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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to a display device using a light modulator and, more particularly, to a display device using a light modulator and having an improved numerical aperture of an after-edge lens system, in which the numerical aperture of the lens system, which is used to focus diffracted light beams having + and − orders that are formed by the light modulator, is significantly reduced.
2. Description of the Related Art
With the development of micro technology, so-called Micro-Electro-Mechanical System (MEMS) devices and small-sized apparatuses into which MEMS devices are assembled are attracting attention.
An MEMS device constitutes a microstructure on a substrate, such as a silicon substrate or glass substrate, and is a device that is formed by electrically and mechanically connecting a driving body for outputting mechanical driving force to a semiconductor integrated circuit for controlling the driving body. A basic feature of the MEMS device is that the driving body having a mechanical structure is placed in a portion of the MEMS device. The driving body is electrically operated using Coulomb's force generated between electrodes.
FIGS. 1 and 2 show a representative construction of an optical MEMS device that uses the reflection or diffraction of light and is applied to an optical switch and an optical modulation element.
An optical MEMS device 1 shown in FIG. 1 includes a substrate 2 , a substrate-side electrode 3 formed on the substrate 2 , a crossbeam 6 provided with a driving-side electrode 4 that is disposed parallel to the substrate-side electrode 3 , and a support 7 configured to support one end of the crossbeam 6 . The crossbeam 6 and the substrate-side electrode 3 are electrically insulated from each other by an aperture 8 therebetween.
The substrate 2 may be formed of a substrate in which an insulation film is formed on a semiconductor substrate such as a silicon (Si) or gallium arsenide (GaAs) substrate, or an insulation substrate such as a glass substrate. The substrate-side electrode 3 may be formed of a poly-crystal silicon film doped with an impurity, or a metallic film such as a Cr deposition film. The crossbeam 6 includes an insulation film 5 such as a silicon nitride film (SiN film), and a driving-side electrode 4 composed of, for example, an aluminum (AL) film that is formed on the insulation film 5 to have a film thickness of about 100 nm, and that is adapted to also function as a reflective film. The crossbeam 6 is mounted in a cantilever manner such that only one end thereof is supported by the support 7 .
In the optical MEMS device 1 , the crossbeam 6 is displaced by electrostatic attraction or electrostatic repulsion that is generated between the crossbeam 6 and the substrate-side electrode 3 by voltage applied to the substrate-side electrode 3 and the driving-side electrode 4 . For example, the crossbeam 6 is displaced between an equilibrium state and a tilt state with respect to the substrate-side electrode 3 , as shown in the solid and dotted lines of FIG. 1 .
Another optical MEMS device 11 shown in FIG. 2 includes a substrate 12 , a substrate-side electrode 13 formed on the substrate 12 , and a beam 14 formed across the substrate-side electrode 13 in the form of a bridge. The crossbeam 14 and the substrate-side electrode 13 are electrically insulated from each other by an aperture 10 that is positioned therebetween.
The crossbeam 14 includes a bridge member 15 formed on the substrate 12 across the substrate-side electrode 13 in the form of a bridge and formed of, for example, an SiN film, and a driving-side electrode 16 formed on the bridge member 15 parallel to the substrate-side electrode 13 , adapted to serve as a reflective film, and formed of, for example, an Al film having a film thickness of about 100 nm. The substrate 12 , the substrate-side electrode 13 and the crossbeam 14 may have the same construction and material as described in conjunction with FIG. 1 . The crossbeam 14 is mounted in a so-called cantilever manner such that only one end thereof is supported by the support 7 .
In this optical MEMS device 11 , the crossbeam 14 is displaced by electrostatic attraction or repulsion that is generated between the MEMS device and the substrate-side electrode 13 by voltage applied to the substrate-side electrode 13 and the driving-side electrode 16 . For example, the crossbeam 6 can be displaced between an equilibrium state and a concave state with respect to the substrate-side electrode 3 , as shown by the solid and dotted lines of FIG. 2 .
The optical MEMS devices 1 and 11 can be applied as an optical switch having a switch function, in which, when light is radiated onto the surface of each of the driving-side electrodes 4 and 16 also serving as optical reflective films, reflected light is detected in one direction based on the fact that the reflection direction of light varies depending upon the driving position of the crossbeam 6 or 14 .
Furthermore, the optical MEMS devices 1 and 11 can be applied as an optical modulation element that modulates the intensity of light. In the case where the reflection of light is used, the intensity of light is modulated by vibrating the crossbeams 6 and 14 based on the amount of reflected light in one direction per unit time. The optical modulation element uses so-called time modulation.
In the case where the diffraction of light is used, an optical modulation element is formed by parallelly arranging a plurality of crossbeams 6 with respect to common substrate-side electrodes 3 and 13 , and the height of driving-side electrodes also serving as optical reflective films is changed by the approach and separation of an alternate crossbeam 6 or 14 to and from the common substrate-side electrodes 3 and 13 . The intensity of light, which is reflected by the driving-side electrodes, is then modulated via diffraction. This optical modulation element employs so-called spatial modulation.
FIG. 3A and FIG. 3B shows the construction of a Grating Light Valve (GLV) device that was developed by Silicon Light Machines (SLM) Corporation as an optical intensity conversion device for a laser display, i.e., a light modulator.
As shown in FIGS. 3A and 3B , in the GLV device 21 , a common substrate-side electrode 23 made of a high melting point metal, such as tungsten or titanium, and a nitride film thereof or a thin polysilicon film is formed on an insulation substrate 22 such as a glass substrate. A plurality of, in this example, six beams 24 ( 24 1 , 24 2 , 24 3 , 24 4 , 24 5 and 24 6 ) are formed parallel to each other across the substrate-side electrode 23 in the form of a bridge. The substrate-side electrodes 23 and the crossbeams 24 have the same construction as described in conjunction with FIG. 2 . That is, a crossbeam 24 is fabricated by forming a driving-side electrode 26 , which also serves as a reflective film and is made of an Al film having a thickness of about 100 nm, on the surface of a bridge member 25 that is parallel to the substrate-side electrode 23 and is formed of a SiN film.
A bridge member 25 and crossbeams 24 composed of the driving-side electrodes 26 and adapted to also serve as a reflective film constitute a part that is commonly called a ribbon.
The Al film used as the material of the driving-side electrodes 26 of the crossbeams 24 is a desired material for optical elements because (1) it can be formed relatively easily, (2) the wavelength dispersion of reflectance in a visible light region is small, (3) a natural Al oxide film created on the surface of an Al film serves as a protection film to protect a reflective surface.
Meanwhile, a SiN (silicon nitride) film constituting the bridge member 25 is a SiN film formed by a reduced pressure CVD method. The SiN film has physical properties, such as strength and a coefficient of elasticity, which are suitable for the mechanical driving of the bridge member 25 .
If a small voltage is applied between the substrate-side electrode 23 and the driving-side electrodes 26 also serving as the reflective film, the crossbeams 24 approach the substrate-side electrode 23 due to the above-described electrostatic phenomenon. If the application of the voltage is stopped, the crossbeams 24 return to their original state.
The GLV device 21 alternately changes the height of the driving-side electrode 26 also serving as the optical reflective film via the approach and separation operations of the crossbeams 24 with respect to the substrate-side electrodes 23 (i.e., the approach and separation operations of the crossbeams), and modulates the intensity of light, which is reflected from the driving-side electrodes 26 by diffraction (one optical spot is projected for all the six beams 24 ).
The dynamic characteristics of the crossbeams that are driven using electrostatic attraction and repulsion are mostly determined by the material properties of a SiN film formed by the CVD method. The Al film usually serves as a mirror.
FIG. 4 is a sectional view illustrating a depression-type diffractive light modulator using a piezoelectric material, which was developed by Samsung Electro-Mechanics.
Referring to FIG. 4 , the depression-type thin film piezoelectric light modulator developed by Samsung Electro-Mechanics includes a silicon substrate 40 and a plurality of elements 42 a to 42 n.
In this case, the elements 42 a to 42 n have uniform widths, are alternately arranged, and form the depression-type thin film piezoelectric light modulator. Alternatively, the elements 42 a to 42 n may be alternately arranged to have different widths and may form the depression-type thin film piezoelectric light modulator. Meanwhile, the elements 42 a to 42 n may be spaced apart from one another by regular intervals (each of the intervals is substantially identical to the width of the elements), in which case a micromirror layer formed on the entire top surface of the silicon substrate 40 diffracts incident light by reflecting the light.
The silicon substrate 40 has a depressed portion to provide an air gap to the elements 42 a to 42 n . An insulation layer 41 is deposited on the top surface of the silicon substrate 40 . The ends of the elements 42 a to 42 n are attached to both ends of the silicon substrate 40 beside the depressed portion.
The elements 42 a (although only the element 42 a is described herein, the remaining elements 42 b to 42 n have the same construction and operation) has a rod shape. The element 42 a includes a bottom support 43 a , the bottom surfaces of both ends of which are attached to both ends of the silicon substrate 40 beside the depressed portion of the silicon substrate 40 so that the center portion of the element 42 a can be spaced apart from the depressed portion of the silicon substrate 40 , and the center portion of which is located above the depressed portion of the silicon substrate 40 and can move perpendicularly.
The element 42 a further includes a bottom electrode layer 44 a formed on the left side of the bottom support 43 a and adapted to provide piezoelectric voltage, a piezoelectric material layer 45 a formed on the bottom electrode layer 44 a and adapted to contract and expand and, thus, generate perpendicular driving force when voltage is applied to both ends thereof, and a top electrode layer 46 a formed on the piezoelectric material layer 45 a and adapted to provide piezoelectric voltage to the piezoelectric material layer 45 a.
