolithic overflow/drainage system ( 1 A 1 ) and electrolyte infeed system ( 1 A 2 ), also installed after the receptacle has been molded and has hardened.
[0063] In order to equip the receptacle of the invention for the electrorefining process, the overflow/drainage system and the electrolyte infeed system are designed as indicated in FIG. 20 a. The overflow/drainage system ( 1 A 1 ) is composed of a unit that is molded separately from receptacle ( 1 ) and consists of a semicircular insert ( 1 A 10 ) on end wall ( 5 ), which is integrally molded with buffer block ( 1 A 11 ), provided with a hole for vertical installation of drain pipe ( 1 A 12 ). Said pipe is inserted at its lower end into block ( 1 A 13 ) separately molded and adhered to the floor of receptacle ( 1 ), or integrally molded with bottom ( 6 ) of receptacle ( 1 ). Block ( 1 A 13 ) is provided with vertical discharge hole with flange ( 1 A 15 ) toward the outside of the receptacle. At the level of the block, a conical rubber ring is installed on the outside of pipe ( 1 A 12 ) in order to support pipe ( 1 A 12 ) and at the same time to seal access to hole ( 1 A 15 ), thereby preventing runoff of the electrolytes when the overflow pipe is installed. In order to drain electrolytes from the cell, pipe ( 1 A 12 ) uses vertically toward its open end over buffer block ( 1 A 11 ), thereby permitting electrolytes to drain through hole ( 1 A 15 ). The accumulated sludge remains in the bottom of the cell and is discharged by a second hole (not shown) located conveniently in the bottom of receptacle ( 1 ).
[0064] The electrolyte infeed system is composed of another very similar unit that is molded separately from receptacle ( 1 ) and consists of a semicircular insert ( 1 A 10 ) on end wall ( 4 ) which is integrally molded with buffer block ( 1 A 11 ), provided with a hole for vertical installation of infeed pipe ( 1 A 22 ). The lower end of said pipe is inserted in block ( 1 A 24 ), which is separately molded and adhered to the floor of receptacle ( 1 ), or integrally molded with bottom ( 6 ) of receptacle ( 1 ). Block ( 1 A 24 ) is provided with a horizontal hole of large diameter ( 1 A 25 ), which is connected outside to the system for rapid filling the cell with electrolyte. Vertical pipe ( 1 A 22 ) may be equipped at a convenient height with “1” piece ( 1 A 23 ) for installing horizontal supply pipes that distribute the electrolyte as desired or in a manner favorable to the electrorefining process. The supply arrangement may be replaced with a vertical supply box or channel (not shown) adhered to end wall ( 4 ) below or adhered to buffer block ( 1 A 11 ).
[0065] [0065]FIG. 20- b shows receptacle ( 1 ) equipped with a wide overflow box (Sa) designed to accommodate the larger electrolyte flows of electrowinning processes, which generally discharge toward the outside of the cell through a pipe of suitable diameter, as shown in FIG. 5A. Incorporated on the aide and front walls of electrolytic cell receptacle ( 1 ) are inner radii ( 8 ) and outer radii ( 9 ) located at the intersections of said walls, and outer radii ( 9 ) are optionally added at the intersections of the walls and bottom ( 6 ), the thickness of the walls either remaining constant or gradually changing at the intersections with bottom ( 6 ), except in areas of seismic-resistance support ( 10 ) for the cells to their foundations or drainage areas ( 10 A of FIG. 1A).
[0066] As shown in FIGS. 3 and 4, the fastening system for the innovative electrolytic cell ( 1 ) eliminates current state of the art inserts in the receptacle and anchoring bolts to the support block and permits the cell to be mounted onto conventional foundations ( 11 ) by an arrangement of adhered polymer concrete blocks, which make it possible to provide fasteners with pins ( 16 ) restraining movement in both directions of the three orthogonal planes, which simultaneously act as seismic fuses. This is achieved by using conventional support blocks with teeth ( 12 ) made of polymer concrete, ‘whose formulation is similar to that of the core, into which is molded a female half-channel ( 13 ) running obliquely longitudinal, to work together with four adjacent seismic stops ( 14 ) provided with female half-channels ( 15 ) that are the mirror image of the previous ones, which are positioned, once the blocks and seismic stops are installed, in such a way that the cavities formed by the opposing half-channels define an oblique bore that will permit the cell to be fastened to and unfastened from the support blocks ( 12 ) by means of pins ( 16 ), preferably PVC tubes filled with polymer concrete. Fuse stops ( 14 ) are adhered to the bottom of the cell receptacle on site after having leveled support block ( 12 ) and cell ( 1 ) with shims ( 17 ), so that half-channels ( 13 , 15 ) are opposite one another and aligned so as to permit insertion of seismic fastening pin ( 16 ), regardless of the height of the shims ( 17 ) used to level the blocks (and the cell) in each cell ( 1 ) support. The alignment of the facing half-channels is achieved by the fact that fusible seismic stop ( 14 ) is able to slide on support pedestal ( 10 ) of cell receptacle ( 1 ) until the facing longitudinal axes of half-channels ( 13 ) and ( 15 ) are aligned. Adherence on site of fusible stops ( 14 ) makes it possible, if a seismic event were to occur, for them to collapse and/or detach from the cell receptacle in order thereby to protect the integrity of bottom ( 6 ) of cell receptacle ( 1 ), since the energy is dissipated primarily in the seismic fuse stops and in the fastening pin.
[0067] The typical formulation for the polymer concrete material of the structural core of cell receptacle ( 1 ) of the invention is characterized by the fact that it has a low resin content, with a maximum of 9.5 wt % of the material. The resin system preferably consists of a mixture of ax least 90 wt % vinyl ester resin (5% elongation) and the balance of other compatible resins with high elongation (50-70% elongation), including polyester/vinyl ester. The solid reinforcement for the resin system is characterized by a system of siliceous aggregates, dosed in a controlled manner according to a continuous diametral gradation of fractions of multiform particles, in a range from a maximum diameter of 12.67 mm to a minimum diameter of 1 micron, with or without incorporation of between 0.1-0.8 wt % of filament-shaped reinforcement, typically fiberglass cut to lengths between 6.35 mm and 3.175 mm. As needed in high stress areas of the cell, according to the structural analysis, and so as to be compatible with the typical polymer concrete material used in the core, the invention calls for formulations for polymer composite materials with higher vinyl ester resin contents reinforced with a system of siliceous aggregates, dosed in a controlled manner, according to a continuous diametral gradation of fractions of multiform particles, in a range from a maximum diameter of 2 mm to a minimum diameter of 1 micron, with the addition of up to 3 wt % fiberglass cut to lengths between 12.67-3.175 mm.
[0068] The polymer composite materials of special characteristics and properties, are judiciously applied, as needed, to the volumes and in the locations of the most highly stressed areas of the cell (thermal or stress of any other origin) as shown in the finite element structural, analysis, replacing in those areas the corresponding volume of polymer concrete having low-resin content that is the primary constituent of the structural core of the cell receptacle. The structural core is monolithically formed as a three-layered polymer composite material in the cell receptacle; in other words, the surfaces of the structural core material are covered inside and out with fiber-reinforced polymer composite materials acting as continuous “seals,” forming a monolithic unit in both the configuration for electrowinning and for electrorefining, due to the fact that the three-layered structural material cures chemically and simultaneously as a single polymer composite material.
[0069] The cell receptacle ( 1 ) incorporates “seals” in the form of layers ( 18 ) of fiberglass-reinforced vinyl ester resin coatings designed according to current DIN and/or ASTM standards, which are integrally applied to the surfaces of the structural core of the cell receptacle. Each seal is a highly compacted polymer concrete, with very low porosity and permeability ( 19 ). In order to protect and ensure impermeability of the cell receptacle, the seals are functionally designed according to the degrees of corrosion resistance and impermeability required in a user's specifications as dictated by the corrosiveness of the electrolytes and the aggressive nature of the processes used to clean the electrolytic cells. The inner surfaces of walls ( 2 , 3 ) and bottom ( 6 ) of the cell ( 1 ) contact chemically aggressive, hot electrolytes, and in the manufacture of receptacles, at least three layers of fiberglass-reinforced vinyl ester resin coating must be applied to the polymer concrete core, according to current standards, although this does not restrict the number of layers applied during manufacture to part or all of the surfaces in contact with the electrolyte. The outer surfaces of walls ( 4 , 5 ) and bottom ( 6 ) of cell (I) are exposed to the environment and to accidental spills of electrolytes, hence, they normally require a lower level of protection, which may be reasonably ensured by applying at least one layer of veil fiber saturated with vinyl ester resin only on the outer surfaces of the cell walls.
[0070] The advantages and consequences of using a polymer concrete material that is formulated with a lower resin content than in the current state of the art for the structural core of cells include:
[0071] Lower raw materials costs in the manufacture of cells;
[0072] Higher and more stable average mechanical properties (ultimate resistance to compression and bending-tensile stresses); and
[0073] Significant decrease in the coefficient of thermal expansion for the polymer concrete material, which is a critical and determining factor of the stresses generated by temperature gradients in the structural core of the cell at operating temperatures.
[0074] The formulation for the structural core material has 9.5% maximum resin content, which corresponds to a coefficient of thermal expansion less than 16 um K− 1 , i.e., a reduction on the order of 10-20% relative to the typical coefficient of thermal expansion for polymer concrete material formulations claimed in conventional, less advanced cells (for example, (Chilean) Patent No. 38,151 and (Chilean) Patent No. 35,446).
[0075] Similarly, the lower resin content results in an increase in the Young's modulus of the material. The higher the modulus, the greater the rigidity as elongation decreases and impact resistance decreases. To improve impact resistance, filament-shaped reinforcement is added to the aggregate system. It must be emphasized that in the surroundings of electrolytic cell operations the greatest stresses on the structural core are those generated by thermal gradients between the internal and external temperatures of the walls and bottom; hence the need to alleviate in practice certain relatively negative effects of the higher modulus, which increases the ultimate resistance of the material of the structural core at the same time that it increases its susceptibility to breakage. On the one hand, the formulation for the polymer concrete material of the electrolytic cells of the invention is naturally aimed at achieving a balance by mixing the vinyl ester resin of the system of resins with compatible high elongation resins, partly compensating for the higher modulus of the polymer composite material with the greater elasticity of the system of resins; and, at the same time, reducing the setting contraction of the material, which is extremely significant in reducing the overall state of internal stress remaining in the polymer concrete of the invention after solidification. The decrease in the resin content also significantly increases the thermal conductivity of the polymer concrete of the invention, and thereby decreases the thermal gradients through the walls and bottoms of electrolytic cell receptacle. On the other hand, the multi-layered coating of reinforcement/inner seal inner of the receptacle has a lower Young's modulus than the polymer concrete structural core. It is also possible to judiciously replace volumetric contents of the polymer concrete structural core having a low resin content in areas of high stress in the cell with polymer composite materials having a high resin content and reinforced with fiberglass and fine aggregates, and accordingly, with a lower Young's modulus, high coefficient of thermal expansion, and increased impact resistance and tension resistance.
[0076] The objectives of the judicious application of polymer composite material with a higher resin content and reinforced with fiberglass and fine aggregates include:
[0077] At normal cell operating temperatures, to judiciously eliminate the areas of high tensile stress in the cell, transforming them into areas of lower or neutral tensile stress, or, one would anticipate, of compression; and
[0078] To significantly increase the overall relaxation of stresses in the structural material core of the cell, thereby improving its safety factor in regard to impact during shipping and handling, and during normal operations when faced with localized point thermal shock events, such as hosing the inside of the hot cell with cold water (10° C.) immediately after emptying, or severe mechanical impact caused by falling electrodes.
[0079] According to FIG. 13, the manufacturing method for an electrolytic cell receptacle ( 1 ) consists of using steel molds ( 19 ) for conventional inverted molding, but constructed with all the interior and exterior vertical intersections of the walls and horizontal intersections of the walls with the bottom of the cell having one or more radii ( 8 , 9 , 20 ) and/or one or more straight segments, with sufficient curvature, preferably never less than the thickness of the bottom of the cell (See FIG. 7, 8, 16 , 17 ). In order to mold the exterior curvature at the horizontal vertices of the walls with the bottom, the molds for the side walls ( 21 , 22 ) are constructed in two sections: The first mold section is limited in height to where the curves commence, and the second mold section, which is mounted to fit On top of the other section, determines the outer curves and the pedestals for horizontal support ( 10 ) of the cell receptacle ( 1 ), which retain the edge arid have no horizontal curvature.
[0080] Installed in the second mold section (FIG. 14), before assembly, is the pro-woven mesh ( 23 ) for bi-directional reinforcement, formed (FIG. 19) of fiberglass rods that are square or hexagonal in cross section and twisted, or circular in cross section with heticoidal braiding ( 23 a ). The pre-woven mesh ( 23 ) is pultruded with vinyl ester resin and joined with resin at the points of intersection in order to maintain the integrity of the carcass ( 24 ), which covers the outer surface of the bottom of the cell ( 6 ) with a lattice whose mesh is preferably 200×200 mm, and the side and end walls with a mesh of preferably 600×600 mm installed just below the upper edge of the side walls. When the second mold section is filled with polymer concrete, the thickness of the polymer concrete over the pre-woven bi-directionally reinforced mesh ( 24 ) on the bottom is controlled so that it remains lodged in the plane with the maximum stresses on the bottom, as indicated by structural analysis using the finite element method.
[0081] In the current state of the art, each of the 4 molds for the side and front walls of the cell are separately covered with seals and then assembled together, and after being assembled are fixed vertically on the central core mold in an inverted position, thereby producing a perimetric 90° joint at the contact vertices of the assembled mold for the side and end walls with the core. This mold design and assembly process introduces the possibility that the molded cells will have dimensional variations, as well as being out-of-square. In addition, the joined side arid end walls do not ensure continuity of the seal or impermeability of the cell on the exterior vertical vertices, which are generally the areas where contracting stresses concentrate during setting. Finally, the joint between the molds at the vertex of contact is typically not watertight when the receptacle is molded, and when the receptacle material is emptied, resin tends to leek from the vertices, thereby producing defective localized polymer concrete due to lack of resin, particularly at the upper horizontal edge of the cell walls, which is the edge most exposed to impact overloads. The correction of all these manufacturing defects requires costly rework repairs at the factory and on site.
[0082] In the present molding process, side molds ( 21 , 22 ) are mounted before applying the outer seal coating ( 18 ), thereby ensuring square joints and continuity of the seal and impermeability over the entire surface perimeter ( 2 - 5 ) of cell ( 1 ). Incorporated in the core mold for the cell of the invention is a contoured section for the upper horizontal edge of the side and end walls of the cell (FIG. 15), and the perimetric joint creates the vertical position stop between the core and the lower side mold. The seal on this single joint is completely leak proof and can be checked before emptying to prevent any resin loss. Just as important as the above is the fact that the multilayered seal coatings applied to the core mold are totally continuous and the inside of the cell is a single piece, and that they extend from the inside of the receptacle over the contoured section of the upper horizontal edge of the side and end walls, always in a single piece. The beginning of the outer coating of the cell commences at the butt joint between the core and the lower side mold, and fully covers outside of the cell. The second side/bottom section ( 22 ) of the steel mold is preferably made in a single piece and covers continuously or with a drip catch ( 25 ) on the horizontal perimeter ( 26 ). In this case, the perimetric joint of seal ( 26 ) between sections ( 21 , 22 ) of the mold is reinforced by an overlap ( 27 ) of sealing material ( 18 ) that overlaps first section ( 21 ) and is designed according to current standards for sealing materials.
[0083] Some designs for electrolytic cells of the current state of the art, such as (Chilean) Patent No. 38,151, claim monolithic molding of an overflow box that drains out from an end wall and uses the same polymer concrete as the core, to that end integrating the mold for the overflow box into the mold for end wall of the cell. The concept does not contribute any significant benefits, rather several disadvantages. It certainly makes the mold construction more expensive and makes it virtually impossible to achieve dimensions with the precise tolerances required for proper flow and the functioning of key measuring devices and electrolyte flow control devices in the overflow box, which affect both the yield of the electrolytic process and the quality of the cathode obtained. In order to compact the polymer concrete during molding, the mold for the above-mentioned overflow box of the current state of the art must be designed with obtuse angles to facilitate the release of air trapped in the concrete mixture. In addition to adding structurally unnecessary volume, this concept also results in incomplete venting of the material in the area of the overflow box and/or, worse, in the concentration of excess mass of polymer concrete which generates uneven contractions between the overflow box and the end wall of the cell receptacle during hardening, particularly at the vertices. The overflow box is an area where cracks, visual defects, voids, etc., typically occur, which require costly repair.
[0084] In the design of the improved cell receptacle of the invention, the receptacle accessories are made separately, although the polymer composite material of the overflow box and the other accessories are also a three-layered monolithic similar to that of the cell. The molding, forming, and curing of the overflow box is independent of the receptacle. When installed, the overflow box is typically positioned to drain out from the end wall for electrowinning processes or drain out vertically toward the ground through the inside of the wall for electrorefining. It is assembled by fitting the overflow box (FIGS. 5 A and SB) finished with an insert into the end wall provided with a semicircular dovetail that is formed on under the upper edge of one end wall of the cell, with later chemical adhesion, using vinyl ester resin, at the matching joint between the wall of the cell and the overflow box. Finally, completed joint is scaled by joining the layers of the corresponding seal coatings ( 5 b ) on the cell receptacle and on the overflow box with overlapping of the respective layers of fiberglass saturated with vinyl ester resin according to ASTM or DIN standards. The entire seal is subsequent to fitting and chemically adhering overflow box ( 5 a ) to cell receptacle ( 1 ), which correctly resolves all the mentioned disadvantages and ensures a virtually absolute degree of impermeability and resistance to corrosion.
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Design improvements in constructing electrolytic cell receptacles for electrowinning and electrorefining of nonferrous metals are disclosed, along with a novel mold and molding method. Also disclosed arc formulations for three-layered polymer composite materials and surface scaling coatings, which are used in monolithic formation of receptacles or containers of electrolytic cells.
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FIELD OF THE INVENTION
This invention relates to dyed poly(trimethylene terephthalate) fibers and processes for making the poly(trimethylene terephthalate) fibers. The fibers are suitable for use in applications wherein the fibers are subjected to significant UV exposure, such as automotive uses.
BACKGROUND
Poly(trimethylene terephthalate) (also referred to as “3GT” or “PTT”) has recently received much attention as a polymer for use in textiles, flooring, packaging and other end uses.
Certain end uses place rigorous demands on fibers. For example, in automotive interiors, fabrics are expected to maintain desirable physical properties over extended periods of use and, potentially, extreme environmental conditions. Even with the advent of sun-shielding tinted windows, UV exposure can be very high. Compounding this are extremes in temperature ranges spanning from sub-freezing, wherein softness is generally preferred to brittleness, to super heated greenhouse-like conditions, especially in more southern areas of the North American continent. Transportation end uses, from aircraft to pleasure boats, have some of the same rigorous conditions of more widespread automotive end uses.
In the area of automotive interiors, different end uses include seat covering material, door panel decorative panels and headliners. Colorfastness is desired in all of these applications. Maintenance of physical characteristics other than color is also desirable. In some of these applications, perhaps more important than absolute value for any given physical parameter, e.g. elongation, (some of which can be compensated for by design considerations), is the stability of physical performance over extended periods of testing/time.
In addition to transportation linked end uses, outdoor end uses including housing (awnings), garden and patio furniture, and certain items of apparel and personnel (sun) protective equipment can place extreme UV and heat stability requirements on fabric materials employed.
A fabric material possessing highly desirable aesthetic qualities is fabric made with fibers comprising poly(trimethylene terephthalate), also referred to as “PTT” or “3GT”. Such fabrics exhibit softness (hand), resiliency, and stretch recovery, among other desirable properties. Physical properties of testing interest include tenacity and elongation.
Travel and Transportation Textiles (Ciba Specialty Chemicals, Inc., April 2000) presents an overview of automotive fabric dyeing technology. The potential utility of poly(trimethylene terephthalate) fiber in automotive fabrics is discussed in view of its attractive physical properties, but results of high temperature light fastness tests indicate “difficulties in reaching the level of performance of regular polyester” (i.e. polyethylene terephthalate). The publication states that “regular polyester has become and will remain the dominant fiber for upholstery for at least the near future”. The use of UV absorbers is discussed as a method of improving lightfastness, but only in connection with regular polyester (Tersuisse® brand of polyester from Rhodia was used in testing.) JP 2000 192375A discloses a method for dyeing poly(trimethylene terephthalate) fabric to yield sublimation color fastness. The publication discloses that after dyeing the poly(trimethylene terephthalate) fabric at 90–140° C., for 15 to 90 minutes, the dyed fabric is removed from the dyebath at a temperature between 55° C. and the boiling point of the dyebath, which provides the desired colorfastness. The only tests carried out on the resulting dyed poly(trimethylene terephthalate) fabrics are tests for sublimation fastness and sublimation fastness during storage.
JP 2002 180384A discloses a dyed article composed of poly(trimethylene terephthalate) fiber having color fastness to light of grade 3 or higher, and a production method thereof, a triazine and/or benzotriazine derivative as a light resistance improving agent. The publication discloses that dyeing can be carried out at 90–130° C. for 15 to 120 minutes, and exemplifies dyeing at 120° C. for 45 minutes. Conditions of UV exposure and lightfastness testing are not disclosed.
It is known that poly(trimethylene terephthalate) can be dyed at atmospheric pressure, at temperatures of 100° C. or less, in aqueous media. For example, U.S. Pat. No. 5,782,935 discloses a process for the dyeing of poly(trimethylene terephthalate) fibers by treating the fibers in an aqueous liquor in the absence of a carrier and without the application of pressure, at or below the boiling point of the aqueous liquor. U.S. Pat. No. 6,187,900 B1 discloses a dyeable fiber of poly(trimethylene terephthalate) and poly(ethylene terephthalate); dyeing is carried out at or below 100° C. in the absence of a carrier. JP 2002 054047A discloses that the dyeing of sewing thread comprising poly(trimethylene terephthalate) is advantageously carried out at atmospheric pressure at 98° C. rather than under pressure at 120° C.
The ability to dye poly(trimethylene terephthalate) fibers at higher temperatures and pressures than those at which such dyeing is conventionally carried out, and to provide poly(trimethylene terephthalate) having improved colorfastness, are desired. The present invention is directed to these and other important ends.
SUMMARY OF THE INVENTION
The present invention provides colored poly(trimethylene terephthalate) fibers, and processes for producing the fibers. The fibers are suitable for use in transportation end uses, in which fibers can be subjected to high UV exposures, often also in the presence of stringent heat conditions. The processes include the use of a benzotriazine derivative UV absorber.
One aspect of the present invention is a composition, i.e., a fiber-dye combination, comprising poly(trimethylene terephthalate), a disperse dye, and a benzotriazine derivative UV absorber, and having a light fastness of 4 or higher after at least 488 kJ incident UV radiation under standard testing conditions. In some embodiments, the fiber has a light fastness of 3 or higher, more particularly 3 to 5, and in preferred embodiments even 4 or higher, more particularly 4 to 5, after at least 779 kJ incident UV radiation under standard testing conditions, depending on the composition of the disperse dye. In preferred embodiments, the fiber-dye combination exhibits a loss of tenacity less than about 10% following exposure to at least 481 kJ of UV radiation.
Another aspect of the invention is a colored fiber comprising poly(trimethylene terephthalate), a disperse dye, and a benzotriazine derivative UV absorber, and having a light fastness of 4 or higher after at least 488 kJ incident UV radiation under standard testing conditions. In some embodiments, the fiber has a light fastness of 4 or higher after at least 779 kJ incident UV radiation under standard testing conditions, depending on the composition of the disperse dye. In preferred embodiments, the fiber-dye combination exhibits a loss of tenacity less than about 10% following exposure to at least 481 kJ of UV radiation.
Another aspect of the invention is a process for making dyed poly(trimethylene terepthalate)s comprising:
a. providing a poly(trimethylene terephthalate) fiber; b. combining at room temperature in an aqueous medium about 0.50 weight percent of an alcohol ethoxylate surfactant, about 0.25 weight percent of a sequestering agent, 3.00 weight percent of a benzotriazine derivative UV absorber, 0.5 weight percent of a disperse dye, and sufficient water to provide a water:fiber ratio from about 2:1 to about 40:1, all weight percents on weight of fiber, to form a dyebath; c. adjusting the pH of the dyebath to about 4.0 to about 5.0; d. heating the dyebath at a rate of at least about 1° C. per minute to a temperature of 132–145° C.; e. immersing the poly(trimethylene terephthalate) fiber in the dyebath; f. maintaining the dyebath temperature for at least about 30 minutes to produce a dyed poly(trimethylene terephthalate) fiber; g. allowing the dye bath to cool; and h. rinsing the dyed poly(trimethylene terephthalate) fiber.
In some embodiments, the fiber has a light fastness of 4 or higher after exposure to 488 kJ incident UV radiation when tested using test method AATCC Method 16-1998.
In some embodiments, the fiber has a light fastness of 4 or higher after exposure to 779 kJ incident UV radiation when tested using test method AATCC Method 16-1998, when the disperse dye is selected from: Chemical Index (CI) Disperse Red 86, CI Disperse Red 161, CI Disperse Yellow 42, CI Disperse Yellow 96, CI Disperse Yellow 160, CI Disperse Blue 200, CI Disperse Blue 60 and CI Disperse Blue 77.
DETAILED DESCRIPTION OF THE INVENTION
The present invention provides fibers comprising poly(trimethylene terephthalate), and processes for making dyed poly(trimethylene terephthalate). Fibers made according to the processes disclosed herein can have lightfastness ratings of at least 4 after exposure to 488 kJ of UV radiation under standardized testing conditions, and even after exposure 779 kJ of UV radiation when certain disperse dyes are used. It has been surprisingly found that with the use of the processes disclosed herein, poly(trimethylene terephthalate) fibers dyed at temperatures and pressures higher than even the highest temperatures disclosed in some prior publications, such as JP 2000 192375A and JP 2002 180384A, have improved colorfastness in comparison with poly(trimethylene terephthalate) fibers dyed using conventional processes. While it is not intended that the invention be bound by any particular theory, it is believed that the processes disclosed herein allow relatively deeper penetration of the fibers by dye molecules, which improves colorfastness.
Fibers made according to the processes disclosed herein can also be referred to as “fiber-dye combinations”, indicating the presence of dye molecules with the fibers.
A process for making dyed poly(trimethylene terepthalate)s according to the present invention comprises:
a. providing a poly(trimethylene terephthalate) fiber; b. combining at room temperature in an aqueous medium about 0.50 weight percent of an alcohol ethoxylate surfactant, about 0.25 weight percent of a sequestering agent, 3.00 weight percent of a benzotriazine derivative UV absorber, 0.5 weight percent of a disperse dye, and sufficient water to provide a water:fiber ratio from about 2:1 to about 40:1, all weight percents on weight of fiber, to form a dyebath; c. adjusting the pH of the dyebath to about 4.0 to about 5.0; d. heating the dyebath at a rate of at least about 1° C. per minute to a temperature of 132–145° C.; e. immersing the poly(trimethylene terephthalate) fiber in the dyebath; f. maintaining the dyebath temperature for at least about 30 minutes to produce a dyed poly(trimethylene terephthalate) fiber; g. allowing the dye bath to cool; and h. rinsing the dyed poly(trimethylene terephthalate) fiber.