The element 42 a further includes a bottom electrode layer 44 a ′ formed on the right side of the bottom support 43 a and adapted to provide piezoelectric voltage, a piezoelectric material layer 45 a ′ formed on the bottom electrode layer 44 a ′ and adapted to contract and expand and, thus, generate perpendicular driving force when voltage is applied to both ends thereof, and a top electrode layer 46 a ′ formed on the piezoelectric material layer 45 a ′ and adapted to provide piezoelectric voltage to the piezoelectric material layer 45 a′.
Korean Pat. Appl. No. 2004-74875. filed Sep. 18. 2004, discloses a projection-type light modulator in detail, in addition to the depression-type light modulator described above.
FIG. 5 illustrates an example of an optical apparatus, which employs a GLV device, that is, an optical modulation device, using a MEMS device, or the piezoelectric diffractive light modulator made by Samsung Electro-Mechanics. In this example, a case where the optical apparatus is applied to a laser display is described.
A laser display 51 related to the example is used as a projector for a large screen, more particularly, a digital image projector, or as an image projection device for a computer.
As shown in FIG. 5 , the laser display 51 includes a laser light source 52 , a mirror 54 disposed opposite the laser light source 52 , an illumination optical system (lens group) 56 and a GLV device or a piezoelectric diffractive light modulator 58 that serves as an optical modulation element.
The laser display 51 further includes a mirror 60 for reflecting laser light the optical intensity of which is modulated by the GLV device or piezoelectric diffractive light modulator 58 , a projection lens 62 , a filter 64 , a diffuser 66 , a mirror 68 , a galvano scanner 70 , a projection optical system (lens group) 72 and a screen 74 .
In the conventional laser display 51 , laser light radiated from the laser light source 52 is incident on the GLV device or piezoelectric diffractive light modulator 58 through the mirror 54 from the illumination optical system 56 .
Further, the laser light is spatially modulated by being diffracted by the GLV device or piezoelectric diffractive light modulator 58 , reflected by the mirror 60 , and then separated by the projection lens 62 on a diffraction order basis. Thereafter, only signal components are extracted from the laser light by the filter 64 .
Thereafter, the laser spectrum of the image signal is reduced by the diffuser 66 , and spread over the space by the galvano scanner 68 synchronized with the image signal through the mirror 68 , and is then projected by the projection optical system 70 onto the screen 72 .
According to the prior art, if the distance between the diffraction gratings of the diffractive light modulator is shortened, the diffraction angle increase. As a result, the Numerical Aperture (NA) of the lens system located behind the projection lens increases.
FIG. 6A shows an example of a prior art optical system having a high diffraction angle. If the diffraction angle θ is large, the NA of the projection lens increases.
FIG. 6B is a view illustrating another example of a prior art optical system having a high diffraction angle. If the incidence angles of illumination beams are different but the diffraction angle θ is large, the NA of the projection lens increases, which is the same as in the embodiment of FIG. 6A . As described above, when the NA of the lens system, such as a projection lens, located behind the diffractive light modulator increases, there are many limitations in designing the laser display. Further, if the NA is large, there is great difficulty in designing a lens because F/# is low.
Moreover, light progressing toward the center of the after-edge lens system, such as the projection lens, forms a radical axis optical system, which improves the performance of the lens. However, the structures of FIGS. 6A and 6B are disadvantageous in that the central portion of the after-edge lens system is not used but the peripheral portion of the after-edge lens system is used, so that it is difficult to expect good performance.
SUMMARY OF THE INVENTION
Accordingly, the present invention has been made keeping in mind the above problems occurring in the prior art, and an object of the present invention is to provide a display device using a light modulator, in which the NA of a lens system, which is used to focus diffracted light beams having + and − orders that are formed by light modulators, is significantly reduced.
In order to accomplish the above object, the present invention provides a display device using a light modulator and having an improved numerical aperture (NA) of an after-edge lens system, including an illumination lens for converting light output from a light source into linear parallel light, and outputting the linear parallel light; a diffractive light modulator for producing diffracted light beams having a plurality of diffraction orders by modulating the linear parallel light incident from the illumination lens according to an external control signal; an NA improvement unit for causing + and − diffracted light beams of the diffracted light beams to come close to each other; a filter system for passing only some of the diffracted light beams having predetermined orders, therethrough; and a projection system for focusing the diffracted light beams onto an object and allowing the focused diffracted light to scan the object.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other objects, features and advantages of the present invention will be more clearly understood from the following detailed description taken in conjunction with the accompanying drawings, in which:
FIGS. 1 and 2 are views illustrating the representative constructions of optical MEMS devices that use the reflection or diffraction of light and are applied to an optical switch and an optical modulation element;
FIGS. 3A and 3B shows the construction of a GLV device that was developed by SLM Corporation as an optical intensity conversion device for a laser display, i.e., a light modulator;
FIG. 4 is a sectional view showing a depression-type diffractive light modulator using a piezoelectric material, which was developed by Samsung Electro-Mechanics;
FIG. 5 is a diagram showing an example of an optical apparatus, which employs a GLV device, that is, an optical modulation device, using a MEMS device, or the piezoelectric diffractive light modulator made by Samsung Electro-Mechanics;
FIG. 6A is a view illustrating an example of a conventional optical system having a high diffraction angle, and FIG. 6B is a view showing another example of the conventional optical system having a high diffraction angle;
FIG. 7 is a view showing the construction of a display device using a light modulator and having an improved NA of an after-edge lens system according to an embodiment of the present invention;
FIG. 8A˜8C is a view showing the path of light passed through an illumination lens of FIG. 7 ;
FIG. 9 is a view showing an embodiment of the diffractive light modulator of FIG. 7 ;
FIGS. 10A and 10B are views showing the diffraction angles of diffracted light beams generated by the diffractive light modulator;
FIG. 11 is a view illustrating an improvement in the NA and compensation for the difference between optical paths;
FIG. 12 is a view showing the path of light passed through the projection lens of FIG. 7 ; and
FIG. 13 is a front view showing the spatial filter of FIG. 7 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention is described in detail in connection with preferred embodiments with reference to FIGS. 7 to 13 below.
FIG. 7 is a view illustrating the construction of a display device using a light modulator and having an improved NA of an after-edge lens system according to an embodiment of the present invention.
Referring to FIG. 7 , the display device using the light modulator and having the improved NA of the after-edge lens system according to the embodiment of the present invention includes a light source 700 , an illumination lens 710 , a diffractive light modulator 720 , an optical path compensator 730 , a filter system 740 , a projection system 750 and a screen 760 .
A light source fabricated using a semiconductor, such as a Light Emitting Diode (LED) or Laser Diode (LD), may be used as the light source 700 .
A cross section of the light sources 700 is shown in “A” of FIG. 8A˜8C . Referring to “A” of FIG. 8A˜8C , the cross section of the light source 700 is circular, and the intensity profile of the light beam has Gaussian distribution as shown in “B” of FIG. 8A˜8C .
The illumination lens 710 converts incident light into linear parallel light having an elliptical cross section. The illumination lens 710 includes a cylinder lens 711 and a collimator lens 712 .
That is, the illumination lens 710 converts a light beam, which is radiated from the light source 700 , into linear light coplanar with optical paths, and then focuses it on a diffractive light modulator 720 , which will be described later.
In this case, the cylinder lens 711 converts the parallel light, which is radiated from the light source 700 , into linear light shown in “C” of FIG. 8A-8C , and then allow the linear light to be incident on the diffractive light modulator 720 through the collimator lens 712 .
In this case, the collimator lens 712 converts spherical light, which is radiated from the light source 700 through the cylinder lens 711 , into parallel light, and then allows it to be incident on the diffractive light modulator 720 .
The collimator lens 712 includes a concave lens 712 a and a convex lens 712 b , as shown in FIG. 8A˜8C .
The concave lens 712 a perpendicularly spreads linear light incident from the cylinder lens 711 , as shown in “D” of FIG. 8A˜8C , and then allows it to be incident on the convex lens 712 b . The convex lens 712 b converts the light beam incident from the concave lens 712 a into parallel light, as shown in “E” of FIG. 8A , and then outputs the parallel light. FIG. 8A is a perspective view illustrating an optical system including a light source, a cylinder lens and a collimator lens, FIG. 8B is a plan view of FIG. 8A , FIG. 8C is a side sectional view of FIG. 8A .
The diffractive light modulator 720 diffracts incident light to output diffracted light having a plurality of diffraction orders. The filter system 740 passes some of diffracted light beams having desired orders through the projection system 750 .
An example of the diffractive light modulator 720 is shown in FIG. 9 .
Referring to FIG. 9 , the diffractive light modulator according to the embodiment of the present invention includes a silicon substrate 901 , an insulation layer 902 , a lower micro mirror 903 , and a plurality of elements 910 a to 910 n . Although, in the present embodiment, the insulation layer and the lower micro mirror are separately constructed, the insulation layer itself can function as the lower micro mirror if it has a light-reflecting characteristic.
The silicon substrate 901 is provided with a depressed portion to provide air spaces to the elements 910 a to 910 n . The insulation layer 902 is formed on the silicon substrate 901 . The lower micro mirror 903 is deposited on the insulation layer 902 above the depressed portion of the silicon substrate 901 . The bottoms of the elements 910 a to 910 n are attached to both sides of the insulation layer 902 beside the depressed portion of the silicon substrate 901 . The silicon substrate 901 can be fabricated of a single material such as Si, Al 2 O 3 , ZrO 2 , quartz or SiO 2 . The upper and lower layers (divided by dotted lines in the drawing) of the silicon substrate 901 can be fabricated of heterogeneous materials.
The lower micro mirror 903 is deposited above the silicon substrate 901 , and diffracts incident light by reflecting it. The lower micro mirror 903 can be fabricated of a metallic material such as Al, Pt, Cr or Ag.
The element 910 a (although only the element 910 a is described herein, the remaining elements have the same construction and operation) has a ribbon shape. The element 910 a includes a lower support 911 a , both sides of the bottom of which are attached to both sides of the insulation layer 902 beside the depressed portion of the silicon substrate 901 , so that the central portion of the lower support 911 a is spaced apart from the depressed portion of the silicon substrate 901 .
Piezoelectric layers 920 a and 920 a ′ are formed on both sides of the lower support 911 a . Driving force is provided to the element 910 a by the contraction and expansion of the piezoelectric layers 920 a and 920 a′.
The lower support 911 a may be fabricated of Si oxide such as SiO 2 , Si nitride such as Si 3 N 4 , a ceramic substrate such as Si, ZrO 2 and Al 2 O 3 , and Si carbide. However, the lower support 911 a may be omitted when necessary.
Each of the piezoelectric layers 920 a and 920 a ′ includes lower electrode layers 921 a and 921 a ′ configured to provide a piezoelectric voltage, piezoelectric material layers 922 a and 922 a ′ formed on the lower electrode layers 921 a and 921 a ′ and configured to contract and expand and generate vertical driving force when voltages are applied to both surfaces thereof, and upper electrode layers 923 a and 923 a ′ formed on the piezoelectric material layers 922 a and 922 a ′ and configured to provide a piezoelectric voltage to the piezoelectric material layers 922 a and 922 a ′. When voltage is applied to the upper electrode layers 923 a and 923 a ′ and the lower electrode layers 921 a and 921 a ′, the piezoelectric material layers 922 a and 922 a ′ contract and expand, thus causing vertical movement of the lower support 911 a.
The electrodes 921 a , 921 a ′, 923 a and 923 a ′ may be fabricated of a material such as Pt, Ta/Pt, Ni, Au, Al or RuO 2 , and may be deposited by sputtering or evaporation to have a thickness within a range of 0.01 to 3 μm.
Meanwhile, an upper micro mirror 930 is deposited on the center portion of the top of the lower support 911 a , and includes a plurality of open holes 931 a 1 to 931 a 3 . In this case, the open holes 931 a 1 to 931 a 3 preferably have a rectangular shape, but may have any closed curve shape such as a circle or an ellipse. When the lower support 911 a is fabricated of a light-reflective material, the upper micro mirror 930 is not necessary. In this case, the lower support 911 a may function as the upper micro mirror.
The open holes 931 a 1 to 931 a 3 pass light incident on the element 910 a therethrough, and allow the light to be incident on the portion of the lower micro mirror 903 corresponding to the portion where the open holes 931 a 1 to 931 a 3 are formed, so that the lower micro mirror 903 and the upper micro mirror 930 can form a pixel.
That is, for example, the portion “A” of the upper micro mirror 930 where the open holes 931 a 1 to 931 a 3 are formed, and the portion “B” of the lower micro mirror 903 can form a single pixel.
In this case, the incident light, which passes through the portion where the open holes 931 a 1 to 931 a 3 of the upper micro mirror 930 are formed, can be incident on the corresponding portion of the lower micro mirror 903 . When the distance between the upper micro mirror 930 and the lower micro mirror 903 is an odd multiple of λ/4, maximally diffracted light is produced. In addition, an open hole-type diffractive light modulator applicable to the present invention is disclosed in Korean Pat. Appl. No. 2004-030199.
Meanwhile, the diffractive light modulator 720 forms diffracted light by diffracting linear light incident from the illumination lens 710 , and cause the diffracted light to be incident on the filter system 740 .
In this case, +1-order diffracted light and −1-order diffracted light, which are formed when the linear light incident from the illumination lens 710 is perpendicularly incident on the diffractive light modulator 720 , are shown in FIGS. 10A and 10B .
FIG. 10A shows that, when incident light is perpendicularly incident, the +1-order diffracted light and the −1-order diffracted light are formed in both directions. An angle θ that is formed with respect to the incident light is proportional to the wavelength. That is, the longer the wavelength, the larger the angle θ.
FIG. 10B shows +1-order linear diffracted light and −1-order linear diffracted light, which are formed when linear parallel light is incident on the diffractive light modulator, in three dimensions.
Meanwhile, the filter system 740 includes a pair of NA improvement mirrors 741 a and 741 b , a projection lens 742 and a spatial filter 743 .
In this case, the NA improvement mirrors 741 a and 741 b have are independent of each other and have different reflection angles, and reflect incident diffracted light having corresponding diffraction orders. That is, the NA improvement mirror 741 a reflects +1-order diffracted light, and the NA improvement mirror 741 b reflects −1-order diffracted light. In this case, the NA improvement mirror 741 a and 741 b have different reflection angles, so that, if the +1-order diffracted light and the −1-order diffracted light can be converged as shown in FIG. 11 , the NA of the projection lens 742 can be improved and, thus, a lens having a low NA can be used. From FIG. 11 , it can be understood that the NA improvement mirrors 741 a and 741 b are independent of each other and have different reflection angles. The reflection angle of the NA improvement mirror 741 a is greater than that of the NA improvement mirror 741 b.
Furthermore, from FIG. 11 , it can be understood that optical paths “a” and “b” along which the diffracted light formed by the diffractive light modulator 720 progresses toward the NA improvement mirrors 741 a and 741 b are the same.
However, it can be understood that the +1-order diffracted light reflected from the NA improvement mirror 741 a and the −1-order diffracted light reflected from the NA improvement mirror 741 b have a difference “c” in their optical paths. That is, it can be understood that there occurs a path difference c of S′−S″ in the drawing. This difference between the optical paths may not influence the application of the display device using the light modulator and having the improved NA, which can be solved by locating an optical path compensator on the optical path of the −1-order diffracted light.
In this case, the optical path compensator can be made of a material whose refractive index is not 1. Glass through which light can be transmitted may be used as the material of the optical path compensator.
If a compensation medium is used as the optical path compensator, the length of a compensated optical path can be usually determined by the following Equation 1 when the refractive index of the compensation medium is N and the thickness of the compensation medium is t.
Δ=( N− 1)* t (1)
The projection lens separates incident diffracted light beams on an order basis, and then converges the light beams. The spatial filter 743 has spatially separated slits, and, therefore, can transmit only diffracted light beams having desired orders.
In this case, the projection lens 742 focuses the light beams output from the NA improvement mirrors 741 a and 741 b , as shown in FIG. 12 . The +1-order diffracted light is focused on a location above a location on the 0-order diffracted light is focused, and the −1-order diffracted light is focused on a location below the location on which the 0-order diffracted light is focused. If the slits of the spatial filter 743 are located near the focal points, only diffracted light having desired orders can be transmitted through the spatial filter 743 . As shown in FIG. 13 showing the front view of the spatial filter 743 , the location of the focal point of the +1-order diffracted light and the location of the focal point of the −1-order diffracted light are different. Thus, the +1-order diffracted light and the −1-order diffracted light can be separated using the spatial filter 743 .
The projection system 750 projects incident diffracted light onto the screen 760 . That is, the projection system 750 serves to focus diffracted beams having predetermined diffraction coefficients, which are incident through the spatial filter 743 , onto the screen 760 , thus forming a spot. In detail, the projection system 750 includes a projection lens 751 and a galvano mirror 752 .
The projection lens 751 serves to focus the +1-order diffracted light and the −1-order diffracted light. The galvano mirror 752 serves to allow the beam to scan the screen 760 .
As described above, in accordance with the present invention, an increase in the NA of a lens is not required even when a diffraction angle increases, so that the present invention is advantageous in that an optical system can be easily designed.
Further, in accordance with the present invention, + order diffracted light and − order diffracted light can be converged, so that a radical axis optical system can be designed, thus improving the performance of a lens.
Although the preferred embodiments of the present invention have been disclosed for illustrative purposes, those skilled in the art will appreciate that various modifications, additions and substitutions are possible, without departing from the scope and spirit of the invention as disclosed in the accompanying claims.
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A display device using a light modulator and having an improved numerical aperture (NA) of an after-edge lens system is disclosed. The display device includes an illumination lens, a diffractive light modulator, an NA improvement unit, a filter system and a projection system. The illumination lens converts light into linear parallel light, and outputs the linear parallel light. The diffractive light modulator produces diffracted light beams having a plurality of diffraction orders by modulating the linear parallel light incident from the illumination lens according to an external control signal. The NA improvement unit causes + and − diffracted light beams of the diffracted light beams to come close to each other. The filter system passes only some of the diffracted light beams having predetermined orders, therethrough. The projection system focuses the diffracted light beams onto an object and allows the focused diffracted light to scan the object.
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RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Patent Application Ser. No. 61/838,930, filed Jun. 25, 2013, which is hereby incorporated by reference in its entirety.
BACKGROUND
[0002] 1. Field of the Invention
[0003] This invention relates to painting and, more particularly, to novel systems and methods for lighting a work area for a paintbrush during a cutting-in operation.
[0004] 2. Background Art
[0005] For residential and commercial painting of interior surfaces, boundaries are the most difficult and time consuming. For example, a window may have a stained wood color, as to the seal and frame, while the surrounding wall is painted a particular color of the room. Although masking is possible, many commercial painters will simply “cut-in” along a boundary line, such as an internal corner, external corner, boundary line, or the like.
[0006] Cutting-in is the process of pressing the bristles of a paintbrush sideways flat against a surface being painted, while bending the handle toward a more perpendicular position with respect to the wall, thus spreading out the bristles to form a very thin edge at the far extreme. By drawing the brush with that line along the boundary, one may precisely position a difference in paint color while drawing the brush and depositing paint.
[0007] Cutting-in may be used around frames of doors, frames of windows, crown moldings, baseboards, internal corners, fixtures and attachments in walls, HVAC inlets and outlets, and the like. Thus, in a room, a significant number of regions may exist that require cutting-in by a painter.