All percentages in the foregoing process are weight percents “on the weight of fiber” (OWF).
The processes disclosed herein provide poly(trimethylene terephthalate) fibers having desirable lightfastness with a rating of 4 or higher, more particularly from 4 to 5, under 488 kJ UV exposure by AATCC Method Number 16-1998 with certain disperse dyes, especially such dyes suitable for dyeing automotive fabrics, particularly Color Index (“CI”) Disperse Red 86, CI Disperse Red 91, CI Disperse Red 161, CI Disperse Red 279, CI Disperse Yellow 42, CI Disperse Yellow 96, CI Disperse Yellow 160, CI Disperse Blue 27, CI Disperse Blue 60, and CI Disperse Blue 77, at 0.5% on weight of fibers (OWF) dyeing depths. According to AATCC Method Number 16-1998, ratings of lightfastness range from 1 to 5, 5 being the highest rating. Thus, a lightfastness of 4 to 5 is highly desirable.
In some preferred embodiments, the processes disclosed herein provide poly(trimethylene terephthalate) fibers having desirable lightfastness with a rating of 4 or higher at 779 kJ UV exposure with certain disperse dyes, particularly CI Disperse Red 86, CI Disperse Red 161, CI Disperse Yellow 42, CI Disperse Yellow 96, CI Disperse Yellow 160, CI Disperse Blue 60 and CI Disperse Blue 77 at 0.5% OWF dyeing depths.
Percentage quantities of dyes are disclosed herein as “% OWF”, which means weight percent dye based on the weight of fiber.
CI Disperse dyes are known to those skilled in the art, and appropriate disperse dyes for use in dyeing polyester fibers, particularly poly(trimethylene terephthalate) fibers, can be selected by the skilled person. Examples of commercially available disperse dyes suitable for use in dyeing fibers, particularly fibers suitable for automotive uses, produced according to the processes disclosed herein include: Terasil® Pink 2GLA-01 (CI Disperse Red 86), Disperserite® Pink REL (CI Disperse Red 91), Dorospers® Red KFFB (CI Disperse Red 161), Dorospers® Red KFFN (CI Disperse Red 279), Terasil® Yellow GWL (CI Disperse Yellow 42), Dorospers® Golden Yellow R. Conc (CI Disperse Yellow 96), Dianix® Yellow SG (CI Disperse Yellow 160), Terasil® Blue GLF (CI Disperse Blue 27), Terasil® Blue BGE-01 (200) (CI Disperse Blue 60) and Dorospers Blue BLFR (CI Disperse Blue 77). Newly developed disperse dyes having the colorfastness characteristics and suitable for use under the conditions disclosed herein for dyeing poly(trimethylene terephthalate) fibers are intended to be within the scope of the present invention. One skilled in the art will recognize that such dyes can be tested using the standard conditions disclosed herein, on commercially available poly(trimethylene terephthalate)s such as, for example, Sorona® 3GT polymer.
Unless otherwise stated, the terms “poly(trimethylene terephthalate)”, “3GT” and “PTT”, as used herein, include homopolymers and copolymers containing at least 70 mole % trimethylene terephthalate repeat units, and polymer blends containing at least 70 mole % of trimethylene terephthalte homopolymers or copolyesters. Preferred poly(trimethylene terephthalate)s, including copolymers and blends, contain at least 85 mole %, more preferably at least 90 mole %, even more preferably at least 95 mole %, still more preferably at least 98 mole %, and most preferably about 100 mole %, trimethylene terephthalate repeat units. For convenience, poly(trimethylene terephthalate)s are also referred to herein as “3GTs”.
The term “mole percent”, as used herein, means the percent of a particular component, in moles, based on the total number of moles of, for example, monomer units in a polymer.
Examples of poly(trimethylene terephthalate) copolymers include copolyesters made using 3 or more reactants, each having two ester forming groups. For example, a copoly(trimethylene terephthalate) can be made using a comonomer selected from linear, cyclic, and branched aliphatic dicarboxylic acids having 4–12 carbon atoms, such as butanedioic acid, pentanedioic acid, hexanedioic acid, dodecanedioic acid, and 1,4-cyclo-hexanedicarboxylic acid); aromatic dicarboxylic acids other than terephthalic acid and having 8–12 carbon atoms, such as isophthalic acid and 2,6-naphthalenedicarboxylic acid; linear, cyclic, and branched aliphatic diols having 2–8 carbon atoms, other than 1,3-propanediol, such as ethanediol, 1,2-propanediol, 1,4-butanediol, 3-methyl-1,5-pentanediol, 2,2-dimethyl-1,3-propanediol, 2-methyl-1,3-propanediol, and 1,4-cyclohexanediol); and aliphatic and aromatic ether glycols having 4–10 carbon atoms, such as hydroquinone bis(2-hydroxyethyl) ether. Alternatively, a copoly(trimethylene terephthalate) can be made using a poly(ethylene ether) glycol having a molecular weight below about 460, such as diethyleneether glycol. The comonomer typically is present in the copolyester at from about 0.5 mole % to about 15 mole %, and can be present in amounts up to 30 mole %.
The poly(trimethylene terephthalate) can contain minor amounts, e.g., about 10 mole % or less, in some embodiments about 5 mole % or less, of one or more comonomers other than trimethylene terephthalate, and such comonomers are usually selected so that they do not have a significant adverse affect on properties. Exemplary comonomers that can be used include functional comonomers such as 5-sodium-sulfoisophthalate, which is preferably used at an amount within the range of about 0.2 to 5 mole %. Very small amounts, about 5 mole % or less, even 2 mole % or less, of trifunctional comonomers, such as, for example trimellitic acid, can be incorporated for viscosity control.
A poly(trimethylene terephthalate) homopolymer or copolymer can be blended with one or more other polymers. Preferably, if blended, the poly(trimethylene terephthalate) is blended with about 30 mole percent or less of one or more other polymers. Examples of polymers suitable for blending with a poly(trimethylene terephthalate) homopolymer or copolymer are polyesters prepared from other diols, such as those described above. Preferred poly(trimethylene terephthalate) blends contain at least 85 mole %, more preferably at least 90 mole %, even more preferably at least 95 mole %, still more preferably at least 98 mole %, poly(trimethylene terephthalate) polymer. In certain highly preferred embodiments, blends contain substantially about 100 mole % poly(trimethylene terephthalate) homopolymer or copolymer. For some applications, blends are not preferred.
The intrinsic viscosity of the poly(trimethylene terephthalate) is at least about 0.70 dl/g, preferably at least about 0.80 dl/g, more preferably at least about 0.90 dl/g and most preferably at least about 1.0 dl/g. Also, the intrinsic viscosity is preferably not greater than about 2.0 dl/g, more preferably not greater than about 1.5 dl/g, and most preferably not greater than about 1.2 dl/g.
The number average molecular weight (M n ) of the poly(trimethylene terephthalate) is preferably at least about 10,000, more preferably at least about 20,000, and is also preferably about 40,000 or less, more preferably about 25,000 or less. The preferred M n depends on the components of the poly(trimethylene terephthalate), and also can be affected by the nature and amount of any additives or modifiers used that affect the physical properties of the poly(trimethylene terephthalate).
Poly(trimethylene terephthalate) and methods for making poly(trimethylene terephthalate) are known and are described, for example, in U.S. Pat. Nos. 5,015,789, 5,276,201, 5,284,979, 5,334,778, 5,364,984, 5,364,987, 5,391,263, 5,434,239, 5,510,454, 5,504,122, 5,532,333, 5,532,404, 5,540,868, 5,633,018, 5,633,362, 5,677,415, 5,686,276, 5,710,315, 5,714,262, 5,730,913, 5,763,104, 5,774,074, 5,786,443, 5,811,496, 5,821,092, 5,830,982, 5,840,957, 5,856,423, 5,962,745, 5,990,265, 6,235,948, 6,245,844, 6,255,442, 6,277,289, 6,281,325, 6,312,805, 6,325,945, 6,331,264, 6,335,421, 6,350,895, and 6,353,062, EP 998 440, WO 00/14041 and 98/57913, H. L. Traub, “Synthese und textilchemische Eigenschaften des Poly-Trimethyleneterephthalats”, Dissertation Universitat Stuttgart (1994), S. Schauhoff, “New Developments in the Production of Poly(trimethylene terephthalate) (PTT)”, Man-Made Fiber Year Book (September 1996), and U.S. patent application Ser. No. 10/057,497, all of which are incorporated herein by reference. Poly(trimethylene terephthalate)s are commercially available from E. I. du Pont de Nemours and Company, Wilmington, Del., as Sorona® 3GT polymer.
Other polymeric additives can be added to the poly(trimethylene terephthalate) polymers, copolymers or blends to improve strength, to facilitate post extrusion processing or provide other benefits. For example, hexamethylene diamine can be added in minor amounts of about 0.5 to about 5 mole % to add strength and processability to the polymers. Polyamides such as Nylon 6 or Nylon 6—6 can be added in minor amounts of about 0.5 to about 5 mole % to add strength and processability to the polymers. A nucleating agent, preferably 0.005 to 2 weight % of a mono-sodium salt of a dicarboxylic acid selected from the group consisting of monosodium terephthalate, mono sodium naphthalene dicarboxylate and mono sodium isophthalate, as a nucleating agent, can be added as disclosed in U.S. Pat. No. 6,245,844, which is incorporated herein by reference.
The poly(trimethylene terephthalate) polymers and blends can, if desired, contain additives, e.g., delusterants, nucleating agents, heat stabilizers, viscosity boosters, optical brighteners, pigments, and antioxidants. TiO 2 or other pigments can be added to the poly(trimethylene terephthalate)s and blends, or in fiber manufacture. Additives suitable for use with the poly(trimethyene terephthalate)s are disclosed, for example, in U.S. Pat. Nos. 3,671,379, 5,798,433 and 5,340,909, EP 699 700 and 847 960, and WO 00/26301, which are incorporated herein by reference.
In some embodiments, the poly(trimethylene terephthalate) fiber is provided in the form of a fabric, e.g., a woven fabric or a nonwoven fabric. Also, in some embodiments, the fiber, optionally as a fabric, is immersed in water prior to the addition thereto of the surfactant, the sequestering agent, the UV absorber, and/or the dye.
Preferably, the process is initiated, i.e., the fiber and dyebath components are combined, at room temperature, which can be, for example, about 22 to 28° C. Also preferably, the process is carried out at autogenous pressure in a sealed vessel. Because the vessel is sealed, during the process, the pressure within the vessel rises. About 0.50 weight percent of an alcohol ethoxylate surfactant, about 0.25 weight percent of a sequestering agent, 3.00 weight percent of a benzotriazine derivative UV absorber, and 0.5 weight percent of a disperse dye, are combined in an aqueous medium to provide a water:fiber ratio from about 2:1 to about 40:1. Preferably, the water:fiber ratio is at least about 6:1. The water:fiber ratio can vary depending upon the equipment being used in the process, which depends in part upon the volume of materials being used in the process. In some applications of the process, particularly larger scale production, a water:fiber ratio of about 8:1 to about 12:0 may be preferred, even more preferably about 10:1. When the fiber is used in the form of a fabric, the same ratios apply, i.e. based on weight, the ratio is a water:fabric ratio. However a range of such ratios can be used. The appropriate ratio for a particular application can be selected by one skilled in the art.
In the process, the dyebath and components thereof and the fiber are heated at a rate of at least about 1° C. per minute, and slower than 8° C. per minute. Preferably, the heating rate is about 5° C. per minute or slower, more preferably about 4° C. per minute or slower, most preferably about 3° C. or slower. In highly preferred embodiments, the heating rate is about 2° C. per minute.
The dyebath and components are heated to a temperature of 132–145° C., preferably 132–140° C., more preferably 132–135° C., and in highly preferred embodiments, to about 132° C. Once the dyebath has reached the desired temperature, it is maintained at that temperature for at least about 30 minutes, preferably at least about 45 minutes. Typically, maintaining the dyebath at the desired temperature for about 60 minutes will ensure adequate dyeing; however, shorter or longer periods of time may be desirable for certain dye formulations and depending upon the shade and intensity of color desired in the dyed fiber.
The process uses a benzotriazine derivative UV absorber. Such absorbers are commercially available from, for Example, Ciba Geigy, Inc. A preferred benzotriazine derivative UV absorber is Cibafast USM® UV absorber.
The amount of UV absorber is preferably at least about 2 weight percent, and more preferably at least about 3 weight percent. Although higher UV absorber amounts than, for example, about 4 weight percent, can be used, the use of such higher levels is not required and may not be cost effective for some applications.
The pH of the dyebath can be adjusted by adding a suitable acid. Acetic acid is preferred, although other organic or inorganic acids, including propionic acid and formic acid, can be used. Preferably, the pH of the dyebath is adjusted to within the range of 4.2 to about 4.85, preferably from about 4.25 to 4.7, more preferably 4.50 to 4.75.
Alcohol ethoxylate surfactants are known and are commercially available. An exemplary alcohol ethoxylate surfactant is Surfactant LF-H, available from DuPont Specialty Chemicals, Wilmington, Del.
The processes disclosed herein use a sequestering agent. Sequestering agents, also known as chelating agents, remove undesired or excess ions from solutions. Examples of sequestering agents are ethylene diamine tetraacetic acid (EDTA) and derivatives thereof, including nitrilo triacetic acid (NTA), diethylene triamine pentaacetic acid ((DTPA) and salts thereof. EDTA is a preferred sequestering agent. Sequestering agents are well known and commercially available. EDTA is commercially available, for example, as Versene® 100 EDTA from Dow Chemical Co., Midland, Mich.
After the fiber has been immersed in the dyebath and the dyebath maintained at the desired temperature for the desired period of time, the dyebath is allowed to cool before the fiber is rinsed. The dyebath can be allowed to return to room temperature without the use of any external cooling methods or devices, or, if desired, cooling can be facilitated by, for example, the application of cooling water. Also, upon cooling, the dyebath depressurizes, preferably to atmospheric pressure.
It is advantageous to precede the foregoing process with a prescour to remove dirt, particles, and other impurities that could impede dyeing. A prescour can be carried out, for example, by maintaining the poly(trimethylene terephthalate) fiber at about 60° C. for about 20 minutes in a bath containing: 0.50% surfactant, 0.25% sequestering agent, and 0.50% TSPP (tetrasodium pyrophosphate).
It is also advantageous to follow the dyeing process with a reductive after-scour, to remove loose dye molecules and residual chemicals, which aids in maximizing lightfastness. The after-scour preferably includes: providing a scour bath by adding, at room temperature, 2.0 g/l sodium hydrosulfite and 2.0 g/l soda ash; raising the temperature, e.g., at a rate of about 1–22° C. per minute to about 60° C. or higher, but less than 180° C.; holding at temperature 60° C. for 20 minutes; and rinsing and neutralizing the fiber. Neutralization can be accomplished, for example, with a final rinse in a bath having a pH adjusted to 6.0–7.0 by addition of a suitable organic acid such as acetic acid.
The present processes provide dyed fibers, e.g., colored fibers that perform desirably using standard lightfastness testing. Lightfastness testing procedures are known to those skilled in the art, and are described in publications of the American Association of Textile Chemists and Colorists (AATCC). Poly(trimethylene terephthalate) fibers, including fibers made from blends and compolymers, made according to the processes disclosed herein have been found to show no color break worse than a 4 break, i.e., no lower than a 4 on the AATCC greige scale, after exposure to 488 kJ of UV light according to standard test method AATCC 16-1998. In some embodiments, a color break no worse than 4 has been observed following 779 kJ UV light exposure (using the same testing procedure but effectively using a more stringent testing than a test using 488 kJ of UV light) when certain disperse dyes are employed in the dyeing process.
Further, fibers are obtained that demonstrate desirable retention of physical properties besides color. Tests of tenacity before and after extensive UV exposure indicate little loss in tenacity. Preferably, the tenacity of dyed poly(trimethylene terephthalate) fibers prepared according to the processes disclosed herein exhibit a loss of tenacity of about 10% or less, following exposure to at least 481 kJ of UV radiation. More preferably, the tenacity of dyed poly(trimethylene terephthalate) fibers prepared according to the processes disclosed herein exhibit a loss of tenacity of about 10% or less, following exposure to at least 779 kJ of UV radiation.
For testing color fastness and strength under UV exposure, candidate fibers are typically knitted to test forms in the shape of tubing, or wrapped on cards. Testing can be carried out, for example, in a Weather-O-Meter® UV exposure device. Physical properties that can be tested include tenacity and elongation, and color fastness under rigorous UV light exposure/high temperature conditions.
EXAMPLES
The following examples are presented for the purpose of illustrating the invention, and are not intended to be limiting. All parts, percentages, etc., are by weight unless otherwise indicated.
Tenacity
The tenacity of the poly(trimethylene terephthalate) yarns reported in the following examples was measured using an Instron Corp. tensile tester, model no. 1122. Tenacity was measured according to ASTM D-2256.
Xenon Light Fastness
The Xenon light fastness testing was done using an “Atlas” Weatherometer (Atlas Material Testing Technology LLC, 4114 N. Ravenswood Ave., Chicago, Ill. 60613) following the established testing procedures of AATCC Method 16-1998 and blue wool light fastness standard L-4 (lot 5).
Visual ratings were made on all samples after exposure to UV light utilizing the AATCC greige scale rating system of 1 through 5, wherein 5 indicates “no visible change” and 1 indicates “severe color change”. The rating of one half unit was considered not to be a significant variation between polymer substrates, and a 4 rating or greater was judged to be excellent fading performance after extended exposure to ultraviolet light.
Degradation of Tenacity by Exposure to UV Radiation
The impact of extended exposure to ultraviolet light on the tensile properties of yarns of Sorona® PTT was tested. The baseline tenacity was obtained from measurements on “mock dyed” knit tubing of the textured yarns of Soma® PTT. “Mock dyeing” means that all components of a dyebath other than a colored dye are used, and all of the steps in the dyeing process, including temperature, pressure etc. are included. Mock dyeing is used to provide a baseline for strength retention testing of the polymer. The reported data is an average of 10 individual Instron measurements.
The dyed knit tubing, prepared with Cibafast® USM ultraviolet absorber in the dyebath, was tested after exposure in the Atlas Weather-O-Meter® device at 481, 486.5, and 496 kJ. The tenacity of the yarns from the dyed knit tubing from the PTT after extended UV exposure was compared to the initial mock dyed (before exposure) baseline data, and the loss in tenacity due to UV exposure was determined.
Source of Materials
All materials used herein are available commercially. Sorona® poly(trimethylene terephthalate) fiber was obtained from DuPont (Wilmington, Del.). Dacron® poly(ethylene terephthalate) fiber (PET) was obtained from Invista, Inc. Chemical reagents used were as follows:
Dianix® dyes (DyStar L. P., 9844-A Southern Pine Blvd., Charlotte, N.C. 28274); Dispersrite® dyes (Rite Industries, Inc., Highpoint, N.C.); Dorospers® dyes (M. Dohmen USA Inc., 25 Ellwood Conn., Greenville, S.C. 29607); Terasil® dyes and Cibafast® USM (Ciba Specialty Chemicals, Colors Div., 4050 Premier Dr., High Point, N.C. 27265); Versene® 100 (Dow Chemical Co., PO Box 1206, Midland, Mich. 48642); Surfactant LF-H (DuPont Specialty Chemicals, Wilmington, Del. 19898); Burco Reduct T® (Burlington Chemical Co., PO Box 111, Burlington, N.C. 27216).
Testing was conducted on false twist yarns of textured Dacron® poly(ethylene terephthalate) homopolymer (control) and yarns of Sorona® poly(trimethylene terephthalate) homopolymer (test) that were knit into tubing on a Lawson-Hempill FAK circular knit machine (Lawson Hemphill Sales Inc., P. O. Drawer 6388, Spartanburg, S.C. 29304).
Test yarns of textured Sorona® poly(trimethylene terephthalate) fiber were tested along with a control yarn of textured Dacron® poly(ethylene terephthalate) utilizing the same dyeing auxiliaries and conditions. In addition to the evaluation of a variety of disperse dyes that were found to exhibit good fastness to light after extended exposure to UV light, the resistance of textured test yarns of Sorona® PTT vs. Dacron® PET control yarns to degradation of tensile properties due to the exposure to UV light was examined. All percentages of dyes and chemicals are weight percents based on the weight of the fabric (OWF). Pre-scour, dyeing, and after-scour were conducted in a Mathis Labomat® BFA 16 test unit (Werner Mathis U.S.A. Inc., 2260 HWY 49 NE/P.O. Box 1626, Concord, N.C. 28206).
Pre-Scour Procedure
Knit tubing of test and control samples was pre-scoured at 60° C. for 20 minutes in a bath containing:
0.50% Surfactant LF-H® surface active agent 0.25% Versene® 100 (sequestering agent) 0.50% tetrasodium pyrophosphate
Dyeing Procedure
A dye bath was prepared in a vessel at room temperature, containing:
0.50% “Surfactant” LF-H 0.25% “Versene” 100 (Sequestering agent) 3.00% “Cibafast” USM (UV absorber) disperse dye (quantities and dyes are shown in Table 1) acetic acid as needed to adjust pH to 4.50–4.75
The fabric for testing was immersed in the dyebath, and the vessel was sealed. The temperature was raised at a rate of 2° C. per minute, to 132° C. (270° F.), then held at 132° C. for 45 minutes. The dyebath was cooled and depressurized, and the fabric sample was removed and well rinsed.
Reductive Afterscour Procedure
An afterscour bath was prepared, at room temperature, containing: 2.0 g/l Burco Reduct T® sodium hydrosulfite and 2.0 g/l soda ash. The temperature was raised at 2° C. per minute to 60° C. (140° F.). The fabric was immersed in the afterscour bath, held at 60° C. for 20 minutes, rinsed well, and neutralized with a final rinse in a bath with pH adjusted to 6–7 with acetic acid.
Lightfastness results for fabrics dyed using various dyes and tested at different times of UV exposure are presented in Table 1.
Xenon Arc Lightfastness Test
TABLE 1
XENON ARC LIGHTFASTNESS
AS FUNCTION OF DISPERSE
EXPOSURE
DYE COMPOSITION
488 kJ
779 kJ
789 kJ
“TERASIL” PINK 2GLA-01
4–5
4–5
(RED 86) 0.5% OWF
“DISPERITE” PINK REL
4
3–4
(RED 91) 0.5% OWF
“DOROSPERS” RED KFFB
5
4–5
(RED 161) 0.5% OWF
“DOROSPERS” RED KFFN
5
(RED 279) 0.5% OWF
“DOROSPERS” RED KFFN
5
(RED 279) 0.25% OWF
“TERASIL” YELLOW GWL
4–5
4
(YELLOW 42) 0.5% OWF
“DOROSPERS” GOLDEN
5
5
YELLOW R conc.
(YELLOW 86) 0.5% OWF
“DIANIX” YELLOW S-G
5
5
(YELLOW 160) 0.5% OWF
“TERASIL” BLUE GLF
5
(BLUE 27) 0.5% OWF
“TERASIL” BLUE GLF
5
(BLUE 27) 0.25% OWF
“TERASIL” BLUE BGE-01 200
5
5
(BLUE 60) 0.5% OWF
“DOROSPERS” BLUE BLFR
5
5
(BLUE 77) 0.5% OWF
Table 2 shows the effect of extended exposure to UV light on the tenacity of textured yarns of Sorona® PTT. The loss of tenacity of the exposed yarns was calculated by comparing the tenacity of the exposed dyed knit tubing to that of the “mock dyed” knit tubing that provided the baseline for the calculations. The high resistance of yarns of Sorona® PTT to the degradation caused by extended exposure to UV light is apparent.
The foregoing disclosure of embodiments of the present invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise forms disclosed. Many variations and modifications of the embodiments described herein will be obvious to one of ordinary skill in the art in light of the disclosure.
TABLE 2
Tenacity of Dyed Textured Yarns of Sorona ® PTT
after Extended Exposure to UV Radiation
Sorona ® PTT Test Sample:
Tenacity
“Mock Dyed” Control with No UV Exposure
2.43 g/d
Disperse Dyes Evaluated
0.50% Disperse Red 86 after 486.5 kJ UV exposure
2.22 g/d
0.50% Disperse Red 91 after 486.5 kJ UV exposure
2.35 g/d
0.50% Disperse Red 279 after 486.5 kJ UV exposure
2.10 g/d
0.50% Disperse Blue 27 after 496 kJ UV exposure
2.19 g/d
0.50% Disperse Blue 60 after 496 kJ UV exposure
2.24 g/d
0.50% Disperse Blue 77 after 496 kJ UV exposure
2.29 g/d
0.50% Disperse Yellow 42 after 496 kJ UV exposure
2.23 g/d
0.50% Disperse Yellow 86 after 481 kJ UV exposure
2.22 g/d
0.50% Disperse Yellow 160 after 481 kJ UV exposure
2.27 g/d
Average Tenacity of 9 Disperse Dyes Tested
2.23 g/d
Pre-exposure Tenacity of “Mock Dyed” Control
2.43 g/d
Tenacity Loss due to UV Degradation
0.20 g/d
The tenacity loss was 8.23%, reflecting retention of >90% of the initial tenacity of disperse dyed samples of textured yarns of Sorona ® PTT after extended UV exposure.
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Dyed poly(trimethylene terephthalate) fibers having a lightfastness of 4 or higher after approximately 480 kJ incident UV radiation, and processes for preparing the fibers, are provided. The fibers are useful in automotive applications and other uses wherein UV absorption is likely.
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TECHNICAL FIELD
The application relates generally to the control of gas turbine engines, and more particularly to conditioning of noisy signals.
BACKGROUND OF THE ART
In modern gas turbines, detection of events, such as a shaft breakage event, can be performed by monitoring engine parameters using suitable sensing devices. The measurements are then sent to a control system, which applies detection logic to the data to determine if a predefined event signature is present. In particular, a derivative of the sensed signals is typically computed in order to determine the rate of change of the monitored engine parameters.
However, the sensed signals often contain noise components, such as steady state and transient noise components. When the derivative of a given sensed signal is taken, the resulting rate of change signal greatly amplifies any small noise component of the underlying sensed signal. The event signatures are in turn rendered undetectable within the noise floor. In order to remove the noise, traditional real-time filters may be applied to the sensed signals. Still, such filtering also induces significant signal delays, which prove unacceptable for high speed event detection, such as detection of shaft breakage events.
There is therefore a need for an improved system and method for conditioning noisy signals.
SUMMARY
In one aspect, there is provided a system for conditioning a noisy signal, the system comprising a receiving unit adapted to receive a sensing signal during each one of a plurality of successive control cycles, the sensing signal comprising a measurement component indicative of a measurement of at least one parameter of an engine and a noise component, and a processing unit adapted to apply a curve-fitting technique to the received sensing signal for filtering thereof to attenuate the noise component, the filtering comprising, during a first one of the plurality of control cycles, asymmetrically filtering the sensing signal received during the first control cycle, thereby generating filtered data, and, during a second control cycle subsequent to the first control cycle, symmetrically filtering the sensing signal received during the first control cycle, thereby generating corrected data.