[0008] Unfortunately, light is a perennial problem. Even in daylight, or room lighting system light, and even with specialized flood lighting set up by a painter, light is a problem. The specific problem is that a painter is close to a brush, the brush is against the wall, and everything culminates at the wall on the edge of the brush as painting continues. However, all light is typically on the opposite side of the painter from the brush.
[0009] Even with excellent illumination, the speed, change of position, and so forth render a shadow in the area of a brush repeatedly. Thus, even if the light is excellent at one moment, a few moments later shadows may intervene. Shadows inhibit an ability to see clearly changes in color and the exact location of paint deposits. Moreover, bright working lights result in reflections from a wall, which tend to close down the pupils of a painter. Accordingly, having adjusted to increased ambient light, the eyes can no longer properly distinguish the fine distinctions in the shadowed region near the tip of the brush.
[0010] What is needed is a localized illumination system and method for a paintbrush during close operations, where sight, color, and precision are required.
BRIEF SUMMARY OF THE INVENTION
[0011] In view of the foregoing, in accordance with the invention as embodied and broadly described herein, a method and apparatus are disclosed in one embodiment of the present invention as including a securement mechanism, a standoff, and a light assembly that secured to a ferrule of a brush, or nearby, such as on a ferrule, in order to readily aim light and illuminate the edge of a paintbrush during cutting-in processes.
[0012] In certain embodiments, the securement mechanism may be selected from hook-and-loop fasteners, a ball and socket type of snap, any other type of snap, various shapes, sizes, and thicknesses of magnets, simple doubly adhesive spacer materials, or a spacing material containing adhesive on of at least two sides, or the like may act like a securement. Meanwhile, the size, or an additional spacer may be selected in order to stand a light assembly some distance off the ferrule of the brush and thereby provide a central axis of light that is offset from an outer surface of the brush in its undisturbed state.
[0013] For example, when the bristles of a brush are bent and drawn to a thin edge, the heel of the brush and handle necessarily aim at a location different from that edge. Accordingly, a standoff permits the light to be centered, or in least include or illuminate the edge where precision and good eyesight is best assisted by the additional illumination.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] The foregoing features of the present invention will become more fully apparent from the following description and appended claims, taken in conjunction with the accompanying drawings. Understanding that these drawings depict only typical embodiments of the invention and are, therefore, not to be considered limiting of its scope, the invention will be described with additional specificity and detail through use of the accompanying drawings in which:
[0015] FIG. 1 is a perspective view of one embodiment of a system for implementing an apparatus and method in accordance with the invention, including a brush, with the bristles in an undisturbed orientation, and a lighting assembly secured at a specific standoff distance to the ferrule;
[0016] FIG. 2 is a perspective view of the system of FIG. 1 , illustrating alternative embodiments of particular components, such as the lighting assembly housing, the standoff, securement mechanisms, batteries, and so forth;
[0017] FIG. 3 is a perspective view of the brush of FIGS. 1 and 2 with a lighting assembly in one embodiment, illustrating the bristles deformed into the fine edge required for cutting-in, and that edge illuminated by a lighting system in accordance with the invention;
[0018] FIG. 4 is a schematic block diagram of one embodiment of a process and method for implementing an apparatus as illustrated in FIGS. 1 through 3 ;
[0019] FIG. 5A is a frontal perspective view of an alternative embodiment to the apparatus of FIGS. 1 through 3 ;
[0020] FIG. 5B is a rear perspective view thereof;
[0021] FIG. 5C is a top plan view thereof;
[0022] FIG. 5D is a bottom plan view thereof;
[0023] FIG. 5E is a front elevation view thereof;
[0024] FIG. 5F is a rear elevation view thereof;
[0025] FIG. 5G is a left side elevation view thereof;
[0026] FIG. 5H is a right side elevation view thereof;
[0027] FIG. 6A is a frontal perspective view of an alternative embodiment of a painting light system in accordance with the invention;
[0028] FIG. 6B is a rear perspective view thereof;
[0029] FIG. 6C is a top plan view thereof;
[0030] FIG. 6D is a bottom plan view thereof;
[0031] FIG. 6E is a front elevation view thereof;
[0032] FIG. 6F is a rear elevation view thereof;
[0033] FIG. 6G is a left side elevation view thereof;
[0034] FIG. 6H is a right side elevation view thereof;
[0035] FIG. 7A is a frontal perspective view of an alternative embodiment of a painting light in accordance with the invention;
[0036] FIG. 7B is a rear perspective view thereof;
[0037] FIG. 7C is a top plan view thereof;
[0038] FIG. 7D is a bottom plan view thereof;
[0039] FIG. 7E is a front elevation view thereof;
[0040] FIG. 7F is a rear elevation view thereof;
[0041] FIG. 7G is a left side elevation view thereof; and
[0042] FIG. 7H is a right side elevation view thereof.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0043] It will be readily understood that the components of the present invention, as generally described and illustrated in the drawings herein, could be arranged and designed in a wide variety of different configurations. Thus, the following more detailed description of the embodiments of the system and method of the present invention, as represented in the drawings, is not intended to limit the scope of the invention, as claimed, but is merely representative of various embodiments of the invention. The illustrated embodiments of the invention will be best understood by reference to the drawings, wherein like parts are designated by like numerals throughout.
[0044] Referring to FIG. 1 , while referring generally to FIGS. 1 through 4 , an apparatus 10 in accordance with the invention may include a paintbrush 11 provided with a light assembly 12 . In the illustrated embodiment, a paintbrush may be of any particular type, but is most applicable for the invention if it contains bristle or individual fibers. The light assembly 12 may be secured to the paintbrush 11 by any of several methods discussed hereinbelow.
[0045] The light assembly 12 may be comprised of a holder 14 or standoff 14 . In reality, the assembly 14 may act as a securement 14 and as s standoff mechanism 14 . For example, it has been found useful the light assembly 12 away from the paintbrush 11 a distance selected to optimize illumination at the tip of the working end of the brush 11 .
[0046] It has been found that having the central axis of the beam of light emanating from the light assembly 12 nearby and parallel to an outer surface of the brush 11 illuminates the brush, but not the space being cut-in. That is, in the cutting-in operation, the brush is bent intentionally to thin the bristles down to a fine edge, and spread them out. Thus, the sweep or area of coverage of the light assembly 12 is most effective when it extends a distance beside the brush, thus capturing the exact line formed by the edge of the brush 11 during a cutting-in operation.
[0047] In the illustrated embodiment, the light assembly 12 includes a housing 16 secured by the holder 14 and positioned away from the standoff 14 . Thus, the housing 16 may be thought of as the structural mechanics, while the holder 14 and standoff 14 may be integrated into a single element, such as a magnet secured to a brush 11 forward (toward the paint-containing, toe or application end) of the brush 11 . Thus, a handle 18 may have a narrower portion for holding, and may extend toward a wider part 17 of the handle 18 , which then engages the ferrule 20 .
[0048] The ferrule 20 is effectively a band 20 , typically of metal, and most typically of steel, capturing and securing the bristles 22 near the heel 19 of the brush 11 . The region of bristles 22 just outside the ferrule 20 is referred to as the heel 19 , and typically holds no quantity of paint. Good painting technique fills the toe portion with paint, always leaving the heel dry.
[0049] As a practical matter, bristles 22 may be synthetic or natural. Actual bristle is an animal product. However, many modern brushes are formed with thin filaments of nylon, polyester, or other appropriate polymeric materials.
[0050] Between the bristles 22 is maintained a quantity of paint by virtue of capillary action. Surface tension maintains the paint within the bristles 22 . Surface tension between the paint on the work piece and paint in the toe 21 or the extreme distal end 21 of the bristles 22 tends to draw more paint out of the bristles 22 toward the handle 18 , such as within the ferrule 20 .
[0051] Referring to FIG. 2 , while continuing to refer generally to FIGS. 1 through 4 , a bulb 24 may be set in the housing 16 in order to illuminate an edge of the bristles 22 . A variety of housing 16 types and standoff spacer 14 mechanisms may be implemented in various embodiments of the invention.
[0052] As a practical matter, the bristles 22 at the toe 21 are formed into a thin, sharp edge 23 by laying a flat aspect of the bristles 22 or the bundle of bristles 22 against the wall 54 , and then pivoting the handle 18 around the heel 19 in order to spread the bristles 22 in two dimensions. That is, the bristles 22 closest to the wall are drawn back away from the edge 23 by bending the entire bundle, thus leaving fewer bristles 22 at the edge 23 . Thus, by bending the bristles 22 , the edge 23 is formed by the few bristles 22 that are closest to the line where paint will be cut-in. Meanwhile, the bristles 22 are accordingly distorted or deformed, being bent to one side.
[0053] In FIG. 3 , if the wall were on the left side of the brush 11 , then the bristles 22 would be bent from the heel 19 to the right. Meanwhile, the bristles 22 along the edge 23 would also deflect or deform upward as the brush 11 is drawn downward.
[0054] The bulb 24 may be offset by the holder 14 or standoff 14 a distance away from the ferrule 20 , typically by being attached by a magnet to the ferrule 20 . Accordingly, the center line of the illumination by the bulb 24 will typically include the edge 23 of the bristles 22 .
[0055] In the illustrated embodiment, various options are illustrated for the holder 14 and standoff spacer 14 , the housing 16 , and so forth. For example, the housing 16 may be made in a shape suitable for a type AA battery, a pair of type AAA batteries, a watch type or flat disc-like battery, or the like. Thus, the different shapes illustrated show how various types of batteries may be encased in housings 16 adapted thereto. The housing 16 will encompass both the batteries 28 and the bulb 24 , it may be sized appropriate to the type of battery 28 being used.
[0056] Typically, the light 24 may be a light emitting diode (LED), or any suitable light source. As a practical matter, LED's require minimal energy for the available illumination and are a reasonable and efficient choice. However, various types of batteries 28 have wide ranging costs, sizes, current capacities, and so forth.
[0057] For example, larger batteries, single batteries, and the like may be preferable to the individual or stacked pancake (e.g., watch batteries) batteries illustrated. Likewise, the leads from the bulb 24 may pass through a switch 30 in order to turn the bulb 24 on and off. That is, power from the battery 28 is passed through an open circuit or to a closed circuit by the opening and closing of the switch 30 .
[0058] In the illustrated embodiment, the securement mechanism 14 , alternatively referred to as a holder 14 or a standoff 14 has several characteristics. Thus, it is a multi-functional device. In some embodiments, a magnet may be glued to the housing 16 , and serve completely adequately. In other embodiments, permanent or temporary fastening mechanisms 14 may be used.
[0059] For example, in the illustrated embodiment, an adhesive layer 32 may be bonded to a spacer 34 . Meanwhile, if these represent the entire mechanism 14 or securement mechanism 14 , then only a limited number of attachments and detachments will be possible. By contrast, a magnet in a bar shape, disc shape, or rectangular block shape as illustrated may serve as the holder 14 , by simply adhering to the ferrous material of which the ferrule 20 is made. Thus, a single, double-sided adhesive tape (e.g., plastic foam, double-stick tape) may secure such a magnet serving as a standoff spacer 14 to the housing 16 , thus securing the light assembly 12 .
[0060] In alternative embodiments, a snap socket 36 may have a face, which may be shaped flat, tapered, such as for piloting, or the like. The snap socket 36 may have an aperture 40 through the face 38 . Typically, a ball 42 or other shape, such as a circular snap 42 or the like, may fit into the aperture 40 by an interference fit. The interference fit thus gives a grip holding the ball 42 or male snap portion 42 securely to the female socket portion 36 .
[0061] The base 44 or trunnion 44 may be secured in any suitable way, such as gluing to a brush 11 , fastening, threading, or any other suitable adhesive method. Typically, the surface area of the trunnion 44 may be considerably greater than that required for the snap ball 42 or the aperture 40 . Thus, lower stress requirements will result. For example, a greater surface area provides that adhesion will persist even against greater forces due to the addition of distribution of stress at the adhesive boundary between the trunnion 44 and ferrule 20 or other portion of the handle 11 .
[0062] In one embodiment, a hook material 46 may be selectively separable from a loop material 48 such as is available in the Velcro™ brand hook-and-loop fastener or similar product. Thus, the two materials 46 , 48 combine to form a hook-and-loop fastener 50 . By adhering one portion of the fastener 50 to the ferrule 20 , the other portion thereof may be selectively separable at will. In the illustrated embodiment, an exploded view thereof illustrates how an adhesive layer 32 may bond a spacer 34 against the ferrule 20 . Meanwhile, another adhesive layer 32 may be placed between the loop material 48 and the spacer 34 . Alternatively, these may be glued together by an adhesive smeared on a surface of the spacer 34 , the loop material 48 , or both.
[0063] The hook material 46 that forms the other half of the fastener 50 may also be adhered by an adhesive layer 32 to the housing 16 of the light assembly 12 . Meanwhile, the hook-and-loop fastener 50 may be selectively separable in order to remove, replace, service, aim, or otherwise manipulate the light assembly 12 , its position, or components.
[0064] Referring to FIG. 3 , while continuing to refer generally to FIGS. 1 through 4 , in one embodiment of an apparatus 10 and method in accordance with the invention, a brush 11 may be used for cutting-in on a painted surface 54 by projecting light 52 onto that painted surface 54 . In the illustrated embodiment, the bristles 22 are deflected toward the right, and upward as typical of a brush 11 being drawn downward, while feathering or edging, as required for cutting-in.
[0065] In this embodiment, the offset 14 is responsible to space the light assembly 12 , and specifically to orient the housing 16 in order to both aim the light, and to secure the housing 16 to the ferrule 20 . Again, the central axis of the beam of light 52 need not be coincident with the edge 23 of the bristles 22 . In fact, so long as the circle of light 52 or other shape of light extends out (e.g., to the right side in the illustrated embodiment) of the edge 23 , then a user can see and detect the position of the edge 23 , and the color at the cut-in portion of the painted surface 54 .
[0066] Referring to FIG. 4 , in one embodiment of a method 58 in accordance with the invention, one may identify 60 the particular painting task to be undertaken. This will determine to a large extent the nature of a brush 11 that is selected 62 . Likewise, the thickness or the effective standoff distance of a holder 14 or securement mechanism 14 will depend, or may depend upon the length, thickness, and so forth of the bundle of bristles 22 in the brush 11 . Thus, one may select 64 a light assembly 12 of suitable size, intensity, like type, beam spread, and so forth.
[0067] In certain embodiments, the housing 16 may include lenses, focus materials, movable portions, or the like in order to better aim the light 52 emanating from the bulb 24 . In other embodiments, the securement mechanism 14 operating as a standoff 14 may be general enough to capture the edge 23 of the bristles 22 in its projected light 52 within a sufficiently broad circle or other shape for virtually any cutting-in and distortions associated therewith.
[0068] Upon selecting 64 a particular light assembly 12 , one may secure 66 the light assembly 12 by means of the holder 14 against a location on the ferrule 20 19 of the brush 11 . Typically, that location will be on the ferrule 20 . This is a convenience because the ferrule 20 is typically made of a high-stress metal, which will often be a ferrous metal. Thus, typically, a ferrule 20 may be magnetic metal, and will receive and hold a magnet 14 as the holder 14 .
[0069] Securing 66 the light assembly 12 might be as simple as setting a magnet 14 of the light assembly 12 against the ferrule 20 , where it will be held by magnetic attraction. In other embodiments, such as those illustrated hereinabove, securement 66 may be temporary, permanent, or a combination. Similarly, it may easily removable, removable with difficulty, positionable without removal, or the like.
[0070] For example, a ball 42 type of securement mechanism 14 may be rotated and pivoted if the face 38 is tapered to provide a range of motion. By contrast, a hook-and-loop type of fastener 50 will have to be removed and re-secured to change in any direction.
[0071] Once the light assembly 12 is in place and properly aiming 74 the light 52 (beam on the lighted region), one may dip 68 the bristles 22 into a source or supply of paint in order to load the bristles 22 by capillary action with paint. Now, the brush 11 is ready to apply 70 the paint to the working surface 54 . As the application 70 of paint to the working surface 54 or painted surface 54 continues, the brush may or may not be positioned for cutting-in. At a time that cutting-in is required, the bending 72 of the bristles 22 will effectively form the edge 23 as described hereinabove. Thus, bending 72 may be thought of as forming 72 the edge 23 required for cutting-in.
[0072] At this point, one may choose to check 74 or adjust 74 , aim 74 , or otherwise correct 74 the light assembly 12 . Typically, the bulb 24 may be positioned in fixed relation to the housing 16 , thus requiring a movement of the entire light assembly 12 in order to provide aiming. By whichever means, one may adjust 74 by a combination of checking, removing, rotating, or otherwise aiming 74 the bulb 24 in order to create the proper region of light 52 illuminating the edge 23 of the bristles 22 .
[0073] As cutting-in 76 proceeds, one may check, by the light of the bulb 24 , to determine that the paint is sufficiently thorough, provides the coverage, opacity, and so forth required. Similarly, the edge 23 of the line of paint on the painted surface 54 may be deemed completed. Thus, once the test 78 determines that the cutting-in 76 has not been done, and a negative response to the test 78 returns the process to dipping 68 , and further applying 70 , and so forth. Nevertheless, a positive or affirmative response to the test 78 indicates that the cutting-in 76 is done. Accordingly, the cutting-in 76 comes to an end 80 . Nevertheless, portions of the process 58 may continue as other portions are painted where cutting-in 76 is not required.
[0074] Referring to FIGS. 5A through 5D , in an alternative embodiment of a design for an apparatus 10 in accordance with the invention, a securement 14 may operate as a stand off 14 as described hereinabove. In this embodiment, the housing 16 has a different aspect ratio of width to height above the surface of the ferrule 20 of the brush 11 . In this instance, the light 24 is replaced by three lights 24 , such as LED (light emitting diode) bulbs 24 , or the like.
[0075] In this embodiment, the switch 30 as well as the securement 14 are showed in broken lines. This is because those items have been discussed in detail with respect to FIGS. 1 through 3 . Here, those elements are not necessary nor critical to all designs. For example, any suitable switch 30 may be substituted. Likewise, any suitable securement 14 discussed hereinabove may be suitable.
[0076] For example, with respect to the illustrations of FIG. 2 , the several different embodiments of a housing 16 may be the approximately rectangular one that is illustrated in FIGS. 1 through 3 . Alternatively, as illustrated in FIG. 2 , and proceeding clockwise from the exploded view therein, one embodiment may simply be represented as a housing 16 shaped to hold two cylindrical batteries and a having a head containing the light 24 . That configuration or embodiment looks the same from either side, and a switch, an opening, or the like may be added to the design.
[0077] Similarly, proceeding clockwise through the next design, which has something of a shield shape, such an apparatus may have a switch 30 and a securement 14 operating as a stand off 14 as described hereinabove, with a housing 16 shaped as illustrated. This embodiment looks the same from either side, and the front being a mirror image. In this embodiment, a row of LED's such as those illustrated in FIGS. 5A through 5H may be suitable. Likewise, this embodiment may be sufficiently thin that it serves best to use flat disc type batteries 28 , rather than conventional cylindrical batteries 28 , such as the common AAA batteries 28 readily available.
[0078] Likewise, moving clockwise to the last design of FIG. 2 , a simple cylinder having suitable openings for receiving a light, as well as for replacing a battery through the same opening or one at an opposite end, may receive a securement 14 on one side thereof, and a switch 30 at any suitable location.