In another aspect, there is provided a method for conditioning a noisy signal, the method comprising receiving a sensing signal during each one of a plurality of successive control cycles, the sensing signal comprising a measurement component indicative of a measurement of at least one engine parameter and a noise component, and applying a curve-fitting technique to the received sensing signal for filtering thereof to attenuate the noise component, the filtering comprising, during a first one of the plurality of the control cycles, asymmetrically filtering the sensing signal received during the first control cycle, thereby generating filtered data, and, during a second control cycle subsequent to the first control cycle, symmetrically filtering the sensing signal received during the first control cycle, thereby generating corrected data.
In a further aspect, there is provided a system for conditioning a noisy signal, the system comprising means for receiving a sensing signal during each one of a plurality of successive control cycles, the sensing signal comprising a measurement component indicative of a measurement of at least one engine parameter and a noise component, and means for applying a curve-fitting technique to the received sensing signal for filtering thereof to attenuate the noise component, the filtering comprising, during a first one of the plurality of the control cycles, asymmetrically filtering the sensing signal received during the first control cycle, thereby generating filtered data, and, during a second control cycle subsequent to the first control cycle, symmetrically filtering the sensing signal received during the first control cycle, thereby generating corrected data.
DESCRIPTION OF THE DRAWINGS
Reference is now made to the accompanying figures in which:
FIG. 1 is a schematic cross-sectional view of a gas turbine engine;
FIG. 2 is a schematic diagram of a system for conditioning noisy signals, in accordance with an illustrative embodiment;
FIG. 3 is a schematic diagram of the conditioning unit of FIG. 2 ;
FIG. 4 is a schematic diagram of the filtering module of FIG. 3 ;
FIG. 5 is a schematic diagram of the filtered data buffering module of FIG. 3 ;
FIG. 6 is a schematic diagram of a data buffer formed by the filtered data buffering module of FIG. 5 ;
FIG. 7 is a flowchart of a method for conditioning noisy signals, in accordance with an illustrative embodiment;
FIG. 8 is a flowchart of the step of FIG. 7 of applying a filter to a resampled data buffer;
FIG. 9 is a flowchart of the step of FIG. 7 of buffering the filtered data buffer over N+1 control cycles; and
FIG. 10 is a flowchart of the step of FIG. 7 of performing event detection on the filtered data buffer.
DETAILED DESCRIPTION
FIG. 1 illustrates a gas turbine engine 10 of a type typically provided for use in subsonic flight, generally comprising in serial flow communication a fan 12 through which ambient air is propelled, a compressor section 14 for pressurizing the air, a combustor 16 in which the compressed air is mixed with fuel and ignited for generating an annular stream of hot combustion gases, and a turbine section 18 for extracting energy from the combustion gases. High pressure rotor(s) 20 of the turbine section 18 are drivingly engaged to high pressure rotor(s) 22 of the compressor section 14 through a high pressure shaft 24 . Low pressure rotor(s) 26 of the turbine section 18 are drivingly engaged to the fan rotor 12 and to other low pressure rotor(s) (not shown) of the compressor section 14 through a low pressure shaft 28 extending within the high pressure shaft 24 and rotating independently therefrom.
Referring to FIG. 2 , a system 100 for conditioning noisy signals will now be described. The system 100 illustratively comprises a conditioning unit 102 , a control unit 104 for controlling the gas turbine engine 10 and one or more monitoring devices, such as sensors 106 , for monitoring one or more parameters of the engine 10 . The sensors 106 may be any sensor suitable for monitoring the engine parameters. Examples of such sensors 106 include, but are not limited to, speed sensors, pressure sensors, temperature sensors, humidity sensors, and accelerometers. The conditioning unit 102 may comprise a digital computer or processor unit for conditioning noisy signals, as will be discussed further below. The control unit 104 may comprise a digital computer or Engine Control Unit (ECU, not shown) in communication with the hardware of the engine 10 for controlling an operation of the latter. In particular, the conditioning unit 102 and the control unit 104 may be part of a Full Authority Digital Engine Control (FADEC) (not shown) used to manage operation of the gas turbine engine 10 by controlling the engine 10 through acceleration, deceleration, and steady state operation. The FADEC may modulate fuel flow to the engine 10 , schedule and control surge protection systems, protect the gas turbine engine 10 from overspeed and overtemperature, perform complete engine start control, as well as control opening and closing of bleed-off valves and other engine variable geometries.
The sensors 106 illustratively monitor responses of one or more engine components, identify the health of these components, and deliver an output as required. In particular, the sensors 106 sense one or more engine parameters and generate sensed signal(s) accordingly. The rate of change in the one or more engine parameters may then be monitored by computing a derivative of the sensed signal(s). In one embodiment, the sensors 106 monitor engine variables including, but not limited to, N1 speed (speed of the first spool 28 of the engine 10 ), N2 speed (speed of the second spool 24 of the engine 10 ), rate of change in N1 speed, and rate of change in N2 speed. It should be understood that other engine variables may be monitored. The signals output by the sensors 106 are then fed to the conditioning unit 102 either in a wired manner using a direct link 110 , such as a wire, or wirelessly over a suitable network (not shown). In this manner, the readings from the sensors 106 can be received at the conditioning unit 102 in real-time during a flight and acted upon to enhance the performance, stability, and reliability of the turbine engine 10 .
The sensor signals are however typically corrupted by noise in transmission lines, electro-magnetic radiation (EMI), cross talk, shaft torsional modes, and the like. The conditioning unit 102 therefore illustratively implements a noise filtering scheme to condition such noisy signals. In particular, the filtering implemented by the conditioning unit 102 enables to extract valid signals, e.g. signals indicative of the measurements taken by the sensors 106 , from the noisy signals. It may be desirable for such filtering to be performed without introduction of undue delays and amplitude distortion. In this manner, any issue or defect with the engine 10 can be detected speedily, thereby preventing potentially harmful consequences. As will be discussed further below, the detection speed illustratively depends on the event detection window set by the conditioning unit 102 . The event detection window may be set so as to ensure only a given event whose event signature is being detected by the conditioning unit 102 produces the event signature. In one embodiment, the event detection window is set to twenty-four (24) ms such that the conditioning unit 102 achieves a detection speed lower than twenty-four (24) ms. It should be understood that other event detection windows may apply.
FIG. 3 is an exemplary embodiment of the conditioning unit 102 . In this embodiment, the conditioning unit 102 comprises a data resampling module 202 , a resampled data buffering module 204 , a filter coefficients computing module 206 , a filtering module 208 , a filtered data buffering module 210 , and an event detection module 212 .
The sensors (reference 106 in FIG. 2 ) illustratively measure the engine variables once every control cycle and the raw sensor data is sent to the conditioning unit 102 where they may be received at a receiving unit (not shown). It should however be understood that the sensors 106 may take measurements at a rate greater or lower than once every control cycle. For instance, the raw sensor data collected by the sensors 106 may be oversampled, i.e. may contain more than one data sample per control cycle, depending on the speed at which the engine (reference 10 in FIG. 2 ) operates. In order to ensure that the data sent to the filtering module 208 contains a desired number L of equispaced data points, the data resampling module 202 may be used to resample the raw data. The number L of resampled points may be chosen and the resampling procedure performed to ensure that there is a consistent number of points per frame despite the fact that a sensor signal is sampled at a variable rate. In particular, the raw sensor data is sent to the data resampling module 202 , which uses any suitable resampling technique, such as linear interpolation, to resample the raw sensor data to achieve the desired number of data points. The resampled sensor data output by the data resampling module 202 then comprises L equally spaced data points and is sent to the resampled data buffering module 204 .
The resampled data buffering module 204 in turn forms a buffer where the resampled sensor data, which is ready to be filtered, is stored. The buffering module discussed herein, e.g. the resampled data buffering module 204 and the filtered data buffering module 210 , may be implemented in a fixed location of a physical memory (not shown) and/or by using a virtual data buffer pointing at a location in the physical memory. It is desirable for the buffer formed by the resampled data buffering module 204 to store the data set of L data points received during the present control cycle (CT 0 ), the data set of L data points received during the previous control cycle (CT- 1 ), and the data set of L data points received during the oldest control cycle (CT- 2 ). The unfiltered data vector provided to the filtering module 208 may then comprise 3L data points. This enables the conditioning unit 102 to cover the CT 0 , CT- 1 , and CT- 2 time ranges, as will be discussed further below. It should be understood that the conditioning unit 102 may cover more or less time ranges, depending on the desired amount of correction to be applied to the noisy signals. Indeed, in the embodiment discussed herein, the conditioning unit 102 processes the sensor data twice through the filtering module 208 , i.e. double filtering of the data set is achieved, thereby requiring coverage of the CT 0 , CT- 1 , and CT- 2 time ranges. In other embodiments, triple, quadruple, or any other level of filtering may apply and other time ranges may thus be covered.
The filter coefficients computing module 206 computes filter coefficients for use by the filtering module 208 . Choosing the appropriate filter coefficients can influence the particular behaviour of the filter implemented by the filtering module 208 . In one embodiment, the filtering module 208 implements a Savitzky-Golay smoothing technique that uses a least-squares curve-fitting approach. Using this technique, filtering of the data with the filter coefficients may create a curve having a given slope and individual data points may then be filtered to be close to the created curve. A time series is thus smoothed by replacing each value of the series with a new value obtained from a moving window using a polynomial fit to 2M+1 neighboring data points (including the data point to be smoothed). In this case, the filter has a length of 2M+1 where M is an integer equal to or greater than the order P of the polynomial. It should be understood that any other appropriate filtering technique, such as using a finite impulse response (FIR) or a suitable low pass filter, may apply. Still, regardless of the filtering technique used, it is desirable for the filter to minimize delays while introducing little complexity and computational load to the control unit (reference 104 in FIG. 2 ).
As known to those skilled in the art, Savitzky-Golay filter coefficients depend on the type of chosen polynomial, e.g. on the order P thereof, and on the number of neighbours around a point, e.g. on the size 2M+1 of the moving window. Thus, knowing the values of P and M, the filter coefficients computing module 206 can precompute the filter coefficients offline regardless of the sensor data to be filtered. In other words, the filter coefficients computing module 206 need not compute the filter coefficients at each control cycle but may compute them once, thereby requiring less processing power. In this manner, using the filter coefficients computed offline, it becomes possible for the conditioning unit 102 to perform curve-fitting to condition noisy signals in real time, as will be discussed further below. For this purpose, a least-squares fitting method can be applied to compute the coefficients, which can then be stored in memory (not shown) in any suitable format, such as in a look-up table. It should be understood that, depending on the type of filter to be implemented by the filtering module 208 , the filter coefficients computing module 206 may use other techniques to derive the filter coefficients.
The filter coefficients computed by the filter coefficients computing module 206 may be terminal (or historical asymmetrical), steady state (or symmetrical), or startup (or future asymmetrical) coefficients. The terminal coefficients can be used to filter most recent samples, which do not have future data available. The steady state coefficients can be used to filter data, which has an equal amount of future and historical data available. The startup coefficients can be used to filter data, which has only future data points available. Once computed, the filter coefficients are then output by the coefficients computing module 206 and sent to the filtering module 208 , which also receives the buffered resampled data from the resampled data buffering module 204 . The filtering module 208 then processes the received data and applies the filter coefficients to the buffered resampled data. The filtering module 208 then outputs filtered data in which noise has been filtered from actual sensor readings. The filtered data output by the filtering module 208 is then stored in the filtered data buffering module 210 to achieve real-time data smoothing, as will be discussed further below.
The event detection module 212 then processes the data buffered by the filtered data buffering module 210 to determine whether a predefined event signature, which is indicative of a problem with the engine 10 , is present. For this purpose, the event detection module 212 is used to detect events that occur over a defined time period (or event detection window). For instance, the event detection module 212 may assess from the buffered filtered data whether the rate of change in N1 speed is below a predetermined threshold while the rate of change of N2 speed remains within a predefined tolerance. If this is the case, the event detection module 212 can conclude to shearing or breakage of the low pressure turbine shaft (reference 30 in FIG. 1 ). The event detection module 212 having detected such shaft breakage, the event detection module 212 can then output to the engine 10 one or more control signals indicative of the detected defect and/or of measure(s) to be implemented to correct the defect. It then becomes possible to prevent potentially damaging consequences of the engine defect. For instance, once the shaft breakage has been detected, the control signal(s) output by the event detection module 212 can cause corrective measures to be taken to prevent failure and fragmentation of the low pressure rotor(s) (reference 26 in FIG. 1 ) of the turbine section (reference 18 in FIG. 1 ). As discussed above, it should be understood that several engine variables may be monitored by the sensors 106 and that the conditioning unit 102 may accordingly be used to detect a variety of issues (e.g. flameout in the combustion chamber) with the engine 10 other than shaft breakage or shearing. The conditioning unit 102 may indeed be used for high speed detection of any event in a given signal or signals.
FIG. 4 is an exemplary embodiment of the filtering module 208 . The filtering module 208 illustratively uses curve fitting to avoid filter lag. In this manner, the sensor signals can be treated with little to no delay and problems with the engine (reference 10 in FIG. 2 ) can be detected at high speed. In particular and as will be discussed further below, by correcting already filtered sensor data and buffering data filtered over past control cycles, the filtering module 208 can be applied to real-time settings and achieve high speed event detection.
Using the filter coefficients received from the filter coefficients computing module 206 , the filtering module 208 illustratively implements the Savitzky-Golay smoothing technique (although it should be understood that any other suitable filtering technique can apply). For this purpose, the filtering module 208 may comprise a vector module 302 comprising a startup vector module 304 , a steady state vector module 306 , and a terminal vector module 308 . Although the filtering module 208 is described herein as comprising the startup vector module 304 , it should be understood that the latter is optional, being primarily used for implementing filter recursion. Thus, depending on the application, the filtering module 208 may or may not comprise such a startup vector module 304 . The filtering module 208 may further comprise a concatenation module 310 and a recursion module 312 .
Each one of the startup vector module 304 , the steady state vector module 306 , and the terminal vector module 308 may respectively receive from the filter coefficients computing module 206 startup, steady state, and terminal coefficients. The startup vector module 304 , the steady state vector module 306 , and the terminal vector module 308 may further receive at each control cycle the resampled buffered data from the resampled data buffering module 204 . Each one of the startup vector module 304 , the steady state vector module 306 , and the terminal vector module 308 then performs a vector operation in which the module 304 , 306 , 308 multiplies the resampled buffered data by the received coefficients to output a filtered data vector of length L. In one embodiment, the steady state vector and the terminal vector are then sent to the concatenation module 310 , which concatenates the two vectors of length L data points to form a final filtered vector of length 2L data points. As the startup vector module 304 may only be used when it is desired to perform recursion, the startup vector is illustratively only sent to the concatenation module 310 whenever filter recursion is used. Using vector operations and a Savitzky-Golay filter implemented by the filtering module 208 , it becomes possible to use all the data points received in a previous control cycle to reconstruct a signal profile, which occurred in between control cycles. This is especially true since the Savitzky-Golay filter is effective at filtering individual raw data points. As such, the confidence that a real event has been detected by the event detection module (reference 212 in FIG. 3 ) is increased.
In one embodiment, during the present control cycle CT 0 , the startup vector module 304 , when used to perform filter recursion, computes the startup vector by applying the startup coefficients to data, which only has future data points available, i.e. to the data sets received during the previous and oldest control cycles, e.g. CT- 1 and CT- 2 data sets. The terminal vector module 308 computes the terminal vector by applying the terminal coefficients to data, which does not have future data points available, i.e. to the data sets received during the present and the previous control cycles, e.g. CT 0 and CT- 1 data sets. The steady state vector module 306 computes the steady state vector by applying the steady state coefficients to data, which has an equal amount of future and historical data points available. The steady state vector is then computed using all three data sets, namely the data received during the present (CT 0 ) and the two previous control cycles (CT- 1 , CT- 2 ). For this purpose, the steady state vector module 306 shifts the data sets by the length of the filter's window, e.g. by 2M+1 data points, until all data points have been filtered. For instance, if M=25, the filter window, and accordingly the number of filter coefficients, is equal to 2*25+1=51. The first element of the steady state vector is then formed by considering twenty-five (25) data points of the CT- 2 data set, twenty-five (25) data points of the CT- 1 data set, and one (1) data point of the CT 0 data set. The second element of the steady state vector is formed by considering 25−1=24 data points of the CT- 2 data set, twenty-five (25) data points of the CT- 1 data set, and 1+1=2 data points of the CT 0 data set. This process is repeated until obtention of the last element of the steady state vector, which is formed by considering one (1) data point of the CT- 2 data set, twenty-five (25) data points of the CT- 1 data set, and twenty-five (25) data points of the CT 0 data set.
The filtered data vector output by the concatenation module 310 is sent to the filtered data buffering module 210 for storage, as will be discussed further below, as well as to the recursion module 312 , which determines therefrom recursion to be implemented, as required. The recursion module 312 may indeed be used to cause the filtered data vector to be further filtered so as to increase smoothing of noise present in the data set. As discussed above, the amount of recursion, e.g. filtering, implemented by the filtering module 208 may vary depending on the applications. In one embodiment, the recursion level is set to a constant, e.g. two (2) times, such that sensor data is filtered twice. Any other predetermined constant number of recursions may be used to achieve the desired level of noise attenuation. The recursion module 312 may, upon receiving the filtered data, perform a statistical check, such as standard deviation, on the filtered data and cause the recursion, e.g. the re-filtering, operation to continue until the statistical measure is within predetermined bounds.
At the next control cycle, the raw data filtered in the previous cycle is then filtered once more by the vector module 302 applying the suitable filter coefficients thereto. In particular, the vector module 302 refilters the raw data using the steady state (or symmetrical) coefficients received from the filter coefficients computing module 206 . This refiltering operation can be performed on the past data now that future data is available, thereby correcting any errors created by applying the terminal coefficients to the sensor data during the first pass of the filtering algorithm. Indeed, using the curve-fitting technique, filtering of the data with the terminal coefficients may create a curve having an incorrect slope. Once future data is available, it becomes possible to ensure that the slope is optimally fit by applying correction (using the steady state coefficients) to the raw sensor data to refit a curve thereto. Using knowledge of past as well as future data, correction of past filtered data can then be achieved in real-time.
As discussed above, the re-filtering step may be recursively applied as many times as desired to achieve a suitable level of noise attenuation of the filtered data. The re-filtered data is then output by the vector module 302 and concatenated by the concatenation module 310 into a single vector. The re-filtered data is then sent to the filtered data buffering module 210 for storage. When the recursion module 312 determines, e.g. from a statistical measure, that the filtered data received from the concatenation module 310 has already been sufficiently filtered, the recursion module 312 accordingly outputs a control signal to the concatenation module 310 . This causes the concatenation module 310 to output the data as last pass filtered data directly to the filtered data buffering module 210 . Indeed, the last pass filtered data need not be corrected as the data fit is considered optimal.
In one embodiment, the filtering module 208 does not comprise the recursion module 312 and only the (one-time) filtered data is in this case sent to the filtered data buffering module 210 during the present control cycle. At the next control cycle, the last pass raw sensor data is re-filtered using the steady state coefficients to correct errors from the first pass of the filtering algorithm, which applied the terminal coefficients.
FIG. 5 is an exemplary embodiment of the filtered data buffering module 210 . The filtered data buffering module 210 illustratively comprises an oldest cycle(s) data storing module 402 , a previous cycle data storing module 404 , and a present cycle data storing module 406 . FIG. 6 is an exemplary embodiment of a data buffer 500 formed by the filtered data buffering module 210 . The data buffer 500 illustratively comprises N+1 elements as in 502 1 , 502 2 , . . . , 502 N+1 , with N+1 the size of the event detection window of the event detection module (reference 212 in FIG. 3 ). Indeed, although the data is imperfectly fit in frame CT 0 , using the refiltering procedure implemented by the filtering module 208 , as discussed above with reference to FIG. 4 , allows to obtain N cycles of optimally fit data (frames CT- 1 , . . . , CT-N). Including the most recent and suboptimally fit data (i.e. CT 0 data) in the event detection window, which then has a size of N+1 cycles, then allows to achieve least possible lag. This in turn provides confidence that the event being detected did happen within the N+1 cycles, which contain both the suboptimally fit dataframe and the N optimally fit data frames. It should be understood that, although buffer element 502 1 is shown as being the last element of the buffer 500 , the buffer element 502 1 may be the first element of the buffer 500 . Element 502 1 of the data buffer 500 stores the most recent data, e.g. the data received during the present control cycle (CT 0 data) and filtered using terminal filter coefficients by the filtering module (reference 208 in FIG. 4 ). Already known and past filtered data is stored in the remaining N elements 502 2 , . . . , 502 N+1 . In particular, at each control cycle, the present cycle data storing module 406 illustratively receives filtered data from the concatenation module (reference 310 in FIG. 4 ) and stores this data in element 502 1 of the data buffer 500 . The previous cycle data storing module 404 illustratively receives re-filtered data and stores this data in element 502 2 of the data buffer 500 . The oldest cycle(s) data storing module 402 illustratively receives last pass filtered data and stores this data in corresponding elements 502 3 , . . . , 502 N+1 of the data buffer 500 .
As can be seen in FIG. 6 , at the first control cycle (e.g. at time T=0), the data buffer 500 only stores in element 502 1 the present control cycle data set (CT 0 data set) that has been filtered by the vector module (reference 302 in FIG. 4 ). At the next control cycle (e.g. at time T=1), the filtered data (CT 0 data set) previously stored in element 502 1 has been re-filtered using the steady state coefficients applied by the steady state vector module (reference 306 of FIG. 4 ). The re-filtered data (CT- 1 data set) is then stored in element 502 2 of the data buffer while the present control cycle data (CT 0 ′ data set) that has been filtered by the terminal vector module 308 is stored in element 502 1 in place of the filtered data (CT 0 data set) of the previous cycle. At the following control cycle (e.g. at time T=2), the present control cycle data (CT 0 ″ data set) filtered by the terminal vector module 308 is now stored in element 502 1 . The filtered data (CT 0 ′ data set) previously stored in element 502 1 has been re-filtered using the steady state vector module 306 . The re-filtered data (CT- 1 ′ data set) is then stored in element 502 2 . The re-filtered data (CT- 1 data set) previously stored in element 502 2 is then stored in element 502 3 as last pass filtered data (CT- 2 data set). This process is repeated until the last control cycle where the data buffer 500 stores in element 502 1 suboptimally fit data, in element 502 2 optimally fit data which has been corrected since the last control cycle, and in remaining elements 502 2 , . . . , 502 N+1 optimally fit data saved from the last pass of the filter algorithm implemented by the filtering module (reference 208 in FIG. 3 ).
Referring now to FIG. 7 , a method 600 for conditioning noisy signals will now be described. The method 600 illustratively comprises receiving filter coefficients, i.e. terminal, steady state, and startup coefficients, at step 602 . As discussed above, the filter coefficients may be computed offline. The method 600 further illustratively comprises receiving raw sensor data at step 604 , resampling the received raw sensor data at step 606 , buffering the resampled data at step 608 . The method 600 further comprises applying a filter, such as a Savitzky-Golay filter, to the resampled data buffer at step 610 , storing the filtered data over N+1 control cycles at step 612 , and performing event detection on the filtered data buffer at step 614 .
Referring to FIG. 8 , the step 610 of applying a filter to the resampled data buffer illustratively comprises at step 702 computing the terminal vector by applying the terminal filter coefficients received at step 602 to the present (CT 0 ) and previous (CT- 1 ) data sets from the resampled data buffer, as discussed above. The next step 704 may then be to compute the steady state vector by applying the steady state coefficients received at step 602 to the present, previous, and oldest (CT- 2 ) data sets from the resampled data buffer. The next step 706 may then be to compute the startup vector by applying the startup coefficients received at step 602 to the previous and oldest data sets. As discussed above, it should be understood that step 706 is optional and may only be performed when implementing filter recursion. The next step 708 may then be to determine whether the desired noise attenuation has been reached. If this is not the case, the method 600 may flow back to the step 702 . Otherwise, the next step 710 may be to concatenate the computed vectors, i.e. the terminal, steady state, and startup vectors, as discussed above.
Referring to FIG. 9 , the step 612 of forming a filtered data buffer illustratively comprises forming at step 802 a filtered data buffer of N+1 control cycles, storing at step 804 the most recent filtered data in a first buffer element, storing at step 806 the most recent re-filtered data in a subsequent buffer element, and storing at step 808 the oldest re-filtered data in the remaining buffer element(s) in the manner discussed above with reference to FIG. 5 and FIG. 6 .
Referring to FIG. 10 and as discussed above when describing the event detection module (reference 212 in FIG. 3 ), the step 614 of performing event detection on the filtered data buffer comprises detecting an event at step 902 and outputting at step 904 one or more control signal(s) in accordance with the detected event.
The above description is meant to be exemplary only, and one skilled in the art will recognize that changes may be made to the embodiments described without departing from the scope of the invention disclosed. Modifications which fall within the scope of the present invention will be apparent to those skilled in the art, in light of a review of this disclosure, and such modifications are intended to fall within the appended claims.
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There is provided a system and method for conditioning a noisy signal. A sensing signal is received during each one of a plurality of successive control cycles, the sensing signal comprising a measurement component indicative of a measurement of at least one engine parameter and a noise component. A curve-fitting technique is applied to the received sensing signal for filtering thereof to attenuate the noise component, the filtering comprising, during a first one of the plurality of the control cycles, asymmetrically filtering the sensing signal received during the first control cycle, thereby generating filtered data, and, during a second control cycle subsequent to the first control cycle, symmetrically filtering the sensing signal received during the first control cycle, thereby generating corrected data.
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CROSS REFERENCE TO PROVISIONAL APPLICATION
This application claims the benefit of U.S. Provisional Application No. 60/028,244, filed Oct. 9, 1996.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to manholes and to the construction, replacement and alteration of such structures in the field. More particularly, the invention relates to a composite manhole system comprising a corrosion resistant plastic cylinder surrounded by a rigid concrete frame which provides structural integrity but does not entirely encapsulate the plastic cylinder, thus facilitating manipulation in the field.
2. Discussion of the Prior Art
Manhole structures provide access to underground facilities, such as sewer systems and pipelines, for the purposes of repair, cleaning, maintenance and inspection. For convenience, manholes are usually placed at frequent intervals along a sewer line. In addition, manholes often provide a junction point for two or more intersecting pipelines.
There are numerous problems associated with present manhole technology, many of which relate to the harshness of the environment. Manholes are constantly exposed to eroding, oxidizing and corrosive elements associated with the soil on the outside and with the acidic sewage that flows on the inside. The concrete frequently used to construct manholes provides the strength necessary to withstand some of the harshness of the environment and load concentration.
The inflow of rainwater into sewer systems causes overloading of sewer plants, resulting in increased expenses associated with the treatment of larger flow volumes. Studies have shown that inflow and infiltrating rainwater can increase the flow in a sewer system up to 40% and that up to 75% of such inflow may result from defects in manholes. Exfiltration from manholes allows seepage of raw sewage into the surrounding soil and eventually into rivers and streams. This defeats the whole purpose of a sewer system, which is to isolate raw sewage away from the rest of the water supply until it can be treated and detoxified.
Another drawback to common manhole technology relates to the difficulty of construction and assembly. Manhole structures are commonly built using brick, tile or concrete, making it necessary to build or cast the structures in place in the field. This adds extra labor costs which could be greatly reduced using prefabricated manhole systems. However, even precast concrete manholes are problematic because they are heavy and difficult to manipulate. Also, concrete manholes are difficult to cut, decreasing their versatility in situations where it becomes necessary to connect new inlet and outlet pipes. Moreover, concrete manholes, whether they are precast or constructed in the field, are still highly subject to corrosive forces and joint leaks at the connections.
The problems associated with conventional concrete manhole technology have led workers in the field to utilize prefabricated manhole structures made of reinforced plastic. For example, U.S. Pat. Nos. 3,715,958 and 3,938,285 both teach large, preformed manhole structures made entirely of plastic and glass fiber. These structures effectively overcome the problems of corrosion associated with conventional concrete manhole technology but they are bulky, difficult to handle, expensive to ship and lack the versatility required for proper sizing and customization to a particular site. Furthermore, they lack structural integrity and resistance to crushing by external forces.
To add strength and versatility to preformed plastic manholes, improvements such as stackable segments and plastic ribs or stiffeners have been developed. For example, U.S. Pat. No. 3,974,599 teaches an underground vault or manhole featuring increased rigidity of the body by the addition of reinforced plastic mortar rings and struts. In addition, U.S. Pat. No. 4,089,139 teaches stackable manhole units with internal reinforcing ribs which are an integral part of the body of each unit.
U.S. Pat. No. 5,386,669 further improves upon manhole technology by disclosing a complex modular manhole system comprising stackable double-walled units. The double walls give two potential sources of strength. First, the cavity between the walls may be filled with a structural material such as concrete that can be pumped through a hole drilled in the upper portion of each unit. Second, adjacent recesses are placed in the outer walls of some units to form structural ribs between the recesses. One disadvantage of this type of system is that the use of rebar to reinforce the concrete poured into the units is difficult and impractical. A second disadvantage is that, once the concrete is poured into the units, the manhole is entirely encapsulated by a thick, hard shell, making it difficult to later cut through the structure when it becomes necessary to splice in new pipelines.
Other patents have also disclosed manhole technology which takes advantage of the strength of concrete and the corrosion resistance of plastic. U.S. Pat. No. 4,540,310 discloses a manhole system comprising a stackable concrete lower section and an upper plastic cylindrical sleeve which has a integral flange extending outwardly from the bottom. The bottom of the sleeve including the flange is integrally cast into the top concrete riser section of the lower concrete structure. When the whole structure is placed underground, the top plastic sleeve is surrounded by the sleeve portion of an iron frame and grade rings of a desired thickness, the lower most of which contacts the flange portion of the iron frame. The manhole cover rests on the top of the sleeve portion of the iron frame. The grade rings are required to bring the manhole cover up to grade level. This sleeve is advantageous because it can be made extra long, preincorporated into the concrete riser section, and then cut to the desired height at the jobsite. One disadvantage of the system is that the bottom section is made entirely of concrete and is subject to the typical corrosive forces and joint leaking problems discussed above. Another disadvantage is that the plastic is only used for the top sleeve portion and is fully encapsulated by the surrounding iron frame. Although this frame provides necessary structural reinforcement, it does not allow workers easy access when it becomes necessary to splice a new pipeline into the plastic sleeve.
U.S. Pat. No. 5,383,311 discloses a manhole system wherein concrete is cast against a plastic preshaped liner containing integral, hollow, outward projections. Once the concrete is cast, the hollow projections become filled with concrete and protrude into the resulting outer layer of concrete, forming a tight lock between the plastic liner and the concrete. This system is disadvantageous because the liner is entirely encapsulated by concrete, making the unit extremely heavy and difficult to manipulate. In addition the encapsulation by concrete makes it extremely difficult to cut as necessary to add pipe connections.
As seen above, the prior manhole technology is not sufficiently versatile and suffers from various disadvantages and problems. For example, prior art that employs concrete by itself allows for corrosion and deterioration over time. On the other hand, plastic alone does not provide the strength that concrete does. The prior art that discloses the use of both plastic and concrete does not allow for easy access to the plastic for the purpose of splicing in new pipelines. Moreover, the technology disclosed by the prior art is highly labor and cost intensive, owing either to the amount of construction which must be done at the jobsite or to the difficulty of manipulating the bulky components of such manhole systems.
SUMMARY OF THE INVENTION
A need exists for a versatile manhole technology that fully utilizes the corrosion resistance of plastic, resins or fibreglass and the strength of concrete or metal, yet allows easy access for splicing in new pipelines. The present invention is a composite manhole unit manufactured from plastic and either concrete or metal such that the primary structural strength is obtained from a concrete or metal skeletal frame, generally of a hollow cylindrical shape. The corrosion resistance is provided by a plastic inner element, generally of a hollow cylindrical shape, which is easily cut in the field for the purpose of inserting pipeline connections. The system is unique in that the plastic portion is not entirely encapsulated by the frame, leaving large sections of plastic that are exposed. The exposed plastic sections can be readily cut in the field as necessary for inlet and outlet pipes to be inserted, using a rubber gasket to form a seal. This eliminates the need to cut through concrete to insert connectors.
Structural load bearing strength is provided by girders which encircle (or surround) the plastic inner element and by wall columns which connect and support the girders. The girders are substantially horizontal and the columns are substantially vertical, though these elements may be placed at up to 45° angles, as in, for example, a lattice configuration. The skeletal or lattice-like structure of the frame, as opposed to a full concrete wall surrounding the plastic for the entire length of the manhole, reduces the material required to manufacture the manhole. This reduction in the use of support material will decrease the overall weight of the manhole units, further facilitating manipulation in the field. Furthermore, the spaces between the wall columns and girders allow for easy access to the inner element for the purposes of fitting connections, outlets and other devices.
To facilitate building a manhole system, the units are stackable and contain a joint projection or protrusion (male joint) which extends or protrudes from the top girder of one unit and fits with a recessed mating joint (female joint) in the bottom of another unit. Of course, the units may be used in either orientation and top and bottom as described herein are used only for convenience and consistency.
Alternatively, a single manhole unit as described herein may be used with the manhole devices of the prior art. For example, it may be desirable to employ the unit of the present invention as the bottom unit of a manhole, retaining the existing system of concrete devices above it. Additionally, a single long unit may be employed in a manhole as opposed to multiple stacked units. Further, multiple skeletal frames may be combined with a single long inner element that can easily be cut to size in the field. The use of long inner elements in combination with multiple frames minimizes the possibility of leakage at the joints.
The linkage between the units may be constructed in a variety of ways using the known art for joint construction. Further, the joints may be sealed to provide a watertight linkage with adhesives, solvents, heat or gasket-like devices. Gasket-like devices include O-rings, D-rings, wedge-shape rings and the like, as well as profile gaskets. Further, multiple gaskets may be employed at different surfaces of the junction and may be combined with other sealing methods such as liquid gaskets, adhesive materials, and solvent or heat welding of the plastic surfaces.
In one embodiment of the invention, the joint comprises a projecting male surface that mates with a recessed female surface. The surfaces of the joint protrusion and mating joint may be angled and/or curved to facilitate a tight seal between units. The mating surfaces may be contained within the frame, leaving the inner elements to merely fit more or less flush against each other, or alternatively, the inner element may also have mating surfaces. The inner element may be flush with the frame, or not, depending on the mating surfaces employed. One or more mating surfaces may be sealed in an appropriate fashion.
In another embodiment of the system, either the inner element or the frame contains small indentations. These indentations may be filled with a corresponding protuberance from the other portion of the unit or may be wholly or partially filled with a grommet-like device which functions to accommodate the differential expansion rates of the two portions of the unit. The use of an indentation/protuberance system functions to increase the friction between the inner element and the skeletal frame, thus holding the components in place.
Once the system is constructed, a lid or riser can be fitted with the joint protrusion of the top unit and an optional sealing disk can be fitted to the mating joint of the bottom unit to seal the system. To further seal the system, the bottom-most unit, with the sealing disk, can be cast in concrete. Alternatively, a special bottom unit may be prefabricated that is complete with its own base for the cylinder. The special bottom inner sleeve has an integral base, thus minimizing the possibility of joint leakage. The special bottom frame likewise is manufactured with an integral base. Alternatively, a regular frame unit can be combined with a sealing disk that has a special inner element with integral base. The frame of the sealing disk may be skeletal or solid as desired, but a skeletal base has the advantage-of minimizing the weight of the frame.
The invention is a manhole unit with a rigid, skeletal, exterior frame having an inner surface and an inner element made of a corrosion resistant material and having an outer surface. The inner element is positioned within the exterior frame such that the inner surface faces towards (is adjacent to) the outer surface. The exterior frame has a plurality of girders encircling the inner element and a plurality of columns connecting the plurality of girders. Each of the plurality of columns is equally spaced around the inner element. The plurality of girders include a top girder with a first joint protrusion and a bottom girder with a first mating joint. The first mating joint is shaped to receive a second joint protrusion of a first adjacent manhole unit and the first joint protrusion is shaped to receive a second mating joint of a second adjacent manhole unit.
The outer surface of the inner element may have a circular or polygonal cross section, in which case the inner surface of the exterior frame preferably conforms and has a similar cross section. The exterior frame may also be coated with a corrosion resistant material such as plastic, fibreglass or paint.
The inner element is maintained within the exterior frame by friction. Friction can be increased with a protuberance on the inner element fitting into a corresponding indention on the exterior frame or vice versa. Alternatively, the indention may be at least partially filled with a grommet to allow for differential expansion of the two units. In yet another embodiment, the inner element and exterior frame have a locking system with a plurality of hollow protuberances projecting from the outer surface of the inner element. Here the exterior frame at least partially fills the plurality of hollow protuberances to lock the pieces together.
Suitable corrosion resistant materials for the inner element include plastic, fiberglass and combinations thereof. A preferred material is plastic such as polyvinyl chloride, polyethylene, polypropylene, polyester and combinations thereof. Suitable materials for the exterior frame include concrete, metal and combinations thereof. If the frame material is concrete, it can also be reinforced with materials including rebar, fibrous material and combinations thereof.
The invention also includes a manhole system made from a plurality of manhole units stacked upon one another. Each of the manhole units is as described above. Individual units of the manhole system can be sealed therebetween. The seal may encompass only the inner element or the exterior frame or both, as desired. Sealing methods include adhesives, gasket-like devices, solvent welding, heat welding and combinations thereof. An alternative manhole system uses a plurality of exterior frames as described fitted over a single inner element.
Modifications to the basic manhole unit include a unit complete with its own base. This manhole unit includes a rigid, skeletal, exterior frame having a first base and an inner surface. The inner element includes a second base and an outer surface. The inner element is positioned within the exterior frame such that the inner surface faces toward the outer surface and the second base is adjacent to the first base. The exterior frame includes a plurality of girders encircling the inner element, a plurality of columns connecting the plurality of girders and the base is preferably a skeletal base, to conserve materials and minimize weight. The top girder of this frame may have either a joint protrusion or a mating joint adapted to conform with an adjacent unit.
DESCRIPTION OF THE FIGURES
FIG. 1 is an perspective view of a composite manhole unit showing the inner element and the rigid, skeletal frame with an inlet/outlet pipe inserted into the inner element.
FIG. 2 is view of a manhole unit from the top showing inlet and outlet pipes connected to the inner element and three columns that are equally spaced around the inner element.
FIG. 3 is a partial cross sectional view of the step-shaped joining surfaces of an upper and lower unit with a gasket indicated.
FIG. 4 is a partial cross sectional view of the slanted joining surfaces of an upper and lower unit with a gasket indicated. Also shown are an indentation/protuberance system and an indentation/grommet system of increasing the friction between the inner element and skeletal frame.
FIG. 5 is a partial cross sectional view of another indentation/protuberance system for increasing the friction between the skeletal frame and the inner element.
FIG. 6 is a partial cross sectional top view of a column and the inner element with a hollow protuberance system for attaching the inner element to the skeletal frame. The hollow protuberance is shown filled with concrete.
FIG. 7 is a partial cross sectional view of two adjacent units with adjacent surfaces that can be sealed with an O-ring gasket. The bottom unit also has a sealing disk attached thereto and is sealed with a profile gasket.
FIG. 8 is a partial cross section of a manhole unit with an integral base comprised of an inner element with a base and a rigid skeletal frame with a base.
FIG. 9 is a partial cross section of a manhole unit sealed with a sealing disk comprised of an inner element of the sealing disk and a frame of the sealing disk. The sealing disk has a joint protrusion adapted to fit the mating joint of the manhole unit.
FIG. 10 is a perspective view of a manhole system which is formed when manhole units are stacked one upon the other.
FIG. 11 is a perspective view of a manhole system which is formed when a single manhole unit is combined with a prior art manhole.
FIG. 12 is a perspective view of a manhole system which is formed when multiple skeletal frames are stacked one upon the other and combined with a single long inner element.
DETAILED DESCRIPTION
FIGS. 1 and 2 depict an embodiment of a manhole unit 1 according to the present invention. The manhole unit 1 takes advantage of the corrosion resistance of plastic and/or fibreglass and the structural support of reinforced concrete or metal. The unit 1 is better than any of the prior art devices because the inner element is not completely encapsulated by concrete, minimizing the weight of the unit and allowing the plastic to be easily cut in the field to splice in new inlet and outlet pipes. In addition, the unit can be prefabricated in a factory in its final form so that construction and labor costs in the field are minimized. A plurality of manhole units 1 may be stacked together into a manhole system, such as is shown in FIG. 10, that is completely sealed and will not allow any infiltration or exfiltration.
Alternatively, as shown in FIG. 11, a manhole unit 1 may be combined with the manhole devices of the prior art. For example, in applications where only the bottom of the manhole is required to resist corrosion, the bottom may be replaced with a single unit of the invention which is then combined with the existing upper portion of the manhole, or vice versa. Further, the units may be employed in any orientation, for example right-side-up, up-side-down or sideways. The system can be used as a way to access any underground facility, vault, cave, mine, tunnel, compartment or similar structure.
The manhole unit 1 of FIG. 1 generally comprises a hollow cylindrical inner element 3 which is surrounded by a skeletal frame 5. The skeletal frame 5 is preferrably comprised of concrete reinforced with rebar or other fibers, but can also be comprised of metal. The inner element 3 can comprise any corrosion resistant material, preferably a plastic, including, but not limited to, polyvinyl chloride, polyethylene, fiberglass or a combination of plastic and fiberglass.
As shown in FIG. 1, the inner element 3 is essentially a hollow cylindrical tube of corrosion resistant material. It may optionally have a hole cut therein for the insertion of an inlet/outlet pipe 17. The skeletal frame 5 has a top girder 7, a bottom girder 9 and a plurality of columns 11. The top girder 7 is preferrably integrally connected, for example, a unitary construction or welded together, with the columns 11 which extend downward to integrally connect with the bottom girder 9. Alternatively, the skeletal frame 5 may be assembled using bolts or other fasteners. The top girder 7 in a preferred embodiment is circular and preferrably fits tightly around the inner element 3. In alternative embodiments, the inner element 3 may be polygonal, having at least three sides, and the inner surfaces of top girder 7 and bottom girder 9 may be altered in shape accordingly to conform to the exterior shape of the inner element 3.
The top girder 7 has a joint protrusion 13 which is shaped to fit with the mating joint 15 of the bottom girder 9 of another manhole unit 1 in order to assemble a plurality of manhole units 1, as shown in FIG. 10, or to fit with the mating joint of the bottom of a prior art unit as shown in FIG. 11. The joint protrusion 13 and mating joint 15 are detailed in FIGS. 3-5, but many other shapes of joint protrusion and mating joint will be satisfactory and are within the skill of the art.
FIG. 2 depicts a top view of the manhole unit 1 and illustrates the skeletal frame 5 viewed from the top, the inner element 3 and inlet/outlet pipes 17. This view shows a preferred 20 embodiment wherein there are three columns 11 equally spaced about the skeletal frame.
FIG. 3 shows cross sections of portions of an upper unit 19 and a lower unit 21.
Only the bottom girder 25 of the lower unit 21 is shown, along with the top girder 23 of the upper unit 19. The concrete girders (and columns) are preferably reinforced with rebar 39 which are integrally cast in the concrete when the frame is made. The diameters of the rebar 39 may be the same or different depending on the structural requirements placed on the frame. The bottom girder 25 has a recessed mating joint 31 shaped to fit against the joint protrusion 33 of an adjacent unit (in this case lower unit 21). In this embodiment, the joint protrusion 33 is substantially step-shaped, having a pair of steps that fit into the corresponding step-shaped recess of the mating joint 31. A gasket 37 serves to seal the joint and is pictured at the corner 35 of the pair of steps of the joint protrusion 33, but may be placed at any appropriate surface of a joint.
FIG. 4 shows a variation in joint construction. Again a partial cross section of an upper unit 41 and a lower unit 43 are shown. The lower unit 43 has a recessed mating joint 49 shaped to fit against the joint protrusion 51 of an adjacent unit (in this case upper unit 41). In this embodiment, however, the surfaces of the joint protrusion 51 are more slanted and curved than in FIG. 3. However, the joint protrusion 51 still fits into a corresponding recess of the mating joint 49. A gasket 55 is pictured at the corner 53 of the of the recessed mating joint 49.
The inner element 3 may be held in place by a variety of means, the simplest being friction between the adjacent surfaces of the inner element 3 and skeletal frame 5. If desired, it is possible to increase the friction between the skeletal frame 5 and the inner element 3. An example is shown in FIG. 4. The outer surface of the inner element 57 (of the upper unit 41) has a protuberance 59 that fits into a corresponding indentation 61 in the inner surface of the bottom girder 45. Alternatively, the indentation 65 of the inner surface of the top girder 47 in the lower unit 43 may be wholly or partially filled with a grommet 67. The grommet serves to increase the friction between the skeletal frame and inner element and is also capable of accommodating the different heat expansion rates of the two materials.
Additional means of frictionally securing the inner element is shown in FIG. 5. FIG. 5 is a partial cross sectional view of a bottom manhole unit (without a mating joint) which may be useful for the bottom-most unit of a manhole system (see also FIGS. 7 and 9 for special bottom-most manhole units). Labeled are the inner surface of the girder 69 and part of an inner element with an indentation 73 on the outer surface of the inner element 71. The corresponding protuberance 75 is provided by the inner surface of the girder 69. Of course, the protuberance/indentation system may be employed in the columns, though the system is only illustrated with respect to the girder.
FIG. 6 is a partial cross sectional top view of a manhole unit. It depicts a hollow protuberance 79 protruding from the outer surface of inner element 77 and having a hollow portion 81 forming, for example, a partial ring or partial tube that can be filled with concrete (as shown). The hollow portion 81 of the hollow protuberance 79 fills with concrete when the girders and columns are formed about the inner element. Thus, in this embodiment, the inner element and skeletal frame are permanently connected and shipped and assembled as a unit.
FIG. 7 depicts a partial cross section of upper and lower manhole units 83 and 85 respectively, showing both a simplified joint and a special bottom unit with sealing disk 107. The frames 87 and 89 are cross sectioned through the columns, as opposed to the earlier figures where only the cross section of a girder is shown. Upper frame 87 and receding end 93 of inner element 91 of the upper unit 83 combine to make a mating joint 111 of the upper unit 83. Likewise, lower frame 89 and top protruding end 97 of the inner element 95 of the lower unit (special bottom unit 85) combine to make a joint protrusion 109. As shown, the joint protrusion 109 and mating joint 111 are simplified versions from those previously illustrated. The inner elements 91 and .95 are not flush with the frames 87 and 89 respectively, but rather serve to create the joint protrusion 109 and mating joint 111. The joint is sealed with an O-ring 101 placed between the joint protrusion 109 and the mating joint 111.
The lower unit is a special bottom unit 85 with a bottom protruding end 99 of the inner element 95. The bottom protruding end 99 fits into a slot 105 of the sealing disk 107. In the illustrated embodiment, the slot 105 is shaped to receive the bottom protruding end 99 of the inner element 95, but it may also be shaped to receive part of the skeletal frame in other embodiments. A watertight seal is provided by a profile gasket 103 (for example, those available from Pine Gasket & Supply, Press Seal, Hamilton Kent or Delta Products) which may be placed against either the inside, outside or bottom of the inner element. Shown here is the profile gasket 103 against the outside of the inner element 95.
FIG. 8 is a partial cross section of a special bottom unit 113 with an integral base 119. The unit 113 has an inner element 117 with an inner element base 123 and a skeletal frame 115 with a skeletal frame base 121. The use of inner element 117 with inner element base 123 eliminates the possibility of joint leakage since there is no joint. The inner element 117 with integral inner element base 123 may alternatively be combined with a regular frame (see FIG. 1) and a sealing disk (see FIGS. 7, 9) may be added.
FIG. 9 is a partial cross section of a manhole unit 135 sealed with a sealing disk 125. The manhole unit 135 is joined to a sealing disk 125 at the base of the unit 135. The sealing disk 125 has an inner element 127 of the sealing disk 125 and a frame 129 of the sealing disk 125. The sealing disk 125 has a joint protrusion 133 adapted to fit the mating joint 131 of the manhole unit 135.
A plurality of manhole units 1 may be stacked on one another to form a manhole system 137 as shown in FIG. 10. In such a system 137, the joint protrusion of one unit 1 is fit into and against the surface, preferrably a conforming surface, of the mating joint of another unit 1. An inlet/outlet pipe may be readily adapted and positioned on any of the manhole units 1 of the manhole system 137. Alternatively, a single manhole unit 1 can be combined with a prior art manhole 139 as in FIG. 11. In yet another embodiment, a single long inner element 141 is combined with a plurality of frames 5 as in FIG. 12. In this way, the number of joints in the manhole system can be minimized.
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A composite manhole unit comprising a plastic inner element and an outer skeletal frame made of a structural material is provided. The plastic inner element is fitted within the skeletal frame, leaving large sections of the plastic inner element exposed. The exposed plastic sections can be readily cut in the field as necessary for attaching inlet and outlet pipes. A plurality of manhole units may be combined and assembled in a stacked manner to form a manhole system. The plastic pipe sections are sealed or connected to each other in a water-tight manner while the skeletal frame of the respective manhole units rest upon each other. The skeletal frame provides the structural support for the manhole unit and system. The excessive weight of the system and each respective manhole unit is reduced by using the skeletal frame in combination with the plastic inner element. The plastic inner element protects the skeletal frame from the corrosive atmosphere within, for example, a sewer system.
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RELATED APPLICATION
This application is a national phase entry under 35 USC 371 of International Patent Application No PCT/CN2014/074531 filed on 1 Apr. 2014, which claims priority from Chinese Patent Application No. 201310401785.9 filed on 6 Sep. 2013, the disclosures of which are incorporated in their entirety by reference herein.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention pertains to the field of semiconductor memory technologies, relates to a method for manufacturing a dynamic random access memory and in particular, relates to a method for manufacturing a semi-floating gate device.
2. Description of Related Art
Semiconductor memories are widely used in many electronic products. There are different requirements for the construction, performance, and density of the semiconductor memory in different application fields. For example, a static random access memory (SRAM) has a very high random access speed and a relatively low integration density, while a standard dynamic random access memory (DRAM) has a very high integration density and a moderate random access speed. Currently, with the continuous expansion of the market demand for semiconductor memories, the processes and methods for manufacturing dynamic random access memory technologies are innovated and many problems which restrain the process for manufacturing dynamic random access memory products are being solved.
Chinese Patent Application No. 201310119651.8 proposes a U-shaped channel semiconductor device and a manufacturing method thereof. A sectional structure of the U-shaped channel semiconductor device along a length direction of a current channel is as shown in FIG. 1 . The memory device includes a source region 201 , a drain region 202 , and a U-shaped channel region 401 formed in a semiconductor substrate 200 , and a first layer of insulating film 203 and a floating gate 205 which is used as a charge storage node and provided with a notch formed above the drain region 202 and the U-shaped channel region 401 . A p-n junction diode is formed between the floating gate 205 and the drain region 202 via a floating gate opening region 204 . A second layer of insulating film 206 and a control gate 207 are formed, covering the source region 201 , the floating gate 205 , and the p-n junction diode structure, and in a length direction of a channel of the device, the control gate 207 isolates the source region 201 from a top of the floating gate 205 on a top of the formed U-shaped groove.
A method for manufacturing the U-shaped channel semiconductor device includes: after forming a U-shaped groove, first removing a hard mask layer 301 , further forming a first layer of insulating film 203 on the surface of the U-shaped groove and a semiconductor substrate, and then forming a floating gate opening region 204 in the first layer of insulating film 203 on a side wall located on a top of the U-shaped groove and close to one side of a drain region 202 , as shown in FIG. 2 ; subsequently, further forming a floating gate 205 , as shown in FIG. 3 . The process procedures of forming a floating gate opening region 204 in the first layer of insulating film 203 on the side wall located on the top of the U-shaped groove and close to one side of the drain region 202 are complex, manufacturing is rather difficult, and it is difficult to control and ensure quality of finished products of the semiconductor device.
SUMMARY OF THE INVENTION
Technical Problem
An objective of the present invention is to provide a method for manufacturing a semi-floating gate device, which overcomes disadvantages of the prior art. The present invention can simplify the existing processes for manufacturing a semi-floating gate device and reduce difficulty in manufacturing a semi-floating gate device, and meanwhile, can improve the yield of semi-floating gate devices.
Technical Solution
The present invention provides a method for manufacturing a semi-floating gate device, including: a process for forming a U-shaped groove in Step 1 and a process for forming a source electrode, a drain electrode, and a control gate in Step 3 , where detailed procedures of the process for forming a U-shaped groove in Step 1 includes the following in sequence:
firstly, forming a doped well of a second doping type in a semiconductor substrate of a first doping type;
secondly, forming a first layer of insulating film and a second layer of insulating film in sequence on a surface of the semiconductor substrate; and
thirdly, positioning a location of a channel region by means of a photolithography process, and then etching the second layer of insulating film, the first layer of insulating film, and the semiconductor substrate to form a U-shaped groove having a bottom lower than a bottom of the doped well, where the U-shaped groove divides the doped well into a drain region and a source region;
where the method further includes a process for forming a floating gate and a floating gate opening region in Step 2 between the process for forming a U-shaped groove in Step 1 and the process for forming a source electrode, a drain electrode, and a control gate in Step 3 , and detailed procedures thereof include the following in sequence:
firstly, growing a third layer of insulating film on a surface of the U-shaped groove in Step 1 ;
secondly, depositing a first layer of polycrystalline silicon to cover the U-shaped groove, until the first layer of polycrystalline silicon fills up the U-shaped groove;
thirdly, etching back the first layer of polycrystalline silicon, where a top of the remaining first layer of polycrystalline silicon after the etching is located between an upper surface of the second layer of insulating film and the bottom of the doped well;
fourthly, etching away the second layer of insulating film, the first layer of insulating film, and the exposed third layer of insulating film;
fifthly, depositing a second layer of polycrystalline silicon on the structure formed by means of the above-mentioned etching processing, where the second layer of polycrystalline silicon and the first layer of polycrystalline silicon form a polycrystalline silicon layer; and
sixthly, depositing a layer of photoresist and forming a pattern by means of a photolithography process, and then etching the polycrystalline silicon layer along the photoresist pattern to form a floating gate and a floating gate opening region, where an etching depth is between a bottom of the drain region and the source region and a top of the third layer of insulating film.