[0079] Referring to FIGS. 5A through 5H , the housing 16 may have an indentation 84 , which may include knurling, ribbing, or another treatment to improve grip. Thus, if a hand is wet, gloved, or otherwise inhibited from providing direct contact or firm contact between the housing 16 and the hand of a user, the indent 84 and its associated grip feature or texture 86 may assist in maintaining a firm grip on the apparatus 10 .
[0080] One will note that the lights 24 are multiple in this, providing a comparatively low profile minimizing the moment (as the word is used in engineering parlance) or leverage. For example, if the apparatus 10 is bumped, then the lower profile tends to provide less leverage of such a touching of the housing 16 against the grip of the securement 14 fastened to the ferrule 20 or adhered to the ferrule 20 . Thus, the apparatus 10 will be more stable in use. Likewise, by having a lower profile, the dynamics of motion and force inherent in movement of a brush 11 equipped with the light assembly 12 will minimize the disruption or movement of the light assembly 12 , thus minimizing readjustments.
[0081] Referring to FIGS. 6A through 6H , an approximately rectangular embodiment of a light assembly 12 includes a separation 80 or parting line 80 that may be positioned at any suitable location, and in any suitable shape for changing out batteries 28 installed therein. In the illustrated embodiment, the bulb 24 is illustrated as a single bulb 24 , but may be replaced by multiple bulbs 24 , such as an array of LED's, or the like. In the illustrated embodiment, the light 24 is illustrated as represented by a single circle which may be appropriate for such a geometry. Here likewise, the switch 30 and securement 14 are not central to the overall design of the housing 16 . Rather, any suitable switch 30 , at any suitable mechanism or geometry for a securement 14 acting as a stand off 14 may be used, as described hereinabove.
[0082] Referring to FIGS. 7A through 7H , one embodiment of a light assembly 12 may rely on a shape that has few corners or edges. It is similarly spaced away from the ferrule 20 on which the light assembly 12 is mounted by the securement 14 . In this illustration, a single securement 14 is illustrated to operate as a stand off 14 . Nevertheless, multiple magnets 14 , clips 14 , or the like may be used, as described hereinabove.
[0083] One advantage to the design of FIGS. 7A through 7H is that the effect (e.g., dislodging, moving) of bumping or sliding against clothing or work pieces, touching by a hand, and the like will be minimized, resisting loss or misalignment of the light 24 and its associated beam 52 . Thus, it may be an advantage to provide a comparatively lower profile with respect to the surface of the ferrule 20 to which the light assembly 12 attaches. Likewise, a comparatively larger base area secured to the ferrule 20 may also provide for additional resistance to tipping (leverage, bearing length) with respect to the ferrule, and improved strength of grip of the securement 14 .
[0084] Of course, a certain distance is required for the stand off 14 or securement 14 in order to position the light element 24 at a height that will illuminate (by the beam 52 ) the edge 23 of the bristles 22 as described hereinabove. Thus, the configurations of FIGS. 5A through 5H and 7 A through 7 H provide comparatively lower profiles of the housing 16 itself, with minimum elevation above the surface of the ferrule 20 . It should be noted that the views of FIG. 2 , of alternative housings 16 are the same on the sides not viewable in the illustration. Similarly, any of the securements 14 or stand offs 14 of FIG. 2 may be applied in a suitable adaptation to any of the designs of FIGS. 5A through 7H inclusive.
[0085] The present invention may be embodied in other specific forms without departing from its purposes, functions, structures, or operational characteristics. The described embodiments are to be considered in all respects only as illustrative, and not restrictive. The scope of the invention is, therefore, indicated by the appended claims, rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope.
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An apparatus and method provide an adjustable, aimed, lighting system that may be selectively secured to and removed from the ferrule of a paintbrush for illuminating the edge of the bristles during a cutting-in process. The light may be moved as appropriate, and may be aimed to ride with the brush, thus illuminating directly at the edge where paint is being deposited. Thus, precise deposition of paint may be done in spite of the shadows cast by the body of the painter and the bulk of the brush during much of such cutting-in procedures.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention pertains to a method for fast setup or retrofit of a weaving machine, to/from which warping beam and auxiliary shedding mechanism are supplied or removed for a change in warp and/or for a change in article.
2. Description of the Related Art
For weaving machines with shaft device according to the state of the art, it is known how to insert a transport card into the weaving machine during a change in the article to be woven and/or warp, and to use said card to remove the warping beam and also the shafts from the weaving machine. The removed parts are then sent to storage, for example.
SUMMARY OF THE INVENTION
The article of the invention is based on a weaving machine with a different design, in which no shaft device is present. The known removal or insertion method, respectively, thus cannot be carried out.
Therefore it is the purpose of the invention to create a method and also a device which will allow, in a simple manner a change in article and/or warp in weaving machines without a shaft device.
This problem is solved according to this invention in that a harness (Jacquard machine) is provided for the weaving machine, which is applied or removed as a unit for the setup or retrofit, under loosening and/or closing of connections to a Jacquard machine and also under release or attachment in the region of a low-tension device. The basic idea is thus to remove, or to install, respectively, the harness by means of defined interfaces from/to the machine in such a manner that it remains as a functional unit, and thus is removed from or supplied to the weaving machine as a quasimodule. This inherently functional unit can, for example at a later time within the framework of an article change, be inserted back into the machine, whereby without greater effort the weaving process can again be resumed. Due to the detachment or closing of connections to a Jacquard machine, the upper region of the harness can be detached from the Jacquard machine, that is, the single harness cords are separated from the Jacquard machine, or is again connected to the Jacquard machine upon an onset of the harness. In the lower region of the harness there is the so-called low-tension device, that is, the single harness cords are connected to elastic elements, which, in turn, are attached to the machine or in the base region of the erection site of the machine. Since according to the invention, a detachment or a coupling, respectively, of the harness in the region of the low-tension device is possible, then the entire harness can be removed as a unit from, or can again be supplied as a unit to, the weaving machine. Since at the same time with the harness, a removal of the warping beam takes place together with the warp, this means that the removal, storage and/or reapplication of the overall structure occurs in an orderly and thus reproducible manner.
The advantage is that a removal or an onset of the weaving reed takes place while retaining the unit as a whole. In the removal of the weaving reed, the warp remains positioned between the teeth of the weaving reed, so that upon a reapplication, no intake work has to be carried out.
Furthermore, it is an advantage that while retaining the unit, a removal or an onset of a warp stop motion, respectively, takes place. The warp stop motion associated with each warp thread thus remains in its allocation to the particular warp thread, according to this invention, after a removal or after an onset, so that here, too, a resumption of operation after a completed removal is possible in a simple manner based on the retention of the overall module.
According to one additional refinement of the invention, while retaining the unit, a removal or an onset of a cord board, respectively, takes place. The cord board is permeated by the harness threads according to a specified, orderly structure, which is retained after a removal, or upon a reapplication of the harness.
In order to implement the detachment, or the closing of connections, respectively, of the harness threads to a Jacquard machine in a simple manner, fast snaps are provided so that a fast and simple connection is possible.
Furthermore, it is an advantage that at least one retention element joined to the harness is detached from at least one receiving element, or is attached to it, irrespectively, in the region of the low-tension device for the release or attachment of the harness. The retention element can be detached from the receiving element during a removal of the harness, that is, the orderly structure of the harness threads held against the holding element with intermediate elastic components or sections, is retained. By removal of this retention element, the entire harness can be separated in its lower region from the machine, or from a mount allocated to the machine erection site.
Already completed fabric, according to a refinement-of the invention, is separated for release from the warping beam. To this extent, the profile of the warp from the warping beam to the separated fabric, that is, to the region just in front of the warping beam, is retained in an orderly structure after a removal.
The invention further pertains to a device for the setup or retrofitting of a weaving machine, characterized by the formation as a harness transport cart which consists of the receiving devices for the removal or acceptance, respectively, of a harness assembly including harness cords, cord board and low-tension device. In particular, it is provided that the harness transport cart has a receiving device for a removal or reception, respectively, of further harness assembly components, including warping beam, warp stop motion and/or weaving reed.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram that illustrates the invented method;
FIG. 2 is a schematic view of a weaving machine equipped with harness and Jacquard machine;
FIG. 3 shows the weaving machine of FIG. 2 with an empty harness transport cart moved up;
FIG. 4 shows the harness transport cart inserted into the weaving machine according to FIG. 3;
FIG. 5 shows the harness transport cart with picked up harness located in the weaving machine;
FIG. 6 shows the harness transport cart supporting the harness and extracted from the weaving machine;
FIG. 7 is a harness transport cart supporting a harness which is to be introduced into a weaving machine;
FIG. 8 shows the harness transport cart introduced into the weaving machine according to FIG. 7;
FIG. 9 is the onset of the harness into the weaving machine by means of the harness transport cart; and
FIG. 10 shows the state after onset of the harness into the weaving machine and extracted harness transport cart.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows a block diagram which illustrates the arrangement of a harness assembly employed in a weaving machine equipped with Jacquard machine. The harness 1 of the assembly features harness cords 2 which are detachably connected at their upper end 3 to collets 5 of a Jacquard machine 6 by means of releasable connectors such as fast snaps 4 (not illustrated). Viewed from top to bottom, the harness cords 2 pass through a cord board 7 which is detachably attached to the base frame of a weaving machine 8 (see FIG. 8). Beneath the cord board there is an auxiliary shedding mechanism 9 which is formed from strands 10 located in the-particular longitudinal profile of the harness cords 2. That is, the individual harness cords 2 are connected to the individual strands 10. The strands 10 continue downward to a low-tension device 11. The low-tension device 11 has restoring springs 12 and the harness cords 2 are attached to the upper ends of the springs. The lower ends of the restoring springs 12 are attached to a preferably common retaining element 13 which is detachably connected to a receiving element 14. The receiving element 14 is fixed in position, for example, attached to the base frame 17 of the weaving machine 8 or to the floor of the erection site of the weaving machine 8.