A further preferable solution of the present invention is as follows.
Detailed procedures of the process for forming a source electrode, a drain electrode, and a control gate in Step 3 in the present invention include the following in sequence:
firstly, growing a fourth layer of insulating film on a surface of a device of the structure formed in Step 2 , and depositing a third layer of polycrystalline silicon on the fourth layer of insulating film;
secondly, depositing a fifth layer of insulating film on the third layer of polycrystalline silicon;
thirdly, etching the formed fifth layer of insulating film and the third layer of polycrystalline silicon by means of a photolithography process and an etching process and forming, by the remaining third layer of polycrystalline silicon after the etching, a polycrystalline silicon control gate sacrifice material;
fourth, depositing a layer of insulating film on the device of the formed structure and etching back the formed sixth layer of insulating film to form a gate side wall;
fifthly, performing source and drain etching and an epitaxial growth process at both sides of the formed gate side wall, so as to form contact regions of the source region and the drain region;
sixthly, depositing a first layer of interlayer dielectric material on the device of the formed structure and performing polishing until the polycrystalline silicon control gate sacrifice material is exposed;
seventhly, etching away the exposed polycrystalline silicon control gate sacrifice material;
eighthly, depositing a seventh layer of insulating film and a layer of metal control gate material on the fourth layer of insulating film, and performing polishing to enable the metal control gate material to occupy a location of the polycrystalline silicon control gate sacrifice material; and
ninthly, depositing a second layer of interlayer dielectric material on the device of the formed structure and arranging contact holes in the second layer of interlayer dielectric material and the first layer of interlayer dielectric material, and forming a source electrode, a drain electrode, and a gate electrode.
Step 3 of the present invention includes after etching away the polycrystalline silicon control gate sacrifice material, first etching away the fourth layer of insulating film and then forming the seventh layer of insulating film and the metal control gate material.
Step 3 of the present invention includes after etching away the polycrystalline silicon control gate sacrifice material, directly forming the metal control gate material on the fourth layer of insulating film.
Step 3 of the present invention includes after forming the gate side wall, directly forming a high-concentration doped region in the source region and the drain region by means of an ion injection method, so as to form contact regions of the source region and the drain region.
A material of the first layer of insulating film of the present invention is silicon oxide, and a material of the second layer of insulating film is silicon nitride.
Materials of the fifth layer of insulating film and the sixth layer of insulating film of the present invention are respectively silicon oxide or silicon nitride.
Materials of the third layer of insulating film, the fourth layer of insulating film, and the seventh layer of insulating film of the present invention are respectively silicon dioxide, silicon nitride, an insulating material with a high dielectric constant, or a laminated layer thereof.
An implementation principle of the present invention is that the manufacturing method of the present invention includes: after a U-shaped groove of an existing semi-floating device is formed, on the basis of retaining an original hard mask layer, first depositing a first layer of polycrystalline silicon and performing an etching back process to protect the gate dielectric layer, and subsequently, removing the hard mask layer; then, depositing a second layer of polycrystalline silicon, subsequently, etching the polycrystalline silicon to form a floating gate of the device by the remaining second layer of polycrystalline silicon and first layer of polycrystalline silicon, and automatically forming a floating gate opening region by a part of the floating gate in contact with a semiconductor substrate.
Advantageous Effects
Compared with the prior art, the present invention has the following notable advantages.
Firstly, a floating gate of the present invention is formed by means of two deposition processes, one photolithography process, and two etching processes, and although the number of processes for manufacturing the floating gate is increased, a photolithography process and an etching process for separately forming a floating gate opening region are omitted, so that process procedures for manufacturing a semi-floating gate device with a U-shaped channel is optimized on the whole, thereby reducing manufacturing difficulty and production costs of the semi-floating gate device with a U-shaped channel.
Secondly, the floating gate opening region of the present invention is formed by means of self-alignment in a procedure for forming the floating gate, so that the process for manufacturing the semi-floating gate device with a U-shaped channel is simple and reliable and exhibits excellent controllability, and the yield of the semi-floating gate devices with a U-shaped channel can be improved.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic cross-sectional diagram of a semi-floating gate device with a U-shaped channel disclosed in Chinese Patent No. 201310119651.8;
FIG. 2 to FIG. 3 are schematic flowcharts illustrating processes for manufacturing the semi-floating gate device with a U-shaped channel disclosed in Chinese Patent No. 201310119651.8;
FIG. 4 to FIG. 18 are schematic flowcharts illustrating processes for manufacturing a semi-floating gate device of the present invention;
FIG. 19 is a schematic cross-sectional diagram of a semi-floating gate device of a dual-storage unit manufactured according to the present invention; and
FIG. 20 is a schematic diagram of a circuit of a storage unit array constituted by a plurality of semi-floating gate devices manufactured according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
In order to clearly describe specific implementation manners of the present invention, layers and regions disclosed in the present invention are enlarged in terms of thickness in schematic diagrams listed in the accompanying drawings of the description, and sizes of the schematic diagrams do not represent actual sizes; the accompanying drawings are illustrative and shall not define the scope of the present invention. Embodiments listed in the description shall not be limited to specific shapes of regions shown in the accompanying drawings, but include that an obtained shape, for example, has deviation and the like caused by manufacturing and a curve obtained by etching, for another example, usually has a curving or mellow and full characteristic, but the shapes are all represented by rectangles in the embodiments of the present invention; meanwhile, in the following description, a term in use, namely, a substrate, may be interpreted as a semiconductor wafer which is being processed by means of a process and also includes other film layers which are prepared thereon.
The specific implementation manners of the present invention are described in further detail below with reference to embodiments and the accompanying drawings.
The present invention proposes a method for manufacturing a semi-floating gate device, including: forming a U-shaped groove in Step 1 , forming a floating gate and a floating gate opening region in Step 2 , and forming a source electrode, a drain electrode, and a control gate in Step 3 , thereby further manufacturing a semi-floating gate device with a U-shaped channel. According to a technical solution of the present invention in combination with the accompanying drawings, a specific embodiment of a method for manufacturing a semi-floating gate is now further disclosed and a process procedure thereof includes the following in sequence.
As shown in FIG. 4 , a doped well 301 of a second doping type is formed in an existing semiconductor substrate 300 of a first doping type where a shallow trench isolation structure (STI) has been formed; a material of the semiconductor substrate 300 is silicon or silicon on insulator; the first doping type is an n-type, and the second doping type is a p-type, or the first doping type is the p-type, and the second doping type is the n-type.
A first layer of insulating film 302 and a second layer of insulating film 303 are grown on a surface of the semiconductor substrate 300 in sequence, then a location of a channel region is determined by means of a photolithography process, and the second layer of insulating film 303 and first layer of insulating film 302 are etched by using a photoresist as a mask, where the etching is stopped on the surface of the semiconductor substrate 300 , and are as shown in FIG. 5 after the photoresist is removed; a material of the first layer of insulating film 302 is silicon oxide, and a material of the second layer of insulating film 303 is silicon nitride; and an effect of a silicon oxide film is reducing a stress between the silicon nitride film 303 and the semiconductor substrate 300 .
The semiconductor substrate 300 is continued to be etched by using the silicon nitride film 303 and silicon oxide film 302 as masks, a U-shaped groove is formed in the semiconductor substrate 300 , and the formed U-shaped groove has a bottom lower than a bottom of the doped well 301 of the second doping type and divides the doped well 301 of the second doping type into two regions which respectively serve as a source region 304 and a drain region 305 of the device, and the semiconductor substrate of the first doping type at the bottom of the U-shaped groove connects the source region 304 with the drain region 305 and forms a channel region of the device, as shown in FIG. 6 .
A third layer of insulating film 306 is grown on a surface of the formed U-shaped groove, and a material of the third layer of insulating film 306 is silicon dioxide, silicon nitride, silicon oxynitride, an insulating material with a high dielectric constant, or a laminated layer thereof; subsequently, depositing a first layer of polycrystalline silicon 307 of the first doping type on the formed structure, the deposited first layer of polycrystalline silicon 307 shall fill up the formed U-shaped groove, then the formed first layer of polycrystalline silicon 307 is etched back, and a top of the remaining first layer of polycrystalline silicon 307 after the etching shall be located below an upper surface of the second layer of insulating film 303 and above a bottom of the doped well 301 of the second doping type (namely, bottoms of the source region 304 and drain region 305 ), as shown in FIG. 7 ; FIG. 7 a illustrates an embodiment where the top of the first layer of polycrystalline silicon 307 after the etching is located below a lower surface of the second layer of insulating film 303 and above the bottom of the doped well 301 of the second doping type; and FIG. 7 b illustrates another embodiment where the top of the first layer of polycrystalline silicon 307 after the etching is located below an upper surface of the second layer of insulating film 303 and above a lower surface of the second layer of insulating film 303 .
The second layer of insulating film 303 , the first layer of insulating film 302 , and the exposed third layer of insulating film 306 are etched away, as shown in FIG. 8 , where FIG. 8 a corresponds to a structure formed after FIG. 7 a , and FIG. 8 b corresponds to a structure formed after FIG. 7 b ; in FIG. 7 b , because the third layer of insulating film 306 is covered by the first layer of polycrystalline silicon 307 , it is unnecessary to etch the third layer of insulating film 306 in this process.
A second layer of polycrystalline silicon of the first doping type is continued to be deposited on a surface of the device of the formed structure, the second layer of polycrystalline silicon of the first doping type and the first layer of polycrystalline silicon 307 constitute a polycrystalline silicon layer 308 of the first doping type together, and the polycrystalline silicon layer 308 is in contact with the source region 304 and drain region 305 , as shown in FIG. 9 , where: the polycrystalline silicon layer 308 in FIG. 9 a is in contact with the source region 304 and drain region 305 at the same time at the top of the U-shaped groove and on the surface of the semiconductor substrate 300 , and the polycrystalline silicon layer 308 in FIG. 9 b is in contact with the source region 304 and drain region 305 at the same time only on the surface of the semiconductor substrate 300 .
The device of the structure shown in FIG. 9 a is used below as an example for further describing the method for manufacturing a semi-floating gate device of the present invention.
A layer of photoresist 401 is deposited on the polycrystalline silicon layer 308 , and then a pattern is formed by means of a photolithography process, as shown in FIG. 10 ; the remaining photoresist is located above the U-shaped groove and covers a part of the drain region on one side of the drain region 305 , but does not cover the source region 304 on one side of the source region 304 , and a part of the polycrystalline silicon layer 308 located in the U-shaped groove and close to one side of the source 304 is exposed.
The polycrystalline silicon layer 308 is etched by using the photoresist 401 as a mask, after the semiconductor substrate 300 is exposed, the semiconductor substrate 300 is continued to be etched, a depth for etching the semiconductor substrate 300 shall be higher than the bottoms of the source region 304 and drain region 305 and not higher than a top of the third layer of insulating film 306 , and in this embodiment, the depth for etching the semiconductor substrate 300 is on a level with a height of the third layer of insulating film 306 ; the remaining polycrystalline silicon layer 308 of the first doping type after the etching forms a floating gate 308 of the device; because the photoresist does not cover the source region 304 , and a part of the polycrystalline silicon layer 308 located in the U-shaped groove and close to one side of the source 304 is exposed, a notch is formed on one side, close to the source region 304 , of the floating gate 308 when the polycrystalline silicon layer 308 and the semiconductor substrate 300 are being etched and is isolated from the source region 304 by the third layer of insulating film 306 ; and in addition, because the photoresist 401 , close to the drain region 305 , covers a part of the drain region 305 , after the polycrystalline silicon layer 308 and the semiconductor substrate 300 are etched, the floating gate 308 , close to the drain region 305 , is in contact with a part of the semiconductor substrate 300 which is not etched, and forms, together with the drain region 305 , a p-n junction contact, as shown in FIG. 11 .
After the photoresist 401 is removed, a fourth layer of insulating film 309 is formed on a surface of the formed structure, subsequently, a third layer of polycrystalline silicon 310 is formed on the formed fourth layer of insulating film 309 and a fifth layer of insulating film 311 is deposited on the third layer of polycrystalline silicon 310 , then the formed fifth layer of insulating film 311 and third layer of polycrystalline silicon 310 are etched by means of a photolithography process and an etching process, and the remaining third layer of polycrystalline silicon 310 after the etching forms a polycrystalline silicon control gate sacrifice material of the device, as shown in FIG. 12 ; because in the process of forming the floating gate 308 , the floating gate 308 is in partial contact with the semiconductor substrate 300 and forms, together with the drain region 305 , the p-n junction contact, that is, the floating gate 308 covers and protects a part of the drain region 305 , after the fourth layer of insulating film 309 is formed, an opening region is automatically formed between the fourth layer of insulating film 309 and the third layer of insulating film 306 (that is, the region where the floating gate 308 covers the drain region 305 ), and the opening region is a floating gate opening region between the floating gate 308 and the drain region 305 ; a material of the fourth layer of insulating film 309 is silicon dioxide, silicon nitride, silicon oxynitride, an insulating material with a high dielectric constant, or a laminated layer thereof, and a material of the fifth layer of insulating film 311 is silicon oxide or silicon nitride.
Depositing a sixth layer of insulating film 312 on the formed structure, and etching back the formed sixth layer of insulating film 312 to form a gate side wall, and then the exposed fourth layer of insulating film 309 is etched away to expose the source region 304 and drain region 305 , as shown in FIG. 13 ; and a material of the sixth layer of insulating film 312 is silicon oxide or silicon nitride.
On both sides of the formed gate side wall, the exposed parts of the source region 304 and drain region 305 are etched away, and a silicon germanium or silicon carbide material is epitaxially grown on parts of the source region 304 and drain region 305 after the etching, so as to form a source region contact region 313 and a drain region contact region 314 , as shown in FIG. 14 a ; and alternatively, on both sides of the gates side wall, a high-concentration ion-doped region can be directly formed by means of an ion injection method without undergoing an etching process and an epitaxial growth process in the source region 304 and drain region 305 , so as to form a source region contact region 313 and a drain region contact region 314 , as shown in FIG. 14 b.
A first layer of interlayer dielectric material 315 is deposited on the device of structure shown in FIG. 14 b , and the formed first layer of interlayer dielectric material 315 is polished by means of a chemical-mechanical polishing technique until the polycrystalline silicon control gate sacrifice material 310 is exposed, as shown in FIG. 15 ; then the exposed polycrystalline silicon control gate sacrifice material 310 and fourth layer of insulating film 309 are etched away, as shown in FIG. 16 ; subsequently, a seventh layer of insulating film 316 and a layer of metal control gate material are formed over the floating gate 308 , and then are polished, so as to enable the metal control gate 317 to occupy a location of the original polycrystalline silicon control gate sacrifice material 310 , as shown in FIG. 17 ; alternatively, the fourth layer of insulating film 309 may be not etched, and an seventh layer of insulating film 316 and a metal control gate 317 are directly formed after the polycrystalline silicon control gate sacrifice material 310 is etched away; alternatively, the fourth layer of insulating film 309 is not etched, and a metal control gate 317 is formed by directly covering the fourth layer of insulating film 309 ; and a material of the seventh layer of insulating film 316 is silicon dioxide, silicon nitride, silicon oxynitride, an insulating material with a high dielectric constant, or a laminated layer thereof.
As shown in FIG. 18 , a second layer of interlayer dielectric material 318 is deposited, then contact holes are formed in the second layer of interlayer dielectric material 318 and the first layer of interlayer dielectric material 315 , and a source electrode 319 , a drain electrode 320 , and a gate electrode (not shown in FIG. 18 ) are formed.
An embodiment for manufacturing a semi-floating gate device of the present invention is further described below with reference to the accompanying drawings.
As shown in FIG. 18 , a semiconductor substrate 300 of a first doping type is provided, and a source region 304 and a drain region 305 of a second doping type are formed in the semiconductor substrate 300 ; a U-shaped groove is recessed into the semiconductor substrate 300 and formed between the source region 304 and drain region 305 , the semiconductor substrate of the first doping type at a bottom of the U-shaped groove connects the source region 304 and the drain region 305 and forms a channel region of a device; a gate dielectric layer 306 is formed by covering a surface of the U-shaped groove, and a top of the gate dielectric layer 306 shall be located above bottoms of the source region 304 and drain region 305 and not higher than a surface of the semiconductor substrate 300 .
A floating gate 308 of the first doping type serving as an electric charge storage node is formed in the U-shaped groove by covering the gate dielectric layer 306 , a notch exists on one side, close to the source region 304 , of the floating gate 308 , a bottom of the notch shall be higher than the bottoms of the source region 304 and drain region 305 and is not higher than a top of the gate dielectric layer 306 , the floating gate 308 exceeds the gate dielectric layer 306 at one side, close to the drain region 305 , and extends over the surface of the semiconductor substrate 300 and to be in contact with the drain region 305 to form p-n junction contact.
On both sides of the floating 308 , surfaces of the source region 304 and drain region 305 are lower than the surface of the semiconductor substrate 300 and are on a level with the bottom of the notch of the floating gate 308 , so as to enable the gate dielectric layer 306 to isolate the source region 304 from the floating gate 308 ; an insulation dielectric layer 316 is formed by covering the source region 304 , floating gate 308 , and drain region 305 , and a metal control gate 317 is formed by covering the insulation dielectric layer 316 and surrounding the floating gate 308 ; a floating gate opening region exists in the gate dielectric layer 306 and insulation dielectric layer 316 , and the floating gate 308 is connected to the drain region 305 through the floating gate opening region; in FIG. 18 , the floating gate opening region is located at a top of the U-shaped groove and on a surface of the semiconductor substrate 300 located in the drain region 305 and close to one side of the U-shaped groove; and alternatively, a height of the gate dielectric layer 306 may be on a level with the surface of the semiconductor substrate 300 , so that the floating gate opening region is located only on a surface of the semiconductor substrate 300 located in the drain region 305 and close to one side of the U-shaped groove.
A gate side wall 312 is formed on both sides of the metal control gate 317 ; source region contact 313 and drain region contact 314 are formed on both sides of the gate side wall 312 and in the source region 304 and drain region 305 ; and an interlayer dielectric material (an insulation dielectric layer material 315 and an insulation dielectric material 318 ) is formed for isolating the device, and contact holes, a source electrode 319 , a drain electrode 320 , and a gate electrode (not shown in FIG. 18 ) are formed in the interlayer dielectric materials.
FIG. 19 illustrates an embodiment of a semi-floating gate device structure with two storage units manufactured according to the present invention, which is constituted by two semi-floating gate devices as shown in FIG. 18 , where the two semi-floating gate devices present a symmetrical structure, the two semi-floating gate devices share the drain region 305 , drain region contact 314 , and drain region electrode 320 , and the semi-floating gate device structure with two storage units can store two-bit data.
FIG. 20 is a schematic diagram of a circuit of a storage unit array constituted by a plurality of semi-floating gate devices as shown in FIG. 18 manufactured according to the present invention. As shown in FIG. 20 , any one among a plurality of source lines SL 603 a - 603 b is connected to sources of the plurality of semi-floating gate devices; any one among a plurality of word lines WL 601 a - 601 d is connected to control gates in the plurality of the semi-floating gate devices; any one among a plurality of bit lines BL 602 a - 602 d is connected to drains of the plurality of semi-floating gate devices; any one among the plurality of bit lines BL 602 a - 602 d may be combined with any one of the plurality of word lines WL 601 a - 601 d , which can select an independent semi-floating gate device; the word lines WL 601 a - 601 d may be selected by a word line address decoder 901 , the bit lines BL 602 a - 602 d may be selected by a bit line selection control module 902 , and the bit line selection control module 902 generally includes an address decoder, a multi-way selector, and a group of sense amplifiers; and meanwhile, the source lines SL 603 a and 603 b may be connected to a common source line or a source line selection control module.
Any technical means that is not explained in the present invention is prior art well-known to a person skilled in the art.
The specific implementation manners disclosed above with reference to the accompanying drawings and embodiments specifically support the technical thought of a method for manufacturing a semi-floating gate device proposed in the present invention and cannot be used to define the protection scope of the present invention. Any equivalent variations or equivalent modifications made according to the technical thought proposed in the present invention and on the basis of the present technical solution still belong to the scope claimed by the technical solution of the present invention.
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A manufacturing method for a semi-floating gate device, mainly comprising a manufacturing method for a floating gate and a floating gate opening area, and the specific process thereof is: reserving a hard mask layer after a U-shaped groove is formed, growing a gate dielectric layer on a surface of the formed U-shaped groove, depositing and etching back a first layer of polysilicon to protect the gate dielectric layer, etching away the exposed gate dielectric layer and hard mask layer, then covering a formed structure to deposit a second layer of polysilicon, then etching a formed polysilicon layer by a photoetching process and an etching process so as to form a floating gate, and forming a floating gate opening area in a self-aligning way. The manufacturing method can simplify the existing manufacturing process for a semi-floating gate device, reduce the difficulty in manufacturing the semi-floating gate device with a U-shaped channel, and improve the yield of the semi-floating-gate device.
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CROSS REFERENCE TO RELATED APPLICATION
This application claims the benefit under 35 U.S.C. §119(e) on U.S. provisional patent application No. 60/602,387 filed Aug. 17, 2004, which is hereby incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to an anti-tilting mechanism for a pivotable, sliding panel made from any rigid material such as glass, wood, or fiber structure intended for use such as on balconies, verandas, piscine, wall separation, etc.
2. Brief Description of Prior Developments
Traditional glazing for balconies or the like consists of a plurality of sash glass panels mounted on upper and lower guide rail and adapted to slide laterally past one another. A major disadvantage with this type of glazing is that at most only 50 percent of the glazed-in area can be opened. Furthermore, the outer surface of the pane is awkward to clean.
Glazing structures have been proposed in which the panes can be stacked against a side wall of the balcony by pivoting about a vertical axis. In WO 89/05389 this is achieved by means of a double upper rail arrangement having a straight outer rail and an inner rail. Within the curved portion of the inner rail the trailing edge of the pane turns inwards and the pane can opened against the side wall of the balcony. Such an arrangement is, however, not particularly aesthetically pleasing and friction can arise in the system and still be a lot of effort to clean
In an effort to eliminate these drawbacks, WO 90/121183 proposes a structure in which the top edge pivot pin of the glass pane is held stationary, no curved guide rail for the trailing edge is required. Whilst eliminating some of the disadvantages of the prior systems, the arrangement according to WO 90/121183 introduces its own drawbacks; one being that the pane must be tilted to disengage the upper trailing wheel from its guide rail before pivoting can commence. Since the leading edge of the pane is locked first only when pivoting has commenced, there is a risk that the trailing wheel may not disengage should the pane topple back before pivoting commences. The fact that the leading edge is locked only once rotation has commenced further implies that a flange protruding from the upper guide rail adjacent the opening for the trailing wheel is required to support the trailing wheel during the initial opening operation. Such protruding flanges hinder the possibility to mount curtains or blinds across the glazing. In addition, because only the upper leading pivot pin is immobilized, the pane cannot be opened through more than 90 degree, due to the fact that the lower leading pivot pin would otherwise be forced along the lower guide rail as a result of the change in position of the center of gravity of the pane.
SUMMARY OF THE INVENTION
The solution to problems described above and the invention can comprise interlocking air-tight panels that are able to slide laterally guided by an upper and a lower rail, while simultaneously pivoting on their axis. It offers many benefits such as easily glass cleaning, frictionless sliding panels, pivoting the panels to serve as doors at any point of the rail, and stacking the panels at any point of the rail.
In accordance with one aspect of the invention, a panel movement system is provided including top and bottom rails having racks with registration teeth along their lengths; top and bottom rail attachments movably attached to respective ones of the rails for lateral movement along lengths of the rails; and a gear movement synchronization system. Each rail attachment includes a rotatable gear engaging the registration teeth on respective ones of the rails. The gear movement synchronization system connects the rotatable gear of the top rail attachment to the rotatable gear of the bottom rail attachment such that the top and bottom rail attachments move along the rails in unison. The top and bottom rail attachments are adapted to have a panel connected therebetween.
In accordance with another aspect of the invention, a panel movement system is provided comprising top and bottom rails; a panel mounted to the rails by top and bottom movement sections to longitudinally slide along the rails, wherein the movement sections comprise rotatable platforms connected to respective top and bottom ends of the panel for allowing the panel to rotate relative to the rails; and a rotation synchronization system connecting the rotatable platform of the top movement section to the rotatable platform of the bottom movement section to rotate the top and bottom rotatable platforms in unison when the panel is rotated relative to the rails.
In accordance with one method of the invention, a method of manufacturing a movable panel system is provided comprising connecting top and bottom movement systems to top and bottom ends of a panel; connecting the movement systems to respective top and bottom rails such that the movement systems can traverse along the rails; and connecting the movement systems to each other such that the top and bottom movement systems operate in registration with each other and traverse along the rails in unison with each other. The movement systems are connected to the panel by rotatable top and bottom platforms to allow the panel to rotate relative to the rails. The method further comprises connecting the movement systems to each other comprises limiting rotation of the top and bottom platforms relative to each other such that the platforms are rotatable in unison with each other.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing aspects and other features of the invention are explained in the following description, taken in connection with the accompanying drawings, wherein:
FIG. 1 is a perspective view of a movable panel assembly incorporating features of the invention;
FIG. 2 is a perspective view of a portion of one of the rails of the frame of the assembly shown in FIG. 1 ;
FIG. 3 is a perspective view of components of the assembly shown in FIG. 1 ;
FIG. 4 is a perspective view of the components of the assembly shown in FIG. 3 from an opposite side; and
FIG. 5 is a perspective view of the components of the assembly shown in FIGS. 3 and 4 in a gear box frame.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1 , there is shown a perspective view of a movable panel assembly 10 incorporating features of the invention. Although the invention will be described with reference to the exemplary embodiment shown in the drawings, it should be understood that the invention can be embodied in many alternate forms of embodiments. In addition, any suitable size, shape or type of elements or materials could be used.
The panel assembly 10 in this embodiment is a window or glass door for use in a building. However, in alternate embodiments the invention could be used in any suitable type of assembly where panels are intended to be moved relative to each other. The assembly 12 comprises two panels 12 , 14 which are window panes. Non-window panels could be provided. More or less than two movable panels could be provided. The assembly 12 also comprises a frame with two rails 16 , 18 , top and bottom movement sections 20 , 22 for each panel 12 , 14 , and a synchronization system 24 for each panel 12 , 14 .
Referring also to FIG. 2 , the two rails 16 , 18 are identical to each other. In alternate embodiments the rails could be different. The rails 16 , 18 extend in a general cantilever fashion from the frame 26 . Preferably, the rails 16 , 18 extend substantially the entire width of the window. Each rail 16 , 18 has a track section with upper and lower convex curved sections 32 , 34 and a rack section 28 with registration teeth 30 . Referring also to FIGS. 3 and 4 , the top and bottom movement systems 20 , 22 are identical to each other, but reversely oriented or flipped relative to each other. In alternate embodiments the movement sections could be different from each other. Each panel 12 , 14 has the pair of the movement sections 20 , 22 attached to its top and bottom ends. The top movement sections 20 are mounted on the top rail 16 and the bottom movement sections 22 are mounted on the bottom rail 18 .
Each movement section 20 , 22 comprises a rail attachment 36 , a panel attachment 38 and part of the synchronization system 24 . The rail attachment 36 comprises rollers 40 and a rotatable gear 42 . Four rollers 40 are provided; two against the top convex curved section of the rail and two against the bottom convex curved section of the rail. However, in alternate embodiments more or less than two rollers on each top and/or bottom side could be provided. The rollers 40 have a general concave profile to mate with the convex shapes of the rail sections 32 , 34 . However, in alternate embodiments, any suitable complementary shapes could be provided. The rollers are attached by shafts to a gear box frame of the movement sections 20 , 22 . The rollers 40 are able to rotate to roll the movement sections 20 , 22 along the rails 16 , 18 . This allows the panel 12 , 14 mounted to the rails by a pair of the top and bottom movement sections 20 , 22 to longitudinally slide along the rails in general lateral directions as indicated by arrow 44 in FIG. 1 .
The rotatable gear 42 is connected to a rotatable shaft 46 . The shaft 46 is rotatably mounted to the gear box. An intermediate gear 48 is also connected to the shaft 46 . Thus, intermediate gear 48 is rotated when the gear 42 is rotated. The gear 42 has its teeth engaged with the teeth 30 of the rack section 28 . The gear 42 forms a pinion in a rack and pinion system. When the panel 12 , 14 is longitudinally moved along the rail 16 , 18 , the gear 42 moves along the length of the rack section 28 and rotates because of interaction between the teeth. This causes the gear 48 to rotate.
The panel attachment 38 comprises a first section 62 adapted to be directly attached to one of the ends of one of the panels 12 , 14 . The panel attachment 38 also comprises a second section 64 fixedly attached to the first section 62 . The second section 64 has a hole 66 . A rod 52 of the synchronization system 24 extends through the hole 66 . The rod 52 is rotatably mounted in the hole 66 by a bearing such that the rod can axially rotate in the hole. The axis 68 of rotation of the rod 52 is offset from the axis 60 of rotation of the panel attachment 38 . The panel attachment 38 can rotate about the axis 60 relative to the gear box.
Synchronization system 24 includes another intermediate gear 50 and the vertical axially rotatable rod 52 . The gear 50 is fixed to the gear box for axial rotational movement only about the axis 60 . The gear 50 has a top gear section 54 and a bottom gear section 56 . The bottom gear section 56 is engaged with the teeth of the gear 48 . The top gear section 54 engages teeth of a gear section 58 on the end of the rod 52 . The rod 52 has gear sections 58 at both its top and bottom ends.
The rod 52 provides two different types of movement synchronizations. For each panel 12 , 14 , the respective rod 52 can help synchronize translation movement of the rail attachments 36 of the top and bottom movement sections 20 , 22 relative to each other on their respective top and bottom rail 16 , 18 . In addition, for each panel 12 , 14 , the respective rod 52 can help synchronize rotational movement of the panel attachments 38 of the top and bottom movement sections 20 , 22 relative to each other.
For synchronized translation movement of the rail attachments 36 of the top and bottom movement sections 20 , 22 relative to each other on their respective top and bottom rail 16 , 18 , the rod acts as a mechanical connection between the movement sections 20 , 22 . The gears 42 of the two movement sections 20 , 22 are connected to each other by the respective intermediate gears 48 , 50 of the two movement sections 20 , 22 and by the rod 52 and its gears 58 at its opposite ends. Thus, as the gear 42 of the bottom movement section 22 moves along the teeth 30 of the bottom rail 18 , the two sets of shafts 46 and gears 48 , 50 , 58 , and the rod 52 insure that the gear 42 of the top movement section 20 moves along the teeth 30 of the top rail 16 in the same direction and with the same amount of movement. Likewise, as the gear 42 of the top movement section 20 moves along the teeth 30 of the top rail 16 , the two sets of shafts 46 and gears 48 , 50 , 58 , and the rod 52 insure that the gear 42 of the bottom movement section 22 moves along the teeth 30 of the bottom rail 18 . This insures a synchronized movement of the top and bottom ends of the panel 12 or 14 along the width of the window. The panel 12 , 14 is, thus, prevented from tilting and perhaps jamming during this lateral translation movement.
The panels 12 , 14 can also be individually rotated inward and/or outward as indicated by arrows 70 in FIG. 1 . For synchronized rotational movement of the panel attachments 38 of the top and bottom movement sections 20 , 22 relative to each other, as the panel attachments 38 are rotated along axis 60 at each of the movement sections 20 , 22 the gear 50 can remain stationary. The rod 52 , because of its connection at the hole 66 to the panel attachment 38 , rotates about the axis 60 . The teeth of the gear sections 58 rotate about the perimeter of the top gear section 58 resulting in axial rotation of the rod 52 about its axis 68 . Thus, as the panel 12 or 14 is rotated open or closed the gear section 58 at the bottom movement section 22 moves along the teeth of the gear 50 of the bottom movement section 22 and the rod 52 axially rotates to insure that the gear section 58 at the top of the rod at the top movement section 20 moves along the teeth of the gear 50 at the top movement section 20 for the top and bottom panel attachments 38 to move in synchronized unison rotation. The rotational movement can also occur at the same time as translational movement if desired.
The invention can comprise interlocking air-tight panels that are able to slide laterally guided by an upper and a lower rail. This can occur with simultaneous pivoting on their axes of rotation 60 . This was accomplished by the introduction of specialized gearboxes, located at the extremities of the panels, connecting it to the rails. In order to keep the panel stable while in motion, the gearboxes holding the panels preferably move synchronously else, the panel could be subject to tilting; since one end of the panel may be leading or lagging the other end. The synchronization of the gearbox movements is made possible using a solid beam; the rod 52 . The beam 52 connects gear or cog 58 of the lower gearbox with cog 58 of the upper gearbox, enabling them to rotate simultaneously. Rotation of the cog 58 is controlled by a series of other cogs which link it to the rack 28 that lines the rails on which the panel slides aided by the four rollers or pulleys 40 .
As the panel is moved laterally, the rack causes pinion 42 to rotate which, in turn, causes the other cogs to rotate relaying rotation to cog 58 . Solid beam 52 relays rotation to the upper gearbox. Similarly, the upper gearbox moves the exact distance as that covered by the lower gearbox.
When the panel needs to be rotated on its axis 60 , one can simply turn the panel by hand. Cog 58 would travel on the perimeter of cog 50 , since the panel is fixed on platform 38 which is secured onto axis 60 known as the synch axis, resulting in the rotation of cog 58 . This would cause the simultaneous rotation of both cogs, thus maintaining the vertical parallel position of the beam 52 with respect to the panel; avoiding collision of the beam with the panel while in rotation. The end result is a panel, made out of any rigid material, which can be moved laterally guided by rails, while being simultaneously rotated onto its axis. The panel's motion is smooth and easy to move regardless of its weight. With the invention, the panels 12 , 14 can also rotate more than 90 degrees; such as 360 degrees for example. In the embodiment described above, the gears 48 only rotate when the panel laterally slides/rolls along the rails. The platform 38 does not rotate with the gear 48 . The platform 38 only rotates when the user pivots the panel and rotation of platform 38 cause gear 58 to circle around the gear section 54 . The panels 12 , 14 can preferably overlap each other when then are slid towards each other, such as more than 50 percent overlap.
It should be understood that the foregoing description is only illustrative of the invention. Various alternatives and modifications can be devised by those skilled in the art without departing from the invention. Accordingly, the invention is intended to embrace all such alternatives, modifications and variances which fall within the scope of the appended claims.
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A panel movement system including top and bottom rails having racks with registration teeth along their lengths; top and bottom rail attachments movably attached to respective ones of the rails for lateral movement along lengths of the rails; and a gear movement synchronization system. Each rail attachment includes a rotatable gear engaging the registration teeth on respective ones of the rails. The gear movement synchronization system connects the rotatable gear of the top rail attachment to the rotatable gear of the bottom rail attachment such that the top and bottom rail attachments move along the rails in unison. The top and bottom rail attachments are adapted to have a panel connected therebetween.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to vehicle barriers, and more specifically to devices for remotely preventing car movement.
2. Description of the Prior Art
High-speed vehicular police chases of criminal suspects can, needless to say, result in harm to innocent bystanders, especially in densely populated urban areas. For this reason and for the sake of apprehending a fleeing criminal, it is highly desirable to stop such chases before unnecessary harm can result. Because a police car chasing a criminal suspect's vehicle is necessarily some distance from that vehicle, an effective device for stopping the suspect's vehicle must operate remotely from that vehicle. While most police carry remotely operating projectile weapons, in the form of guns, these guns can be ineffective in stopping continued movement of a vehicle. Guns typically carried by police are designed to stop movement of people rather than vehicles, and are not suitable for use in stopping a chased vehicle. What is needed is a device that will accurately and effectively disable a fleeing vehicle. The device should be usable regardless of the path that the fleeing vehicle takes. Numerous efforts have been made in these regards, yet nothing prior to the present invention meets the clear need for a remote device for disabling a fleeing vehicle.
U.S. Pat. No. 2,353,386, issued on Jul. 11, 1944, to Charles D. Bourcier, describes a device for deflating pneumatic tires. The device acts by passively providing a conduit between the inside space of such a tire and the environment. There is no projectile and no laser aiming or guiding.
U.S. Pat. No. 4,055,104, issued on Oct. 25, 1977, to Irving B. Osofsky et al., describes a tire-piercing device which is intended to be imbedded in a paved surface. There is no projectile and no laser aiming or guiding.
U.S. Pat. No. 4,382,714, issued on May 10, 1983, to Walter G. Hutchison, describes a passive device for deflating pneumatic tires by providing a conduit between the inside space of such a tire and the environment. The device may be interconnected with similar devices, which are together placed on pavement where a vehicle is expected to pass. There is no projectile and no laser aiming or guiding.
U.S. Pat. No. 4,995,756, issued on Feb. 26, 1991, to Donald C. Kilgrow et al., describes a tire deflator with a supporting base that supports and then releases puncturing conduits once such conduits are imbedded in tires. There is no projectile and no laser aiming or guiding.
U.S. Pat. No. 5,243,894, issued on Sep. 14, 1993, to Michael A. Minovitch, describes a blinding light intended to immobilize assailants. The light is not used to guide or aim a projectile.
U.S. Pat. No. 5,253,950, issued on Oct. 19, 1993, to Donald C. Kilgrow et al., describes a foldable tire deflator. There is no projectile and no laser aiming or guiding.
U.S. Pat. No. 5,328,292, issued on Jul. 12, 1994, to Francis R. Williams, describes a tire-puncturing traffic barrier chain. There is no projectile and no laser aiming or guiding.
U.S. Pat. No. 5,330,285, issued on Jul. 19, 1994, to Kenneth J. Greves et al., describes an apparatus for deflating tires that is collapsible. It is to be placed in front of cars. There is no projectile and no laser aiming or guiding.
All of the above patents are drawn to devices useful for deflating tires of a vehicle following a known path, and are useless in high-speed vehicle chases in which the path of a chased vehicle cannot be predicted. None of the above inventions and patents, taken either singly or in combination, is seen to describe the instant invention as claimed.
SUMMARY OF THE INVENTION
By the present invention, a device for remotely disabling a vehicle by deflation of the vehicle's tires is provided. The device is mounted on an underside of a law enforcement agent's chase vehicle. A laser light in the device indicates to the agent where a projectile expelled by the device will pass. The device is operated by directing the laser light at an underside of a chased vehicle and by causing the device to expel the projectile. When the projectile is so expelled, it extends numerous spikes which destroy the integrity of the chased vehicle's tires, deflating the tires and thereby disabling the chased vehicle and preventing harm to innocent bystanders.
Accordingly, it is a principal object of the invention to disable a vehicle having tires.
It is another object of the invention to provide disablement of vehicles from remote locations.
It is a further object of the invention to ensure accuracy through use of laser aiming light.
Still another object of the invention is to prevent harm to innocent bystanders as a result of a high-speed vehicle chase.
It is an object of the invention to provide improved elements and arrangements thereof in an apparatus for the purposes described which is inexpensive, dependable and fully effective in accomplishing its intended purposes.
These and other objects of the present invention will become readily apparent upon further review of the following specification and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an environmental, perspective view of the vehicle-disabling device according to the present invention, subsequent to projection of the device.
FIG. 2 is a top view of the vehicle disabling device according to the present invention in a closed configuration.
FIG. 3 is a bottom view of the vehicle disabling device according to the present invention in a closed configuration.
FIG. 4 is a top view of the vehicle disabling device according to the present invention in an open configuration.
FIG. 5 is a detail side view of a front end of the present invention showing a shock-absorbing and friction-reducing member.
FIG. 6 is a cutaway view showing a mechanism for preventing undesired closure of open arms of the present invention.
FIG. 7 is a partial, exploded view of an arm of one embodiment of the present invention, showing the optional detachable nature of spikes on the arm.
Similar reference characters denote corresponding features consistently throughout the attached drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
When high-speed automobile chases occur, there is a risk of harm to innocent bystanders stemming from reckless driving. Moreover, the chased automobile in such a chase must be stopped to apprehend the fleeing driver. For these reasons, it is highly desirable to provide a device that law enforcement officials can use to stop a chased automobile, while it is being chased. Because a path of a chased vehicle cannot generally be predicted, a mere stationary blockade cannot provide the desired effect of stopping a chased automobile. Instead, the present invention provides a device that can destroy an automobile's tires, thereby disabling it, even when the automobile is a substantial distance from the device's initial position. This remote effect is accomplished by providing an automatically deploying, tire-puncturing projectile.
Referring to the drawings, the vehicle disabling device 10 of the present invention has an elongated, hollow central body portion 12, elongated arms 14 pivotally connected to a front end 16 of the central body portion 12, and a deploying mechanism 18 that extends the arms 14 from a closed configuration in alignment with the central body portion 12, as shown in FIGS. 2 and 3, to an extended, T-shaped configuration at right angles with the central body portion 12, as shown in FIG. 4.
On a bottom side 20 of the front end 16 of the central body portion 12, there is a shock-absorbing and friction-reducing member 22. This shock-absorbing and friction-reducing member 22 is constructed of a flexible, resilient material, such as rubber, and impregnated by known means with a low-friction material, such as graphite. Alternately, this member 22 could be constructed of a single material having properties of resiliency and low-friction. This shock-absorbing and friction-reducing member 22 is curved in such a way as to form a hollow region 24 between much of the shock-absorbing and friction-reducing member 22 and the central body portion 12. In this way, the shock-absorbing and friction-reducing member 22 can flex without being obstructed by the central body portion 12.
The arms 14 are connected at first ends 26 to the front end 16 of the central body portion 12 by pivot joints 28. The arms 14 rotate in a ninety-degree arc, from a closed configuration parallel with the central body portion 12, as in FIGS. 2 and 3, to an open configuration perpendicular to the central body portion 12, as in FIG. 4. Preferably, means are employed to ensure that such rotation occurs only from a closed configuration to an open configuration. As one example, there are latches 80 of known type on the central body portion 12 that maintain the arms 14 in a pivotally extended, open configuration, until the latches 80 are released for re-use of the vehicle disabling device 10. As another example, there is a cylindrical anchor member 82 within a lumen 40 of the central body portion 12. As the arms 14 are moved into an open configuration, the anchor member 82 is forced away from the front end 16 of the central body portion 12. Such movement is irreversible because of teeth-and-notch portions 84 disposed along an interior surface 86 of the lumen 40 and an exterior surface 88 of the anchor member 82. These teeth-and-notch portions 84 allow movement of the anchor member 82 away from the forward end 16 of the central body portion 12, but not toward the forward end 16 of the central body portion 12. Because opening and closing of the arms 14 is directly related the position of the anchor member 82, the anchor member 82 ensures that opening of the arms 14 is irreversible.
Disposed along the arms 14 are hollow spikes 30 through which gaseous matter can freely pass. The arms 14 and spikes 30 are constructed of a sturdy material that preferably has a light weight relative to the central body portion 12. When the vehicle disabling device 10 is in an open configuration, these spikes 30 point upward and rearward, relative to a typical projected path of the vehicle disabling device 10. The spikes 30 are thus oriented so that they are likely to bring about puncturing when a pressurized container, such as a tire 32, is impaled by the spikes 30, as by running over the spikes 30 when the vehicle disabling device 10 is lying open on a road surface. As shown in FIG. 7, these spikes 30 are preferably integral with an elongated member 31 which is insertable into and detachable from a slot 33 in arms 14, in such a way that if the spikes 30 are hit once, they will detach and lie flat. This result renders the spikes 30 harmless, and prevents puncturing of tires that subsequently run over the spikes 30.
The deploying mechanism 18 has dual cords 34, i.e., one for each arm 14. The cords 34 connect at first ends 36 of the cords 34 to the arms 14 at central points along the arms 14, through eyelets 13, pass around pulley members 38 at the front end of the central body portion 12, and then run through the lumen 40 of the central body portion 12. The cords 34 exit the central body portion 12 at a rear end 42 of the central body portion 12, and second ends 44 of the cords 34 are anchored at an anchor location 46 separate from the vehicle disabling device 10. Pulling of a second end 44 or second ends 44 of the cords 34 pivotally extends the arms 14 from a closed configuration in alignment with the central body portion 12 to an extended configuration at right angles with the central body portion 12. If the anchor member 82 is used, the dual cords 34 attach to the anchor member 82, instead of the anchor location 46. An anchor cord 90 then connects the anchor member 82 to the anchor location 46. Pulling of the anchor cord 90 pulls the anchor member 82, which in turn pulls the dual cords 34.
The vehicle disabling device 10, prior to use, is releasably mounted underneath a vehicle 48, preferably on a sliding track 50 of known type. A slug-like projection 52 on a bottom side 54 of the vehicle disabling device 10 ensures engagement with the sliding track 50. In this way, the vehicle disabling device 10 slides along the sliding track 50 and thereby develops directional momentum, in the direction of the sliding. The vehicle disabling device 10 is unobstructively releasable from the sliding track 50 so that the vehicle disabling device 10 can, when released from the sliding track 50, continue in its sliding path, even though separate from the sliding track 50. To avoid complications related to construction and maintenance, the sliding track 50 is preferably affixed to the vehicle 48 in such a way that the orientation of the sliding track 50 is controlled only by varying the orientation of the entire vehicle 48. Alternately, a known steering mechanism (not shown) could be used for controlling the orientation of the sliding track 50.
To ensure accurate orientation of the sliding track 50, there is a laser-light producing mechanism 56 of known type mounted alongside the sliding track 50. The laser-light producing mechanism 56 directs a beam of light 58 in the direction in which the sliding track 50 is oriented. As a result, the laser-light producing mechanism 56 produces an indicator light 60 at a point near or somewhat behind where the vehicle disabling device 10 will land after being projected, thus indicating the trajectory of the vehicle disabling device 10.
There is a projection mechanism 62 that, when triggered, projects the vehicle disabling device 10. This projection mechanism 62 preferably employs an explosive charge by known means to project the vehicle disabling device 10 in the direction of the indicator light 60, at a speed substantially greater than a typical speed of a chased vehicle. Alternately, a spring-actuated mechanism (not shown) could be employed. Activation of the projection mechanism 62 is preferably accomplished by an electronic activation switch (not shown) of known type, located within a passenger compartment of the vehicle 48 on which the vehicle disabling device 10 is mounted.
In use, the vehicle disabling device 10, while mounted on a law enforcement agent's vehicle 48, is aimed at a rear end 66 of a fleeing vehicle 64. Aiming is preferably accomplished by directing the law enforcement agent's vehicle 48 such that the indicator light 60 is directed underneath the fleeing vehicle 64, between its tires 32. If there is a steering mechanism for controlling the orientation of the sliding track, then this steering mechanism can also be used to direct the indicator light 60 to the desired location underneath the fleeing vehicle 64. When the indicator light 60 is correctly positioned, a law enforcement agent closes the activation switch, thereby causing the projection mechanism 62 to project the vehicle disabling device 10 in the direction of the indicator light 60. Preferably, the vehicle disabling device 10 is thus projected with sufficient force so as to travel well beyond the location indicated by the indicator light 60, relative to the surface on which the fleeing vehicle 64 is traveling. However, the vehicle disabling 10 will land at approximately the location indicated by the indicator light 60, relative to the fleeing vehicle 64 itself, at the time the vehicle disabling device 10 is projected. The shock-absorbing and friction-reducing member 22 absorbs much landing impact and allows the vehicle disabling device 10 to slide underneath the fleeing vehicle 64. In this way, the vehicle disabling device 10 travels beyond the path of the fleeing vehicle's tires 32. Because the cords 34 are of finite length, continued travelling of the vehicle disabling device 10 subsequent to projection by the projection mechanism 62 resulting in development of tension in the cords 34. Development of this tension can be accelerated by slowing of the vehicle 48, immediately subsequent to projection of the vehicle disabling device 10. This tension pulls the cords 34, resulting in extension of the arms 14 so that the vehicle disabling device develops a T-shaped configuration, as shown in FIG. 4. In this configuration, the spikes 30 are oriented toward oncoming tires 32. When the tires 32 roll over the spikes 30, the tires 32 become punctured. Because the spikes 30 are hollow, pressurized gas in the tires 32 passes through the spikes 30 and out of the tires. In this way, the tires are deflated and the fleeing vehicle 64 is disabled. By this use of the vehicle disabling device 10 of the present invention, a fleeing vehicle 64 is disabled from a remote location, even without anyone knowing in advance the path that the fleeing vehicle 64 will take.
It is to be understood that the present invention is not limited to the sole embodiment described above, but encompasses any and all embodiments within the scope of the following claims.
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A device for remotely disabling a vehicle by deflation of the vehicle's tires is provided. The device is mounted on an underside of a law enforcement agent's chase vehicle. A laser light in the device indicates to the agent where a projectile expelled by the device will pass. The device is operated by directing the laser light at an underside of a chased vehicle and causing the device to expel the projectile. When the projectile is so expelled, it extends numerous spikes which destroy and deflate the chased vehicle's tires, thereby disabling the chased vehicle and preventing harm to innocent bystanders.
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BACKGROUND
[0001] 1. Technical Field
[0002] The present disclosure is directed to an axially oriented optical system and method of using the same, and more particularly, the present disclosure is directed to an apparatus for improving the computed radiography image generated by the axially oriented optical system and the method for using the same. The present disclosure is also directed to a method of using the optical system disclosed herein.
[0003] 2. Background of Related Art
[0004] Previously, scanners of X-ray exposed phosphor plates performed their function on a flat-bed or the external surface of a rotating drum. These systems have problems that increase the cost and reduce the quality of the X-ray image. The undesirable results obtained with a flat-bed or rotating drum system are caused by the continuous changing of the angles and distances of the light beam paths used for stimulating the phosphor of the X-ray exposed phosphor plate. Also, the collection of the stimulated light is performed with a different path and angle for each position on the phosphor plate, thereby requiring complicated and expensive compensation measures. Additionally, the complications with attendant increases in cost are exacerbated when existing systems for supporting the phosphor plates do not maintain a fixed positioning during the scanning procedure.
[0005] Accordingly, many, if not all, of these deficiencies have been overcome in U.S. Pat. No. 6,291,831 to Koren, the entire disclosure of which is herein incorporated by reference. As seen in FIG. 1, the Koren Patent discloses a scanning apparatus 10 including a fixed, hollow cylindrical segment 12 having a central, longitudinal axis 16 , the interior of which forms a concave surface for intimate contact with a medium for recording and/or readout 14 (e.g., a phosphor plate), a support structure forming a transport (not shown) for translational movement along the axis, a light source 18 (e.g. laser) mounted on the transport for movement therewith and for providing a beam capable of being directed along the axis, and a slanted mirror 26 , angled 45° with respect to the axis and mounted on the transport for translational movement therewith and for rotational spinning around the axis.
[0006] According to the Koren Patent, the scanning operation involves the mounting of laser 18 and slanted mirror 26 in such a manner so that slanted mirror 26 bends a beam of light 90° and is capable of rotating the beam of light. Accordingly, the beam of light can then be manipulated to form a rotating spot on phosphor plate 14 which follows a path of a portion of a circle on phosphor plate 14 . The transport 38 , including optic system 10 having light source 18 and spinning mirror 26 , and its subsequent movement to traverse phosphor plate 14 is coordinated with the rotative movement of the spot such that when the spot reaches the end of phosphor plate 14 , transport 38 is moved the distance of one pixel in order for the next scan to be conducted. According to the Koren Patent, readout of a previously X-ray exposed phosphor plate is obtained a 635 nm laser 18 stimulating the crystal layer of phosphor plate 14 causing it to radiate light at 390 nm as the beam spot on the phosphor plate 14 makes its scan. The rotating mirror 26 receives the emitted light around its outer periphery for reflection onto a Schott type filter 24 which is transparent to 390 nm light and absorbent to 635 nm light. The light passing through filter 24 is applied to detector photomultiplier tube 20 , which converts the light to an electrical signal that is amplified and gated to represent one pixel on the circular scan and converted to a digital number representing the brightness of the pixel.
[0007] In view of the aforementioned improvements and benefits of the Koren Patent over the prior art device, a need exists for an improved scanning apparatus which further reduces distortion, cost and the overall complexity of the operation while simultaneously improving the accuracy and quality of the resulting scan.
SUMMARY
[0008] The present disclosure provides a shroud for use in an optical scanning apparatus including a hollow cylindrical segment defining a central axis, the cylindrical segment forming a support surface for a medium to be scanned while the medium conforms to an inner surface of the cylindrical segment; a support structure for translational movement along the central axis; a light source mounted on the transport for movement therewith and for providing a beam capable of being directed along the central axis; a reflecting element for directing the beam toward the medium to produce a stimulated light; and a slanted mirror mounted to the transport for translational movement therewith and for rotational spinning around the central axis, the slanted mirror reflecting stimulated light toward a light detector. The shroud includes a base wall configured and adapted to be coupled to the transport, the base wall defining an outer terminal edge; and an annular side wall integrally formed along the outer terminal edge, the annular side wall extending in a direction toward the slanted mirror, wherein the base wall and the annular side wall block the stimulated light from traveling past the detector and stimulating the medium prior to the beam stimulating the medium. It is envisioned that the base wall is configured and dimensioned such that the outer terminal edge thereof is in close proximity with the inner surface of the cylinder segment. It is further envisioned that the shroud could include a wiper or lip extending along the outer surface of the annular wall.