FIG. 2 illustrates the above discussion by using a schematic illustration of the arrangement. It is evident that the collets 5 of the Jacquard machine 6 are connected by means of the fast snaps 4 to the upper ends 3 of the harness cords 2, whereby the coupling takes place preferably by means of a fast-snap system, with which it is possible in a simple manner to connect or to detach, respectively, a number of harness cords 2 to the collets 5 of the Jacquard machine 6 in one working pass. Furthermore, in the lower region of the harness cord 2 it is evident that the retaining element 13 is attached to a lower structure 16 with U-shaped cross section forming the receiving element 14. A warping beam 18 is attached to the base frame 17 of the weaving machine 8, from which a warp 20 formed from a number of warp threads 19 emanates; said warp leads via a whip roll 21 and the warp stop motion 22 to the harness 1, there passes through the strands 10 (not illustrated in detail in FIG. 2), and then passes a weaving reed 23 and then passes via a product take-up unit 24 up to the fabric roller 25.
In FIG. 2 a harness assembly 1 is framed by dashed lines 26 and 27. Dashed line 25 indicates that during a change in article and/or warp, the parts enclosed by the dashed line 26 should be removed, or reapplied, respectively. Parts surrounded by a dashed line 27, namely the warping beam 18, the warp stop motion 22 and the weaving reed 23, which likewise preferably is removed or reapplied during a change in article and/or warp. We will discuss this in detail below.
In order to perform the mentioned change in article and/or warp, according to FIG. 3, a harness transport cart 28 is used. It has a chassis section 29 to which a vertical support 30 is attached, which has two booms with adjustable height, namely an upper boom 31 and a lower boom 32. The height adjustment of the two booms 31 and 32 is indicated by means of doable arrows 33 and 34. The two booms 31 and 32 are designed as kink arm extenders so as to be laterally or horizontally extendable, that is, according to a detailed view sketched above the harness transport cart, they have several arm sections so that a three-joint system is formed based on three pivot axes 35, so that the arm length of the two booms 31 and 32 car. be varied in the direction of the double arrows 36, 37.
At the upper boom 31 a pivot arm 38 can rotate freely so that it can be displaced in the direction of the double arrow 39. Furthermore, the upper boom 31 has a hoisting device 40 which can telescope in the direction of the double arrow 41 and can also he retracted.
The lower boom 32 has a pivot arm 42 which can be displaced in the direction of the double arrow 43. It is evident that the two pivot arms 38 and 42--viewed from the side of the harness transport cart according to FIG. 3--are positioned laterally offset with respect to each other. At the underside 44 of the lower boom 32 there is a hoisting device 45 which can be extended and retracted vertically in the direction of the double arrow 46. Furthermore, at the lower boom 32--perhaps by intermediate positioning of additional structural elements--a cord board holder 47 and a warp stop motion 48 are provided. A warping beam grasper 49 is attached to the chassis part 29 and can pivot and move in the direction of the double arrow 50.
In order to remove the harness assembly 1, that is, the harness cords 2, the cord board 7 and also the retaining element 13 together with the warp 20, the warp stop motion 22, the weaving reed 23 and preferably a short section of the perhaps already completed fabric from the weaving machine 8, the harness transport cart 28 according to FIG. 4 is inserted into the weaving machine 8. With the warp 20 also, the warping beam 18 is removed from the weaving machine 8. Specifically, we proceed as follows: The initially empty harness transport cart 28 shown in FIG. 3 is moved up to the weaving machine 8 in such a manner that the warping beam grasper 49 comes to rest underneath the rotary axis of the warping beam 18.
Since the weaving machine 8 extends into the paper plane of FIG. 4, it is necessary to hold the individual components at their ends, or at their end regions. In this regard the harness transport cart 28 is equipped with two chassis parts 29, vertical supports 30 and also booms 31 and 32 (not visible in the figures) and such, which engage at a spacing from each other, in the particular end regions of the weaving machine 8, whereby these two parts of the harness transport cart 28 are connected to each other by cross supports and such. The width of the harness transport cart can be easily varied in this manner, that is, it can be adapted to any particular width of weaving machine.
In the retracted setting of the harness transport cart 28 shown in FIG. 4, the two booms 31 and 32 are extended by means of their arm sections displaced about the vertical pivot axis 35, so that the hoisting device 40 is located underneath the fist snap system 15 of the harness 1 for connection with the Jacquard machine 6. The grasper-like cord board holder 47 is pushed from the side onto the cord board 7--in both end regions of the cord board--so that the cord board 7 can be locked in place there. The hoisting device 40 is extended out to the upper boom 31, so that the lower part 51 of the fast snap system 15 is held. Thus it is subsequently possible to loosen the fast snaps 4 of the harness cords 2 to the collets 5, without the harness 1 collapsing, that is, the tension of the harness threads 2 is retained. Furthermore, the hoisting device 45 located at the lower boom 32 remains in an extended position so that by means of a grasper-shaped holder 52, the retaining element 13 of the low-tension device 11 is held. Based on the holding of the holding element 13 by means of the grasper-like holder 52, the retaining element 13 can be detached from the holding element 14, without the harness 1 losing its tension. The pivot arms 38 of the two upper booms 31 are pivoted into the position indicated in FIG. 4, in such a manner that the free ends 53 of the pivot arms 38 rest on the side of the harness 1 opposite the cart 28. There the two free ends 52 are joined together by means of a cross strut 54 which can be formed as a hollow shaft. The cross strut 54 is located preferably in a holder at the base frame 17 of the weaving machine 8. This activity is indicated by means of a dashed arrow 55. The two pivot arms 42 of the lower boom 32 are located in the position indicated in FIG. 4, that is, their free ends 56 rest upon the opposite side of the harness, viewed relative to the free ends 52 of the pivot arms 38. The free ends 56 are likewise connected with each other by means of a cross strut 57. Next, the warping beam 18 is unlocked and twisted in such a manner that the warp 20 loosens somewhat. Subsequently, the warp stop motion 22 can be held by the warp stop motion holder 48. The warp stop motion holder is designed as a suspension mount to the underside 44 of the lower boom 32. Provided the weaving machine 8 has an edge thread device, then it can also be accepted into the harness transport cart 28 (not shown). Since now the harness 1 detached from the Jacquard machine 6 and also the low-tension device 11 partly held by the harness transport cart 28 are separated from the weaving machine 8 and in addition, the elements connected to the harness 1, like the warp 20 and its associated parts, such as warping beam 18, warp stop motion 22 and such, are likewise held by the harness transport cart 28, the extraction process can now be implemented. In this regard, as indicated in FIG. 5, the fabric 58 will be cut off. The end 59 of the fabric 58 associated with the warping beam 13 will be installed in the front region of the lower boom 32--together with the weaving reed 23 first detached from the weaving machine 8 and then removed.
Next, the hoisting device 45 will travel upward far enough so that the lower side of the holding element 13, or the holder 52, comes to rest above the upper point of the base frame 17 of the weaving machine 8. Furthermore, the hoisting device 40 is moved downward so that a distance to the Jacquard machine 6 is created. Based on the drawing together of the hoisting devices 40 and 45, the harness 1 will relax. In order to prevent the harness cords 2 from leaving their assigned state, the two pivot arms 38 and 41 will pivot, so that the cross struts 54 will move into the harness and also the cross struts 57 will move into the harness, that is, they will have a zig-zag shape.
According to FIG. 6, subsequently the harness transport cart 28 will be moved out from the weaving machine 8. In order to implement this, first the warping beam grasper 49 will pivot upward, so that the warping beam 18 will be taken from its bearing at the base frame 17. Thus the temporarily not needed harness 1, can be sent to a depot together with warping beam 18, warp 20, warp stop motion 22, cord board 7 and weaving reed 23. It is possible (not shown) that the thus removed harness 1 together with its additional parts will be placed in an arranged manner on a standby cart, in order to store it in the depot in this manner. Thus the harness transport cart 28 is used only for removal and--as will be shown below--for reinsertion of the harness 1.
FIG. 7 shows a reinsertion of a previously not needed harness assembly 1 into the weaving machine 8. The harness transport cart 28 has held the install harness 1 together with the accessory elements in a position like that shown according to FIG. 6--for the removal. The harness transport cart 28 is moved up to the weaving machine 8 such that the position according to FIG. 8 will be assumed. In this position, the warping beam grasper 49 will pivot out and thus the warping beam 18 is inserted into the base frame 17 of the weaving machine 8. The two booms 31 and 32 will be extended, so that they assume the positions indicated in FIG. 8. The upper boom 31 is located in an opposing position to the Jacquard machine 6. The lower boom 32 has a position in which the retaining element 13 can be placed onto the receiving element 14 by vertical extension of the hoisting device 45.
In the course of further installation of the harness 1 into the weaving machine 8 (according to FIG. 9), the two hoisting devices 40 and 45 will be moved upward or downward, respectively. Next, by means of the fast snaps 4 a coupling of the individual harness threads 2 with the collets 5 of the Jacquard machine 6 will occur.
Simultaneous with the movement of the hoisting device 40 and 45, the pivot arms 38 and 42 pivot from the harness 1 so that a tension will build up on the harness threads 2. The cross strut 54 is subsequently removed from the pivot arms 38 and placed into the mount provided for this at the base frame 17 of the weaving machine 8. The dashed arrow 55 illustrates this activity.
Furthermore, the holding element 13 is fixed in position to the undercarriage 16 and the warp stop motion is removed from the harness transport cart 28 and sent to the weaving machine 8. The weaving reed 23 is likewise brought into its position at the weaving machine 8 and locked. Provided an edge thread device is used, it will also again to sent to the weaving machine 8 (not shown). The detached grasper elements of the cord board holder 47 release the cord board 7 so that also the cord board 7 can be moved back into its position at the base frame 17 of the weaving machine 8.