[0009] The present disclosure further relates to an optical system for an internal drum readout apparatus, including a hollow cylindrical segment defining a central axis, the cylindrical segment forming a support surface for a medium to be scanned while the medium conforms to an inner surface thereof, a support structure configured and adapted to translate along the central axis, a mirror mounted on the support structure for translational movement therewith and for rotational spinning around the central axis, the mirror angled with respect to the central axis, a light source mounted to the support structure for providing a beam capable of being directed along the central axis which in turn is directed against the medium thereby producing a stimulated light, a detector coaxially aligned with the central axis, the detector being configured and adapted to absorb stimulated light direct toward and reflected off of the angled mirror, and a shroud mounted on the support structure for blocking stimulated light which is not directed toward the angled mirror, wherein the stimulated light not directed toward the angled mirror would otherwise degrade the medium prematurely. It is envisioned that the shroud is configured and dimensioned to block stimulated light which is not directed toward the detector. It is further envisioned that the shroud is configured and dimensioned to block errant light from entering the detector.
[0010] In one aspect of the present disclosure, the shroud includes a base wall defining an outer terminal edge and an annular wall integrally formed around the outer terminal edge of the base wall. The annular wall of the shroud preferably extends toward the angled mirror. It is contemplated that the annular wall is orthogonally oriented with respect to the base wall. It is envisioned the annular wall extends toward the angled mirror a distance sufficient to block errant light while still permitting transmission of the beam and the stimulated light. It is further envisioned that the optical system could include a wiper or lip extending along the outer surface of the annular wall, wherein the wiper reduces a gap between the outer surface of the annular wall and an inner surface of hollow cylindrical segment. It is envisioned that the wiper is constructed from a resilient polymeric material and/or a brush-like material.
[0011] In another aspect of the present disclosure, the shroud includes a base wall extending radially outward and having an outer terminal edge in close proximity with an inner surface of the hollow cylindrical segment, wherein the base wall is constructed from a polymeric material. It is envisioned that the optical system could further include a wiper or lip extending radially outward from the outer terminal edge thereof, wherein the wiper is constructed from resilient polymeric material and/or a brush-like material.
[0012] According to an embodiment of the present, the mirror is angled at about 45° relative to the central axis. In one embodiment, the mirror is angled to reflect the stimulated light toward the detector. In another embodiment, the mirror is angled to reflect the beam toward the medium.
[0013] It is envisioned that the light source is proximal of the angled mirror and the detector includes a reflecting surface mounted thereto for directing the beam toward the angled mirror. The light source is distal of the angled mirror and the angled mirror includes a central opening through which the beam passes and a reflecting surface mounted to the angled mirror for directing the beam toward the medium.
[0014] It is contemplated that the light source is a laser. It is further contemplated that the medium is a phosphor plate. The phosphor plate emits a stimulated light when excited by the beam which stimulated light corresponds to data recorded thereon.
[0015] It is envisioned that the detector includes a filter which permits light having a specific wavelength therethrough.
[0016] The present disclosure is also directed to a method of improving a computer radiography image in a scanning apparatus wherein the scanning apparatus includes a fixed hollow cylindrical segment having a central, longitudinal axis, the interior of which forms a concave surface for intimate contact with a medium for recording and/or readout; a support structure forming a transport for translational movement along the axis; a light source mounted on the transport for movement therewith and for providing a beam capable of being directed along the axis; a slanted mirror, angled 45° with respect to the axis and mounted on the transport for translational movement therewith and for rotational spinning around the axis, the mirror configured to reflect the stimulated light onto a collector tube.
[0017] The method includes the steps of providing a shroud device for reducing the collection of stimulated light and errant light which is not directed toward the angled mirror and which would otherwise prematurely degrade the medium, and mounting the shroud device to the collector tube such that the annular wall extends towards the angled mirror.
[0018] It is envisioned that according to the method disclosed herein, the shroud device includes a base wall extending radially outward and having an outer terminal edge in close proximity with an inner surface of the hollow cylindrical segment and an annular wall integrally formed around the outer terminal edge of the base wall.
[0019] The method may further include the step of providing a wiper or lip on the outer surface of the annular wall to reduce a gap between the outer surface of the annular wall and an inner surface of the cylindrical segment.
[0020] Other objects and features of the present disclosure will become apparent from consideration of the following description taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] By way of example only, preferred embodiments of the disclosure will be described with reference to the accompanying drawings, in which:
[0022] [0022]FIG. 1A is a schematic representation of one embodiment of a prior art arrangement of an optical system as described above;
[0023] [0023]FIG. 1B is a schematic representation of an alternative embodiment of a prior art arrangement of an optical system;
[0024] [0024]FIG. 1C is a schematic representation of a prior art arrangement of FIG. 1A or 1 B including a rotative drive and encoding system;
[0025] [0025]FIG. 2 is a perspective view a shroud in accordance with an embodiment of the present disclosure;
[0026] [0026]FIG. 2A is a cross-sectional side elevational view of a shroud in accordance with an alternative embodiment of the present disclosure as taken through line 2 - 2 of FIG. 2;
[0027] [0027]FIG. 2B is a cross-sectional side elevational view of a shroud in accordance with yet another embodiment of the present disclosure as taken through line 2 - 2 of FIG. 2;
[0028] [0028]FIG. 2C is a cross-sectional side elevational view of a shroud in accordance with still another embodiment of the present disclosure as taken through line 2 - 2 of FIG. 2;
[0029] [0029]FIG. 2D is a cross-sectional side elevational view of a shroud in accordance with a further embodiment of the present disclosure as taken through line 2 - 2 of FIG. 2;
[0030] [0030]FIG. 3 is a plan view of the shroud of FIG. 2;
[0031] [0031]FIG. 4 is a cross-sectional side elevational view of the shroud of FIG. 2 as taken through line 4 - 4 of FIG. 3;
[0032] [0032]FIG. 5 is a plan view of a spacer in accordance with an embodiment of the present disclosure;
[0033] [0033]FIG. 6 is a schematic representation of one embodiment of an optical system in accordance with the present disclosure, incorporating the shroud of FIG. 2 therein;
[0034] [0034]FIG. 7 is a schematic representation of an alternative embodiment of an optical system in accordance with the present disclosure, incorporating the shrouds of FIG. 2 therein;
[0035] [0035]FIG. 8 is a schematic view of the embodiment of FIG. 6 with a rotative drive and encoding system that is applicable to each of the embodiment shown herein;
[0036] [0036]FIG. 9 is a perspective view of a representation of a system for axial movement of the optical system; and
[0037] [0037]FIG. 10 is a block diagram of a control system for operation of the optical system of the present disclosure.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0038] As described above, a prior art arrangement of an optical system is shown and described in FIG. 1A. As seen in FIG. 1B, an alternative embodiment of a prior art arrangement of an optical system is shown whereby the light source 18 lies on axis 16 of shaft 28 which is collinear with hollow cylinder portion 12 , which forms the support for phosphor plate 14 . Shaft 28 is hollow in order to permit the beam to pass therethrough and angled mirror 26 has been provided with a hole 30 at its center in order for the beam to pass onto a small mirror 22 , which is mounted within hole 30 . Accordingly, when the beam passes through shaft 28 , small mirror 22 redirects the beam towards phosphor plate 14 .
[0039] In FIG. 1C, there is shown the prior art embodiment of FIG. 1B with the addition of a conventional motor mechanism including a rotor 32 , mounted for rotation with shaft 28 , and a fixed stator 34 . In the prior art embodiments of FIGS. 1 A- 1 C, filter 24 and detector 20 do not rotate. A conventional on-axis optical encoder system 36 is also mounted with respect to the motor mechanism for providing feedback pulses to stabilize rotation speed and for determining the beam positioning.
[0040] In each of the prior art optical system embodiments shown in FIGS. 1 A- 1 C, the Computer Radiography (CR) image is degraded in at least one of two ways. The CR image can be degraded by the beam reflecting within hollow cylinder 12 and prematurely releasing X-ray energy stored in phosphor plate 14 . Additionally, reflected beams within the CR chamber can cause degradation of the CR image when errant rays enter photomultiplier tube 20 .
[0041] Turning now to FIGS. 2 - 4 , a shroud for use with any of the prior art optical system embodiments shown in FIGS. 1 A- 1 C, is shown generally as 200 . Shroud 200 includes a ring-like planar base wall 202 and an annular side wall 210 extending therefrom. Base wall 202 includes an outer terminal edge 204 and an inner terminal edge 206 defining an aperture 208 formed in base wall 202 . Preferably, base wall 202 and aperture 208 are co-axial defining a central axis “A”. Aperture 208 is configured and dimensioned to permit the emitted light reflected from spinning mirror 126 , as will be described in greater detail below, to pass therethrough and onto a photomultiplier tube (PMT) or detector 120 .
[0042] Annular wall 210 preferably extends from outer terminal edge 204 of base wall 202 and is substantially orthogonally oriented with respect to base wall 202 . However, as seen in FIG. 2B, it is contemplated that annular wall 210 can be oriented at an angle greater or less than 90° with respect to base wall 202 . Annular wall 210 extends substantially around an entire length of outer terminal edge 204 . Preferably, annular wall 210 extends approximately 270° about outer terminal edge 204 , terminating in terminal end walls 210 a , 210 b defining an opening 212 . Opening 212 is configured and dimensioned to receive an arm (not shown) of transport 138 (see FIG. 9).
[0043] In designing shroud 200 it is preferable that shroud 200 is configured and dimensioned to block a maximum amount of air and/or light possible while simultaneously not interfering not interfering with the transmission of the beam of light directed toward phosphor plate 14 or the stimulated light emanating from phosphor plate 14 and directed toward spinning mirror 26 and onto photomultiplier tube 20 . Preferably, shroud 200 should be configured and dimensioned to extend radially outward a distance such that an outer terminal edge of shroud 200 is spaced a distance from the inner surface of cylinder portion 112 which is sufficient to permit phosphor plate 114 to pass between the outer terminal edge of shroud 200 and the inner surface of cylinder portion 112 .
[0044] As seen in FIG. 2A, base wall 202 can be configured and dimensioned to extend radially outward a relatively greater distance such that outer terminal edge 204 is proximate the inner surface of cylinder portion 112 and wherein a wiper 220 is provided on the outer surface of annular wall 210 which wiper 220 is configured and dimensioned to substantially fill the gap between annular wall 210 and the inner surface of cylinder portion 112 . Alternatively, it is envisioned that base wall 202 extends radially outward a relatively smaller distance and wherein wiper 220 is configured and dimensioned to fill the relatively larger gap between annular wall 210 and the inner surface of cylinder portion 112 . Preferably, wiper 220 is constructed from a resilient polymeric material and/or a brush-like material. In this manner, wiper 220 can contact phosphor plate 114 and simple lightly graze over the surface thereof without damaging or otherwise interfering with the surface of phosphor plate 114 . Preferably, annular wall 210 extends proximally a distance sufficient to block as much errant light as possible without interfering with the transmission of the beam of the stimulated light released from phosphor plate 114 . In this manner, shroud 200 is effective in blocking substantially all of the light from traveling distally through cylinder portion 112 and/or from prematurely striking photomultiplier tube 120 .
[0045] Turning now to FIGS. 2C and 2D, annular wall 210 is removed and base wall 202 is configured and dimensioned to extend radially outward such that terminal edge 204 is in close proximity with the inner surface of cylinder portion 112 . In FIG. 2C, base wall 202 is constructed from a polymeric material wherein base wall 202 is substantially rigid near the inner terminal edge (not shown) and becomes increasingly pliable and/or flexible in the radially outward direction. In this manner, outer terminal edge 204 will not damage phosphor plate 114 as it passes thereover. Alternatively, as seen in FIG. 2D, base wall 202 is constructed from a rigid material and a wiper 222 is affixed to outer terminal edge 222 . Preferably, wiper 222 is constructed from a resilient polymeric material and/or a brush-like material. In either embodiment, base wall 202 is effective in blocking substantially all of the air and/or light from traveling distally through cylinder portion 112 .
[0046] As seen in FIG. 2B and as previously described, annular wall 210 is oriented at an angle greater than 90° with respect to base wall 202 . Preferably, angled annular wall 210 extends radially from terminal edge 204 of base wall 202 a distance such that the terminal edge of angled annular wall 210 grazes over phosphor plate 114 . It is contemplated that angled annular wall 210 can be integrally formed with base wall 202 or can be fixedly secured to base wall 202 . Preferably, angled annular wall 210 is constructed from a resilient polymeric material and/or a brush-like material in order to keep from damaging the surface of phosphor plate 114 and angled annular wall 210 slides thereover.
[0047] Preferably, shroud 200 may be constructed from any suitable material for blocking errant light in a CR application environment. In an exemplary embodiment, shroud 200 is constructed from a rigid durable material, such as, for example, aluminum and the like. In a particular example, shroud 200 is constructed from 3003-H14 Aluminum having a thickness of about 0.050. Additionally, it is envisioned that shroud 200 is finished to be “hard anodized”, preferably colored black. Other coatings that minimize reflectance may also be used, such as dark surface finishes.
[0048] It is envisioned that base wall 202 of shroud 200 includes a plurality of radially oriented, preferably, evenly spaced, mounting holes 214 formed therein. Mounting holes 214 permit attachment of shroud 200 to transport 138 (see FIG. 9). As seen in FIG. 3, base wall 202 of shroud 200 includes a series of cut-outs 216 formed between terminal end walls 210 a , 210 b of annular side wall 210 . Cut-outs 216 are configured and dimensioned to permit proper mounting of shroud 200 to transport 138 .
[0049] As seen in FIG. 5, a spacer is generally shown as 250 . Spacer 250 is ring-like, having an outer terminal edge 252 and an inner terminal edge 254 defining an aperture 256 . Preferably, outer terminal edge 252 of spacer 250 has a diameter which is greater than the diameter of inner terminal edge 254 . Spacer 250 includes a plurality of mounting holes 258 formed therein. Preferably, mounting holes 258 of spacer 250 radially and axially align with mounting holes 214 of shroud 200 .
[0050] Spacer 250 is typically used when shroud 200 is being mounted to an optical system 100 where aperture 208 is larger than necessary for mounting of shroud 200 to photomultiplier tube 120 . Accordingly, spacer 250 is operatively coupled to shroud 200 such that a center of spacer 250 is axially aligned with axis “A” and thereby reduces the size of aperture 208 of shroud 200 to the size of aperture 256 of spacer 250 .
[0051] Turning now to FIGS. 6 - 9 , operation of optical systems 100 , in cooperation with shroud 200 , is shown. As seen in FIGS. 6 - 9 , shroud 200 is mounted to photomultiplier tube 120 in a manner such that axis “A” is aligned with an axis of rotation 116 of a spinning mirror surface 126 and such that annular wall 210 extends in the direction of spinning mirror 126 . Preferably, base wall 202 of shroud 200 is placed between a distal surface of photomultiplier tube 120 and filter 124 . In this manner annular wall 210 extends distally over filter 124 . Preferably, annular wall 210 extends an amount which is sufficient to extend past a distal surface of filter 124 .
[0052] With shroud 200 in position, operation of optical apparatus 100 involves the presentation of an X-ray exposed phosphor plate or film 114 to the interior of a fixed portion of a hollow cylinder 112 to which phosphor plate 114 is pressed firmly in order for phosphor plate 114 to conform to the circular configuration of the cylindrical portion. Spinning mirror 126 is then mounted in optical system 100 such that a surface of spinning mirror 126 is angled at 45° with respect to its axis of rotation 116 .
[0053] The scanning operation then involves the activation of a light source 118 , such as, for example, a 635 nm laser, thus creating a beam “X” which is co-linear with central axis 16 in order for beam “X” to be bent 90° by spinning mirror 126 and in order to form a rotating spot on phosphor plate 114 that follows a path of a portion of a circle.
[0054] As seen in FIG. 6, when beam “X” emanates from between rotating mirror 126 and filter 124 , no hole in rotating mirror 126 is required. Preferably, light source 118 is positioned such that beam “X” is transmitted toward central axis 116 in a plane parallel to the surface of filter 124 . A small mirror 122 is positioned on the surface of filter 124 , along central axis 116 , for redirecting beam “X” toward spinning mirror 126 , preferably, along central axis 116 , which beam “X” is then redirected by spinning mirror 126 in a perpendicular direction onto phosphor plate 114 .
[0055] As seen in FIGS. 7 and 8, when beam “X” emanates from behind rotating mirror 126 , along central axis 116 , a hole is required at the center of rotating mirror 126 and a small mirror 122 positioned within the hole and oriented in such a manner so as to redirect beam “X” in a perpendicular direction toward phosphor plate 114 .
[0056] Returning to FIGS. 1 A- 1 C, during a readout of a previously X-ray exposed phosphor plate 14 , light source 18 transmits beam “X” onto phosphor plate 14 thereby stimulating a crystal layer of phosphor plate 14 causing it to radiate a light “Y” at 390 nm as beam “X” makes its scan across phosphor plate 14 . Radiant light “Y” is dispersed in all directions and can be generalized as being divided into at least two components, a first radiant component “Y 1 a ” which is directed toward spinning mirror 26 and a second radiant component “Y 1 b ” which is not directed toward spinning mirror 26 . In operation, second radiant component “Y 1 b ” of light “Y 1 ” directed away from spinning mirror 26 (e.g., longitudinally proximally down tube 12 and/or radially around tube 12 ) strikes a region of phosphor plate 14 which has not yet been stimulated. Second radiant component “Y 1 b ” can in turn prematurely stimulate the crystal layer of phosphor plate 14 causing it to release light prior to stimulation by beam “X”. As such, when beam “X” does stimulate the region of phosphor plate 14 which has been prematurely stimulated by second radiant component “Y 1 b ”, less light is radiated from the crystal layer as compared to if the crystal layer had not been previously excited. In addition, second radiant component “Y 1 b ” can strike filter 24 at an angle as compared to directly off of spinning mirror 26 , thereby causing errant image information to reach detector 20 .
[0057] Meanwhile, first radiant component “Y 1 a ” of light “Y 1 ” strikes the surface of spinning mirror 26 resulting in first radiant component “Y 1 a ” being reflected in all directions and can be generalized as being divided into at least two components, a first reflected component “Y 2 a ” which is directed toward filter 24 and a second reflected component “Y 2 b ” which is not directed toward filter 24 (e.g., longitudinally proximally down tube 12 and/or radially around tube 12 ). First reflected component “Y 2 a ” travels toward filter 24 , passes through filter 24 and strikes photomultiplier tube 20 which in turn converts first reflected component “Y 2 a ” into an electrical signal that is amplified and gated to represent one pixel on the circular scan. However, second reflected component “Y 2 b ” can in turn prematurely stimulate the crystal layer of phosphor plate 14 causing it to release light prior to stimulation by beam “X”. As such, when beam “X” does stimulate the region of phosphor plate 14 which may have been prematurely stimulated by second reflected component “Y 2 b ”, less light is radiated from the crystal layer as compared to if the crystal layer had not been previously excited.
[0058] As seen in FIGS. 6 - 8 , shroud 200 improves the CR image in at least one of two ways, namely, reducing the effects of second radiant light “Y 1 b ” on phosphor plate 114 and/or reducing the effects of second reflected light “Y 2 b ” on phosphor plate 114 . In one aspect, annular wall 210 and back wall 202 of shroud 200 reduce, if not eliminate, the amount of second radiant light “Y 1 b ” traveling past spinning mirror 126 and prematurely stimulating the crystal layer of phosphor plate 114 by blocking second radiant light “Y 1 b ” from ever traveling proximally down tube 112 . In addition, annular wall 210 and back wall 202 of shroud 200 reduce, if not eliminate, the amount of second reflected light “Y 2 b ” traveling past filter 114 and prematurely stimulating the crystal layer of phosphor plate 114 by blocking second radiant light “Y 2 b ” from ever traveling proximally down tube 112 .
[0059] Preferably, shroud 200 is provided with a black finish, and more preferably, not polished. In this manner, shroud 200 more readily absorbs second radiant light “Y 1 b ” and second reflected light “Y 2 b ” thus reducing the possibility of second radiant light “Y 1 b ” being reflected and second reflected light “Y 2 b ” from being re-reflected against phosphor plate 114 .
[0060] Schematically illustrated in FIG. 9 is a means for effecting the axial path spacing of optical system 100 having shroud 200 mounted thereto. While the means for movement of optical system 100 along axis 116 can be accomplished in a variety of ways, only one method is illustrated and ill be described. As shown in FIG. 9, a support structure 138 is provided having a pair of rods 140 for stabilizing, guiding and maintaining the direction of transport 138 in a straight line. A threaded member 142 , fixed with respect to any axial movement, is engaged with mating threads in support structure 138 for its axial movement in order to obtain the traversing for scanning of the focused spot with respect to phosphor plate 114 . A linear stepping motor 144 (schematically shown) provides the rotation of threaded member 142 to accurately space the separate scans across phosphor plate 114 .
[0061] Turning now to FIG. 10, a block diagram illustrating the control of optical system 100 , having shroud 200 mounted thereto, is shown. As seen in FIG. 10, a DC motor 132 , 134 , encoder 136 and spinning mirror 126 are connected for simultaneous rotary operation. Motor 132 has a rotation motor control 146 , which in turn is connected for cooperation with encoder 136 . A stepper motor 144 is provided having a linear stepper control 150 , which is also connected with the output from encoder 136 . The output from photomultiplier tube 120 and that of encoder 136 provide input to an analog processing unit 148 , which provides its output to an analog to digital converter 152 for connection with a PC computer 164 .
[0062] While shroud 200 has been described as blocking radiant light “Ylb” not directed toward spinning mirror 26 and second reflected component “Y 2 b ” not directed toward filter 24 , it is envisioned that shroud 200 is effective in blocking any errant light from entering photomultiplier tube 120 from any external and/or internal light source.
[0063] It will be understood that various modifications may be made to the embodiments disclosed herein. Therefore, the above description should not be construed as limiting, but merely as an exemplification of preferred embodiments. Those skilled in the art will envision other modifications within the scope and spirit of the claims appended hereto.
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An optical system for an internal drum readout apparatus is disclosed. The optical system includes a hollow cylindrical segment defining a central axis, a support structure configured and adapted to translate along the central axis, a mirror mounted on the support structure for translational movement therewith and for rotational spinning around the central axis, a light source mounted to the support structure for providing a beam capable of being directed along the central axis which in turn is directed against the medium thereby producing a stimulated light, a detector coaxially aligned with the central axis, the detector being configured and adapted to absorb stimulated light direct toward and reflected off of the angled mirror, and a shroud mounted on the support structure for blocking stimulated light not directed toward the angled mirror, wherein the stimulated light not directed toward the angled mirror would otherwise degrade the medium prematurely.
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CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation in part of application Ser. No. 589,109, filed June 23, 1975, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to colloidal aqueous rosin dispersions of improved mechanical stability useful in the manufacture of paper. The invention includes the dispersions themselves and processes for the manufacture of the dispersions.
2. Description of the Prior Art
It has long been known that natural rosin can be emulsified in hot dilute aqueous alkali solution and that the product (a colloidal dispersion of rosin in dilute aqueous sodium rosinate solution) is an excellent sizing agent for paper. The best known agent of this type is the "Bewoid" size described in Pulp and Paper by James P. Casey, 2nd Ed., (Vol. 11, p. 1049 ff.).
A disadvantage of these dispersions is that they possess poor mechanical stability in that the dispersed phase aggregates and forms agglomerates when the dispersion is subjected to shear forces (as by passage through a centrifugal or gear pump). Pumps of this type are commonly used in size manufacturing plants and in paper mills, and are quickly fouled and jammed by sticky broken rosin emulsion. Moreover, coagulated rosin particles may find their way onto the paper machine causing picking, breaks, rosin spots, wire filling and other problems.
More recently it has been discovered that the sizing efficiency of rosin is increased when the rosin is reacted with a compound of acidic character containing the --CO--C═C-- linkage. The product (termed "fortified rosin") has a substantially higher flow point than rosin (usually above 100° C.) and therefore usually cannot be emulsified at atmospheric pressure in the same manner as unfortified size. To avoid the use of autoclave equipment, it is therefore present-day practice to decrease the flow point of the rosin before use by mixing a volatile rosin solvent (typically toluene) into it. The toluene is later recovered from the emulsion by distillation. The process is disclosed in French Pat. No. 781,729 and in U.S. Pat. Nos. 3,565,755 and 3,817,768.
A disadvantage of this process is that the intermediate dispersion (the emulsion of the solvent-softened fortified rosin) is thermally unstable, in that it aggregates when subjected to heat. Aggregation is particularly rapid when the solvent is removed by the efficient steam distillation process.
Aggregation even occurs at room temperature when no solvent or softening agent is present.
Dispersions which have aggregated have no commercial value.
Up to the present, sodium rosinate (or sodium fortified rosinate as the case may be) has been almost exclusively used as the emulsifier for rosin (or for fortified rosin) because it is easily produced by addition of a small amount of sodium hydroxide or carbonate to the aqueous medium used for the emulsification. However, experience has shown that both sodium rosinate and sodium fortified rosinate are unsatifactory in that they do not render colloidal dispersions of rosin or fortified rosin adequately mechanically stable to withstand stringent high-shear elevated temperature conditions.
In the past, a variety of different emulsifying agents has been tried to remedy the situation, but little or no improvement has been achieved.
SUMMARY OF THE INVENTION
In accordance with the present invention, there is provided a rosin dispersion consisting essentially of colloidal particles of a paper-sizing rosin as dispersed phase in an acidic aqueous medium as continuous phase, said medium having a small but effective dissolved content of a water-dispersible hydrophobic-hydrophilic emulsifying agent selected from the group consisting of tetrasodium N-(1,2-dicarboxyethyl)-N-octadecylsulfosuccinamate, disodium N-octadecylsulfosuccinamate, disodium dodecylpenta(ethoxy)ethylsulfosuccinate, and disodium decylsulfosuccinate as agent improving the mechanical stability of said dispersion, the hydrophilic-hydrophobic balance being such that said agent is at least colloidally soluble in water, and the amount of said aqueous medium being such that the dispersion is of pumpable viscosity. When any one of the aforesaid emulsifying agents is present in the dispersion in sufficient amount, the dispersion becomes mechanically stable so that it does not "break" when it is subjected to steam distillation or when it is subjected to prolonged and intensive shear.
In preferred embodiments, the dispersions of the present invention do not aggregate when subjected to steam distillation or when circulated under normal back pressure through a pump which develops a high degree of shear. The dispersions of the present invention thus can be made efficiently from high-melting rosins, and can be pumped and stored at room or elevated temperatures under commercial conditions without aggregation.
BRIEF DESCRIPTION OF THE DRAWING
The comparative stability of a series of aqueous colloidal anionic fortified rosin dispersions of the present invention is illustrated in the drawing, in which:
The abscissa represents the percent of stabilizing emulsifier which is present in the dispersion, based on the weight of the rosin therein.
One ordinate shows the lengths of time during which the plotted dispersions remain stable when subjected to uniform high intensity shear agitation;
Line A represents a graph of the break points of a series of preferred dispersions as a function of their content of a preferred stabilizing emulsifying agent and the duration of shear agitation.
Points B, C and D represent the break points of three corresponding preferred dispersions which differ from the dispersions of line A only with respect to the stabilizing emulsifying agent therein;
Box E represents the break point area of corresponding dispersions which contain emulsifying agents outside the scope of the present invention and the control dispersion containing none of said emulsifying agent;
The temperature scale at the right hand edge of the drawing shows the temperatures of the dispersions at their break point, the rise in temperature of the dispersions from their starting temperature of about 20°-25° C. being the result of the heat developed by the agitation. For example, the temperature scale shows that the preferred dispersion containing 1.5% of the stabilizing emulsifier by weight resisted aggregation during 21 minutes of high speed agitation, during which time its temperature increased from about 20°-25° C. to 82° C., thus demonstrating that the preferred dispersions of the present invention are resistant both to high speed shear forces and to high temperature.
Line A shows that when a preferred fortified rosin dispersion contains none of the emulsifying agent of the present invention it "breaks" (i.e., coagulates) after about 4.9 minutes of agitation. Line A rises almost vertically from that point to the point where the dispersion contains 0.5% of the emulsifying agent by weight. Line A shows that at that concentration the dispersion resists aggregation for about 17.5 minutes. The line then assumes a moderate slope reflecting the fact that each added increment of emulsifier produces only a minor increase in stability.
The points in the drawing are plotted from data in Examples 1 and 2 which show how these data were obtained.
From the drawing, it appears that, in the instance given, most efficient results are obtained per unit weight of stabilizing emulsifying agent added when the amount of the dispersing agent is between about 1/4% and 3/4% of the weight of the rosin.
The water-dispersible hydrophobic-hydrophilic anionic emulsifying agents defined above are a known group of emulsifying agents which are characterized by at least one oleophilic group (the alkyl chain or chains), and a plurality of hydrophilic groups (the acid groups). The agents are further characterized in that of the acid groups, at least one (the carboxyl group or groups) is mildly acidic and at least one (the sulfo group or groups) is strongly acidic.
As a practical matter, we prefer the agents which are prepared by esterifying maleic or similar acid to the extent of one of its functionalities with a suitable alkanol to introduce a hydrophobic substituent and then reacting the resulting monoester with sodium bisulfite to attach a sulfo substituent. The resulting agents are not unduly costly and provide good stabilizing effect.
Among the hydrophobic substituents which are useful are decyl, dodecyl and octadecyl. We prefer substituents which contain more than 12 carbon atoms because substituents of this length provide significantly better protection on a weight basis.
Hydrophobic substituents can also be introduced by mono-amidating maleic or similar acid with a hydrophobic amine, for example, octadecylamine. Best results to date have been obtained when the amine is a secondary amine which carries carboxy groups, for example: ##STR1##
Other ways of preparing emulsifying agents suitable for the purposes of the present invention will be apparent to a skilled chemist.
There does not appear to be any criticality in the identity of the nucleus of the molecules to which the aforesaid substituents are attached, so long as the complete molecule is water-dispersible, and hydrophobic-hydrophilic (i.e., self-dispersible and forming a hazy solution when placed in water in the same manner as hand soap) and anionic, and carries acid substituents as aforesaid. The skeleton or nucleus of the emulsifying agent will be of the aliphatic type (represented by the nuclei shown in the examples which follow).
The aforesaid agents exercise their beneficial effect when present in surprisingly small amount. No more than about 3% of the agent based on the weight of the dispersion (the combined weight of the rosin and water and solvent softener when present) is needed to provide near-maximum protection, and a much smaller amount will often prove enough as a practical matter. Our laboratory investigations have indicated that the benefits imparted by the agents rise rapidly per increment of agent added until an inflection point is reached, after which the amount of protection provided by each additional increment of the agent becomes progressively less. This inflection point varies between about 1/4% and 1% depending on the emulsifying agent used, the percent of fortifying component in the rosin, the specific surface area of the dispersed rosin, the pH of the dispersion and the temperature of the dispersion, and the specific surface active properties of the stabilizing emulsion used. The optimum or most efficient amount of agent in any instance is therefore most conveniently found by trial.
From these and other data it appears that aqueous colloidal dispersions of rosin are most efficiently protected when the amount of the emulsifying agent is in the range of about 1/4% to 1.5% based on the weight of the dispersion. Valuable results, however, are achieved when the amount of emulsifying agent is on either side of this range, as the emulsifying agents of the group recited above differ substantially from each other in their protective efficiency.
The reason why the aforesaid emulsifying agents so effectively protect aqueous colloidal rosin dispersions from deterioration resulting from shear forces is not known, and applicants do not wish to be bound by any theory. However, we point out as an aid to understanding the invention, that since the emulsifying agent always contains one strongly acidic group (the sulfo group) and at least one comparatively mildly acidic group (the carboxyl group or groups), the emulsifying agent in the pH range of 2 to 6 exits predominantly as a mixed salt and free acid. We also point out that the emulsifying agent may be attached to the colloidal rosin particles because of the affinity of the long chain alkyl substituents for the hydrocarbon portion of the rosin molecules, and so may serve to cover the rosin particles with a shell of non-adhesive hydrophilic acidic substituents, and that these substituents may impart a high degree of mutual repellence to the particles. Thus while sodium dodecyl benzene sulfonate and sodium naphthalene sulfonate are ineffective for the purpose, they evidently lack the combination of properties which our defined class of emulsifying agents possess.
The rosin in the dispersion of the present invention may be of any of the natural or fortified paper-making rosins. Thus the rosin may be ordinary gum or wood rosin, or ordinary tall oil rosin, or tall oil rosin which has been heat-isomerized or disproportionated or reacted with formaldehyde to render it non-crystallizing. Such rosins generally have flow points below about 90° C.
The rosins may also be any of the foregoing rosins which have been "fortified" by reaction with compounds which increase their molecular weight and which introduce carboxy groups into the molecule. Such rosins are generally prepared by reacting the foregoing or other rosins with at least about 1/20 mol of maleic anhydride, fumaric acid, itaconic acid, citraconic acid, acetylenedicarboxylic acid, etc. About 1/4 mol of the acid is usually the optimum, but up to 1 mol of the --CO--C═C----containing acid may be reacted, in which event the product is usually diluted with unreacted rosin to decrease the content of the --CO--C═C----containing rosin to the 1/4 mol level.
The dispersions of the present invention have an acid pH, so that substantially all the rosin is present in free acid (i.e., unsaponified) form. Substantially no sodium rosinate is therefore present. Usually the pH of the dispersion is the autogenous pH of the colloidal rosin present. Usually this is in the range of pH 4 to 5.5. The dispersion therefore can be and generally preferably is prepared without the use of acid or base. In certain instances, however, the dispersions possess better stability at a lower pH, and dispersions having pH values as low as 1 or lower are therefore within the scope of the invention.
In the dispersions the rosin is in colloidal state, i.e., it is so finely divided that the dispersion substantially does not cream when allowed to stand.
The stabilizing emulsifying agents which are present in the dispersions of the present invention can be prepared by known methods. Thus suitable agents can be prepared by reacting a suitable alkyl maleate (e.g., sodium octadecyl maleate) or a N-alkyl maleamate (e.g., sodium N-dodecylmaleamate) as intermediate with sodium bisulfite. The alkyl substituent need not be directly esterified with the maleate, and thus there may be employed as starting material a maleate which has been esterified with an ethylene oxide adduct of a suitable alkanol, for example, the adduct of four mols of ethylene oxide with one mol of 1-decanol. The maleamic acid employed may carry one or more N-carboxy substituents, as disclosed in U.S. Pat. No. 2,438,092. Suitable agents are commercially available.
The aforesaid intermediates are in such hydrophilic-hydrophobic balance that after reaction with sodium bisulfite they are at least colloidally soluble in water.
In the specification and claims the terms "dispersion" and "emulsion" are respectively used in their customary sense to designate a dispersion of particles (which may be solid or liquid) in a liquid medium. Moreover, the terms "sulfo" and "carboxy" are employed to designate respectively the --SO 3 H and --COOH substituents, as well as the alkali metal salts thereof.
The invention is more particularly illustrated by the examples which follow. These examples are preferred embodiments of the invention and are not to be construed in limitation thereof.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
EXAMPLE 1
The following illustrates the comparative mechanical stabilities of typical acidic paper-sizing rosin dispersions which contain a water-dispersible anionic hydrophobic-hydrophilic emulsifying agent of the invention. The following also illustrates the comparative mechanical stabilities of such rosin dispersions which contain emulsifying agents which are outside this group.
The rosin used is a commercial paper-making unsaponified fortified rosin (hereinafter termed "rosin") having a reacted content of about 1/4 mol of fumaric acid and about 1/5 mol of formaldehyde, prepared according to U.S. Pat. No. 3,400,117.
A stock anionic colloidal dispersion of this rosin is formed by dissolving 2 kg. of the rosin in 2 kg. of toluene, pouring the solution into 4 liters of water at room temperature containing 20 g. of sodium naphthalenesulfonate (1.0% on the weight of the rosin and 0.5% on the combined weight of the rosin and the toluene) and 10 g. of potassium hydroxide with vigorous agitation thereby forming a crude emulsion, and passing the emulsion twice through a homogenizer at about room temperature. The product is a white creamy emulsion having a pH of 5.5 which does not separate or form two layers on standing and which is of easily pumpable viscosity. Under the microscope the particles are seen to display Brownian movement, and at least 98% have a diameter of 1.4μ or less. When subjected to steam distillation at atmospheric pressure the dispersion aggregates. The solvent is removed without aggregation by vacuum distillation at a temperature <70° C. The final solids content is adjusted to 35% total solids content by addition of water.
Samples of this emulsion are then treated with 1% based on the weight of the rosin of the surfactants as shown in the table below. All dispersions are adjusted to 35% total solids content by addition of water.
The comparative mechanical stability of each emulsion is then obtained by placing 200 g. of emulsion at a temperature between 20° C. and 25° C. in a Waring blendor, running the blendor at maximum speed, and noting the time which elapses before the emulsion breaks (i.e., coagulates). The agitation causes the emulsion to heat, and the temperature of the emulsion at the break point is noted, which provides an indication of the thermal stability of the emulsion under high shear conditions.
A control run is performed without addition of any stabilizing agent.
The high-temperature stability of the emulsion is determined by the boil test, wherein a loosely stoppered vial of the emulsion is immersed in boiling water for one hour. The sample is rated "O.K." if it is unchanged, and "N.G." if it aggregates or had started to aggregate.
Results are as follows.
______________________________________ Stability Blender Test Mins. Max.Stabilizing Emulsifer Added* to Temp. BoilDesig. Name Break ° C. Test______________________________________-- [Control 4.9 43 N.G.]A Tetrasodium N- 18.6 74 O.K. (1,2-dicarboxyethyl)-N-octadecylsulfosuc- cinamateB Disodium 16.2 70 O.K. N-octadecylsulfo- succinamateC Disodium 14.2 62 O.K. dodecylpenta(ethoxy)- ethyl sulfosuccinateD Disodium decylsulfosuce- 11.6 56 O.K. cinate1. Sodium 6.1 44 N.G. dicyclohexylsulfo- succinate2. Sodium dibutylsulfo- 5.5 41 N.G. succinate3. Sodium diamylsulfo- 5.7 43 N.G. succinate4. Sodium dihexylsulfo- 5.4 41 N.G. succinate5. Sodium dioctylsulfo- 3.3 35 N.G. succinate6. Sodium ditridecylsulfo- 4.8 42 N.G. succinate______________________________________ *All emulsions contain 1.0% sodium naphthalenesulfonate and 0.5% potassiu hydroxide on weight of rosin. Additional surfactants added at 1.0% on weight of rosin.
Dispersions 1-6 inclusive are unsatisfactory in that the colloidal particles in the dispersion aggregate when the dispersion is subjected to intense agitation or high temperature after the softening agent has been removed. These dispersions have about the same break point and boil test values as the control dispersion, and so represent no improvement.
EXAMPLE 2
The following illustrates the effect of varying the amount of the stabilizing emulsifier in the dispersion.
The procedure of Example 1 is repeated except that tetrasodium N-(1,2-dicarboxyethyl)-N-octadecylsulfosuccinamate is the stabilizing emulsifier used and the amount thereof is varied as shown in the table below. Results are as follows.
______________________________________% StabilityEmulsi- Blender TestRun fier Min. to Max. BoilNo. Added Break Temp. ° C. Test______________________________________-- None 4.9 44 N.G.1 0.25 8.2 54 N.G.2 0.50 17.5 75 O.K.3 0.75 17.9 76 O.K.4 1.0 18.6 77 O.K.5 1.5 21.0 82 O.K.______________________________________
A sample of the dispersion of run 4 at 35% rosin content by weight is tested for its mechanical stability as follows.
A 400 cc. sample of the dispersion is supplied to a laboratory centrifugal pump running at 3200 r.p.m. pumping at the rate of 1500 cc. per minute. The discharge from the pump is vented into a catch pan elevated four feet above the pump where it is cooled to 20° C., from which it flows by gravity back to the pumps, so that it is continuously circulated.
The dispersion is unchanged after eight hours of circulation in this manner, showing that the dispersion is almost indefinitely stable.
The procedure is repeated with a similar dispersion in which the emulsifying and stabilizing component is 2% by weight of the sodium salt of the rosin component in the dispersion. The dispersion breaks down and becomes useless in less than 2 hours.
EXAMPLE 3
The procedure of Example 1 is repeated except that the sodium naphthalenesulfonate and potassium hydroxide are omitted and the stabilizing agent of Example 2 is employed in lieu thereof. Substantially the same results are obtained as in Example 2, showing that the omitted components are not necessary to provide stability of the dispersion.
EXAMPLE 4
The procedure of Example 1 is repeated except that the sodium naphthalenesulfonate and potassium hydroxide are omitted and that these materials are replaced by 3 g. of sodium hydroxide. Substantially the same results are obtained as in Example 1.
EXAMPLE 5
The following illustrates the preparation of a dispersion according to the present invention by a process wherein the rosin is a high melting point rosin but which does not contain any softening agent.
The rosin used is the rosin of Example 1.
The apparatus used is a standard laboratory autoclave fitted with a high-speed stirrer, electrical heating, and a valved discharge line which runs to a heated high-pressure closed homogenizer discharging through a water-cooled pressure reducing valve.
Into the autoclave is discharged 590 g. of the fortified rosin of Example 1 (containing no solvent or other softening agent), 7.5 g. of tetrasodium N-(1,2-dicarboxyethyl)-N-octadecylsulfosuccinamate, and 1124 g. of water. The autoclave is sealed, heated to 180° C., and the stirrer is run at top speed for three minutes. The crude emulsion thus formed is then discharged under autogenous pressure and at autogenous pH (about 5) into the homogenizer which is heated to 160° C. After homogenization the dispersion is discharged through the chilled reducing valve and is a white acidic dispersion of pumpable viscosity. It is substantially the same as the product of Example 1.
EXAMPLE 6
The following illustrates the preparation of an emulsion from which the solvent may be removed by atmospheric pressure steam distillation.
1000 g. of the rosin of Example 1 is dissolved in 667 g. of toluene. This solution is poured into 1667 g. of water containing 10 g. of tetrasodium N-(1,2-dicarboxyethyl)-N-octadecylsulfosuccinamate with vigorous agitation. The resulting crude emulsion is passed twice through a homogenizer at room temperature and the resulting white emulsion is stripped of solvent by direct steam sparging at atmospheric pressure.
The product has substantially the same stability as the product of Example 1.
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Colloidal aqueous dispersions of rosin possess improved mechanical and heat stability when they have a small dissolved content of a water-dispersible emulsifying agent selected from the group consisting of tetrasodium N-(1,2-dicarboxyethyl)-N-octadecylsulfosuccinamate, disodium N-octadecylsulfosuccinate, disodium dodecylpenta(ethoxy) ethylsulfosuccinate, and disodium decylsulfosuccinate as stabilizing agent.
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[0001] The present application is a continuation of International Application No. PCT/EP2004/009095, filed Aug. 13, 2004, and claims priority under 35 U.S.C. § 119 to German Application No. 103 38 789.7-22, filed Aug. 23, 2003. The entire disclosure of these documents are herein expressly incorporated by reference.
BACKGROUND AND SUMMARY OF THE INVENTION
[0002] The present invention relates to a door locking system for a motor vehicle.
[0003] Door locking systems for motor vehicles with and without central lock function are known. To check on whether a vehicle is in fact properly locked, including all doors and hatches after being locked, the user must either rely on the position of the lock pins on the doors and manually check the locking of the trunk, or manually check all doors and the trunk in one inspection operation around the vehicle. A manual check by the user is a problem, in particular in systems having a so-called electronic lock. Such systems function automatically and automatically initiate an opening procedure as soon as the user (i.e., the key) is at a specified distance from the vehicle so that either the vehicle is unlocked in a fully automatic process or preparations are made for an unlocking operation and the vehicle is automatically unlocked as soon as the user operates an opening handle (see for example German Patent DE 199 42 485 A1). Conversely, the vehicle is automatically locked as soon as the key is beyond the specified distance range from the vehicle. A manual check of the lock positions by the user would thus be very tedious, and would in fact be possible only if the user is not carrying the vehicle key with him.
[0004] Furthermore, a door lock for a motor vehicle is disclosed in German Patent DE 101 55 836 A1. With this door lock the open position of the locking element is monitored. A contact switch is provided for this purpose, monitoring the open position of the locking element and generating a signal as soon as this open position has been reached, the signal being used by a control unit to interrupt the power supply to the drive motor of the locking element. This prevents the drive motor from running on block and being burdened unnecessarily.
[0005] The present invention provides a door locking system for a motor vehicle that is improved with regard to comfort and safety.
[0006] According to the present invention, this object is achieved by a locking element that can be operated for opening or locking via an actuator; a control unit for triggering the actuator; and a position monitoring means for detecting a lock position of the at least one locking element, and which is assigned to at least one locking element, wherein each position monitoring means cooperates with a control means for checking on whether a proper locked state prevails such that a setpoint state and actual state of the at least one locking element are comparable and an acknowledgement signal can be generated when the states do not match. Such a door locking system includes an actuator in the form of an electric or hydraulic drive or the like for opening and/or locking a locking element, a control unit (e.g., a separate door controller or a central engine controller) for triggering the actuator and position monitoring means (e.g., photoelectric barrier, proximity sensor or a position sensor) for position monitoring of the locking element. This system also includes control means for checking on whether a proper locked state has been achieved. In this way, the setpoint and actual conditions of the locking elements are compared so that if the states do not correspond, an acknowledgement signal is generated. This acknowledgement signal may be used either for triggering a signal generator such as a horn or headlight or the like or it may serve as an intermediate signal for generating a triggering signal for a signal generator.
[0007] The control means are preferably designed as part of door controller or a central controller. Both the locking commands and the opening commands by means of which the corresponding setpoint status of the locking elements is defined is sent to these controllers as is the locking state detected by the position monitoring means by which the particular actual state of the locking elements is defined. According to this invention, the control means are designed so that they detect an improper locking state (not locked despite a locking command having been issued) on the basis of a deviation between the setpoint and actual states and then generate an acknowledgment signal. To generate an acknowledgment signal, for example, light sources (headlights, flashing lights, rear lights, interior lights, . . . ) or acoustic sources (horn) of the vehicle are triggered in a suitable manner by a certain signal pattern.
[0008] The position monitoring may be performed in various ways. In a first possible embodiment, the position monitoring is implemented via sensors, where the sensors detect the actual position of the locking means. In a second possible embodiment of this invention, the position monitoring is implemented by analyzing internal data within the controller. For example, the self-diagnosis within the controller triggering the actuators and/or the corresponding separately designed control means or control means integrated into a controller may be used for this purpose. In particular, the typical current characteristic of the startup current and/or running current and/or square-wave current of the actuator designed as an electric motor is performed. The actual position of the locking elements or actuators is not detected in this way. Instead, the instantaneous position of the locking elements is deduced on the basis of a check of boundary conditions.
[0009] Finally, the position monitoring and function monitoring may also be performed in particular by a combination of sensor monitoring and software monitoring.
[0010] In one aspect of the present invention, a locked state detected as not the proper state is also stored in the vehicle's onboard electronics and/or in the vehicle key. In this way, the user can at any time ascertain via the onboard computer which locking element has not locked properly and is therefore possibly defective. Secondly, the user, although already at a distance from the vehicle, may at any time determine on the basis of an inquiry by his key whether his vehicle has been properly locked. To this end, the key may be queried by depressing a certain button and the information displayed by an LED lighting up (green=properly locked, red=not properly locked).
[0011] The inventive door locking system can be used in systems having a central locking function.
[0012] With a door locking system designed according to this invention, the user receives an acknowledgment after locking is completed and/or after a locking procedure is concluded, indicating whether or not the vehicle is in fact properly locked and secured. If the vehicle is not properly locked despite the locking procedure having been initiated because, for example, an actuator in the form of an electric motor for driving a locking means is defective, for example, or is simply jammed, reference is made to this situation through suitable measures such as light signals and/or horn signals. A vibrating signal on the key is also conceivable as an acknowledgment signal. This is advantageous in particular when the user has assumed despite a light warning and/or acoustic warning that his vehicle has been properly locked. This vibrating signal may advantageously be initiated with a certain time lag whenever it is not suppressed by an acknowledgement (e.g., depressing a button) on the part of the user after a locking command has been issued.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The present invention is explained in greater detail below with reference to figures, in which:
[0014] FIG. 1 shows a schematic diagram of an exemplary embodiment of the present invention,
[0015] FIG. 2 shows the time chart for the locking operation with the door locking system according to this invention and
[0016] FIG. 3 shows as an example the different current characteristics in triggering an actuator for correct and incorrect locking operations with a locking element.
DETAILED DESCRIPTION
[0017] The schematic diagram in FIG. 1 shows a control unit 2 for triggering an actuator 4 in the form of an electric motor for locking a vehicle door and/or a trunk lid and/or a sun roof and/or other doors. A locking element 6 can be operated for opening and locking procedures by means of the actuator 4 . Position monitoring means 8 are assigned to each locking element 6 . The position monitoring elements 8 may be designed as sensors in the form of position sensors 8 a or the like or as software means 8 b for analyzing internal data within the controller or in the form of a combination of sensors and software means 8 b. The position monitoring means 8 are connected to the control unit 2 so that the latter is always notified at least of the locking position of each locking element 6 . The locking positions thus detected, in particular in the event when the locking position detected is not correct, can be saved together with the assignment to the respective locking element 6 in memory means 2 a. These memory means may be, for example, a part of the control unit 2 or a central controller.
[0018] In addition, a signal generator 10 connected to the control unit 2 is provided for signaling an incorrect locking state of at least one locking element 6 . A lock signal S can be generated via a key 12 to initiate a locking operation. The locking operation may take place by remote signal or manually. A system having a control unit 2 , an actuator 4 and locking signal means 8 is preferably assigned to each locking element 6 . The individual control units 2 (door controllers) are each connected via a bus system to other controllers, in particular a central controller. Alternatively, the control units 2 may also be omitted and replaced by corresponding functions in a central controller.
[0019] FIG. 2 shows the time chart for a locking operation belonging to the diagram according to FIG. 1 . By initiating a locking operation, the lock signal S is generated for the period of time td 1 at point in time t 1 . Essentially simultaneously with that, a reading signal L is preferably also generated for period td 2 within the control unit 2 . With the descending flank of the reading signal L at point in time t 3 , the lock position of each locking element 6 is queried. To do so, the individual lock signals VE of the locking elements 6 are input.
[0020] In the event of proper locking of all locking elements 6 , each position monitoring means 8 will yield a corresponding lock signal VE 1 (here: high). For this case, the control unit 2 will supply a signal R 1 (here: low) which initiates an acknowledgment signal that cannot be perceived by the user. In the event one or more locking elements 6 is not locked properly, each position monitoring means 8 of an improperly locked locking element 6 will supply a lock signal VE 2 (here: low) corresponding to this state. Because of the lock signal VE 2 , an acknowledgment signal R 2 is generated at the point in time of the query (here: the falling flank of the reading signal L). The query of the lock states explained here is to be understood only as an example. For example, the additional reading signal L may be omitted and the query may be performed with the falling flank of the lock signal S. It is also conceivable for the query to be implemented entirely independently of the lock signal S. In this case, the query would be made with only a separate test signal of the lock state prevailing at that moment in the locking elements 6 and a check will be performed to determine whether this result matches the command received (saved) last (locking command—lock active/opening command—lock inactive).
[0021] FIG. 3 shows four different current characteristics over time for controlling an actuator 4 in the form of an electric motor.
[0022] The first current characteristic I 1 (t) represents the triggering current for the actuator 4 in a correct error-free locking operation of the locking element 6 triggered by the actuator 4 . The current characteristic of the triggering current for the actuator 4 generated in an error-free locking operation is divided into essentially three phases. In the first phase I, there is briefly an increased startup current at the start of operation of the engine, which then stabilizes at an operating current which is established in normal operation of the engine. In the second phase II, the running current that is set prevails during the entire operating phase of the engine. In the third phase III, the engine has reached its final position and nevertheless continues to receive a current supply without any change, so that it pulls a greatly increased current because of a greatly increased load (engine running on block). This current characteristic is very typical and is thus easy to monitor. Corresponding deviations in this characteristic are directly indicative of an error. The control means are preferably designed so that the type of error can be dedicated on the basis of the current characteristic detected.
[0023] The current characteristics I 2 , I 3 and I 4 represent current characteristics when the locking operations are not correct.
[0024] The second current characteristic I 2 (t) illustrates a locking operation in which the locking element 6 to be driven by the motor is blocked and therefore cannot move starting at the beginning of the motor triggering and thus the motor runs on block from the beginning, drawing a greatly increased square-wave current over the entire triggering time.
[0025] In the third current characteristic I 3 (t), the motor is mechanically separated from the locking element 6 because of a defect. The motor is thus running without load and therefore pulls a much lower current over the entire triggering time. Furthermore, the motor is not running on block toward the end of the triggering time, so there is also no characteristic current rise toward the end of the triggering time. Finally, the last diagram shows the current characteristic I 4 (t) with the motor electrically separated and the current characteristic I 4′ (t) with the motor electrically short-circuited. All definitive current characteristics differ significantly from the current characteristic for a correct locking operation of a locking element 6 , so that by simple query of current values at previously defined points in time, it is possible to deduce the occurrence of a defective locking operation and the type of error or defect that has occurred. In particular, a conclusion regarding the existence of a correct or incorrect locking operation can be derived by a query of the current values for the triggering current in the peak times of the startup current (phase I) and the blocking current (phase III) as well as a query of the running current preferably in the middle range of phase II—and if there has been an incorrect locking operation, a conclusion can also be reached regarding the type of error that has occurred.
[0026] The foregoing disclosure has been set forth merely to illustrate the invention and is not intended to be limiting. Since modifications of the disclosed embodiments incorporating the spirit and substance of the invention may occur to persons skilled in the art, the invention should be construed to include everything within the scope of the appended claims and equivalents thereof.
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A position monitoring means for detecting the locked position of a locking element is assigned to at least one locking element. Furthermore, each position monitoring means is operatively connected to a control means for checking on whether a proper locked state prevails such that the actual state and the setpoint state of the locking element are comparable so that if these states do not correspond, an acknowledgment signal can be generated. In this way, it is possible to check on whether all the doors and hatches of a vehicle are properly locked after a locking operation has been performed.
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