After the reinsertion of the hoisting devices 40 and 45, the two booms 31 and 32 will pivot in, and the harness transport cart 28 will be moved out from the weaving machine 8 according to FIG. 10. The now empty harness transport cart is thus available for additional article and/or warp change tasks.
According to another design embodiment, it is also possible to use two different transport carts, whereby one is used for the warping beam and the other for the harness. Thus the change process and the construction per cart will be somewhat simpler, but the old warp must be cut before removal of the warping beam and then--after insertion of the new harness and after introduction of the new warping beam--knotted again in the weaving machine. With regard to the warp threads with warp stop motion and of the weaving reed, we proceed such that these elements, already located outside of the weaving room, are pulled into the new harness, but without the warping beam. If the rear portion of the weaving machine with the rear, side parts, the warping beam, the back rail, the warp stop motion and the edge thread device are separable from the front part of the weaving machine, then we have a special design of the weaving machine and the harness transport cart will be simplified in that instead of the special holder for the warping beam, for the warp stop motion, for the edge thread device and such, now only a receiving device is needed for the rear portion of the weaving machine, in addition to the harness and weaving reed holder. The receiving device of the cart will hold the entire rear portion of the weaving machine.
It is a particular advantage when the cord board 7 of the weaving machine 8 has a consistent frame with fixed adjusting holes and that adjusting spindles are provided that correspond to the attachment points of the weaving machine, so that in the mounted position of the cord board 7, they engage in the adjusting holes and in this manner allow a precise alignment. The frame of the cord board is held by means of a fast snap device to the attachment sites of the base frame 17 of the weaving machine 8, whereby this can be reinforced by the use of spring force, lever force, electrical or pneumatic devices. A corresponding design can be provided with reference to the retaining element 13 and the holding element 14, that is, an adjusting hole/adjusting spindle lead, and the use of a fast snap device in order to join the parts together or to detach them from each other.
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A method and a device for fast setup or retrofit of a weaving machine, from/to which a warping beam and auxiliary shedding mechanism are removed or supplied for a change in warp and/or for a change in article to be woven. A harness is provided for the weaving machine, which is applied or removed as a unit for the setup or retrofit, under loosening and/or closing of connections to a Jacquard machine and also under release or attachment in the region of a low-tension device.
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[0001] These cleaning operations aimed at removing the polymer residues are most commonly carried out today by bringing said residues into contact with one or more solvents or mixtures of solvents.
[0002] These solvents are most commonly organic solvents, some of which are foul-smelling, more or less toxic and damaging to the environment, but also especially toxic and harmful to the users responsible for cleaning said polymer residues.
[0003] Many of these solvents are today banned, or are going to be banned, either by government directives, or directly through the determination of the manufacturers themselves, worried about preserving the health of their employees.
[0004] For example, it is known that molds used for manufacturing polyurethane objects are generally cleaned with dimethylformamide (DMF) which is today considered to be harmful and toxic.
[0005] Thus, a first objective of the present invention is to provide novel polymer-residue-cleaning products, formulations and compositions which are less toxic and less harmful than the solvents used today, or even residue-cleaning products, formulations and compositions which are not toxic and not harmful to the environment and to users.
[0006] Another objective of the present invention is to provide polymer-residue-cleaning products, formulations and compositions which are more efficient than the solvents known and used today.
[0007] Other further objectives will emerge during the description of the present invention which follows.
SUMMARY OF THE INVENTION
[0008] One aspect of the present invention relates to a composition comprising:
from 40% to 95% of dimethyl sulfoxide (DMSO); from 1% to 60% of at least one amine; from 0% to 30% of water; and from 0% to 10% of at least one additive.
[0013] Another aspect of the present invention relates to a composition comprising:
from 40% to 95% of a mixture of dimethyl sulfoxide (DMSO) and at least one non-nitrogenous solvent chosen from alcohols, ethers, and esters; from 1% to 60% of at least one amine; from 0% to 30% of water; and from 0% to 10% of at least one additive.
[0018] Yet another aspect of the present invention relates to process for partially or totally dissolving a polymer, comprising bringing the polymer into contact with the composition, wherein the composition comprises:
from 40% to 95% of dimethyl sulfoxide (DMSO); from 1% to 60% of at least one amine; from 0% to 30% of water; and from 0% to 10% of at least one additive.
[0023] Another aspect of the present invention relates to a process for cleaning polymer residues present on devices used in the transformation of plastics, comprising bringing said device soiled with said polymer residues into contact with at least one composition at a temperature of ranging from ambient temperature to 90° C., wherein said composition comprises:
from 40% to 95% of dimethyl sulfoxide (DMSO); from 1% to 30% of at least one amine; from 0% to 30% of water; and from 0% to 10% of at least one additive.
DETAILED DESCRIPTION OF THE INVENTION
[0028] It has now been found that it is possible at least partially, or even completely, to achieve the abovementioned objectives by using, as polymer-cleaning composition, a mixture comprising dimethyl sulfoxide (DMSO) and at least one amine.
[0029] The composition of the invention comprises, and according to a preferred aspect consists of, DMSO and at least one amine, with optionally water and/or at least one additive.
[0030] More specifically, the present invention relates to a composition comprising, and preferably consisting of:
from 40% to 95% of dimethyl sulfoxide (DMSO); from 1% to 60% of at least one amine; from 0% to 30% of water; and from 0% to 10% of at least one additive.
[0035] In the description of this invention, all the percentages are expressed by weight, unless otherwise explicitly mentioned.
[0036] DMSO is a solvent considered to be nonharmful and nontoxic. In addition, it can be available in various degrees of purity. DMSO of high purity has virtually no odor, or at the very least no nauseating odor. According to one variant, the DMSO used can be advantageously odorized with at least one odorant.
[0037] According to one preferred embodiment, the composition according to the invention comprises, and preferably consists of:
from 50% to 95%, preferably from 60% to 97%, of dimethyl sulfoxide (DMSO); from 1% to 30%, preferably from 2% to 20%, of at least one amine; from 0% to 30% of water, preferably from 0% to 15%; and from 0% to 10%, preferably from 0% to 5%, of at least one additive.
[0042] The amine(s) present in the composition of the invention can be of any type known to those skilled in the art. However, primary, secondary or tertiary amines with a molecular weight of less than 500 daltons, preferably less than 300 daltons, or preferably even less than 200 daltons, more particularly preferably less than 100 daltons, are preferred. Primary or secondary amines are preferred, primary amines being most particularly preferred.
[0043] Amines comprising a single amine function are preferred. Amines also comprising at least one oxygen atom, and preferably one or two oxygen atoms, are also preferred.
[0044] In at least one embodiment, amines comprising one or two groups chosen from hydroxyalkyl and alkoxyalkyl, where alkyl represents methyl, ethyl, propyl or butyl, are still further preferred. Most particularly preferred are amines comprising one or two hydroxyethyl groups and/or a methoxy group. Amines bearing one or two hydroxyethyl groups are the most preferred.
[0045] By way of nonlimiting examples, the amines which can be advantageously used in the compositions according to the invention are chosen from alkylalcanolamines, alkyldialcanolamines and alkoxyamines.
[0046] According to one embodiment, and among the amines which are usable in the compositions of the invention, mention may be made, by way of nonlimiting examples, of monoethanolamine (MEoA), diethanolamine (DEoA), propanolamine (PoA), butyl-iso-propanolamine (BiPoA), iso-propanolamine (iPoA), 2-[2-(3-aminopropoxy)ethoxy]ethanol, N-2-hydroxyethyldiethylenetriamine, (3-methoxy)propylamine (MoPA), 3-isopropoxypropylamine (IPOPA) and triethylamine (TEA).
[0047] According to one most particularly preferred aspect, the compositions according to the invention comprise at least one amine chosen from monoethanolamine (MEoA), diethanolamine (DEoA), propanolamine (PoA) and (3-methoxy)propylamine (MoPA), more preferably from monoethanolamine (MEoA) and diethanolamine (DEoA).
[0048] In addition to the DMSO and at least one amine, such as they have just been defined, the presence of an amount of water in the compositions of the invention has proved to be advantageous for enabling even more efficient dissolution of polymer residues.
[0049] Moreover, the presence of water in the compositions of the invention has the additional advantage of lowering the crystallization point of said compositions.
[0050] Thus, and according to yet another aspect, the present invention relates to a composition comprising, and preferably consisting of:
from 40% to 95% of dimethyl sulfoxide (DMSO); from 1% to 60% of at least one amine; from 1% to 30% of water; and from 0% to 10% of at least one additive.
[0055] In one preferred embodiment, the present invention relates to a composition comprising, and preferably consisting of:
from 50% to 95%, preferably from 60% to 97%, of dimethyl sulfoxide (DMSO); from 1% to 30%, preferably from 2% to 20%, of at least one amine; from 1% to 30% of water, preferably from 1% to 15%; and from 0% to 10%, preferably from 0% to 5%, of at least one additive.
[0060] Finally, the compositions according to the present invention can comprise one or more additives commonly used in the field. These additives advantageously do not have specific or intrinsic polymer-cleaning or polymer-dissolving properties. Among the additives which can be present in the compositions according to the invention, mention may be made, by way of nonlimiting examples, of corrosion inhibitors, antioxidants, dyes, aromas and other odor-masking agents, stabilizers, wetting agents, and the like.
[0061] Among the corrosion inhibitors, mention may be made of catechol, sodium tolyltriazolate and morpholine, for example.
[0062] A particularly preferred composition for cleaning polymer residues according to the present invention comprises, and preferably consists of, from 80% to 90% of DMSO, from 2% to 9% of MEoA and from 5% to 15%, for example approximately 8%, of water. This composition can also comprise from a few ppm by weight to 1% of a corrosion inhibitor.
[0063] According to yet another aspect, the compositions of the present invention can comprise, instead of the DMSO, a mixture of DMSO and at least one other non-nitrogenous solvent. Among the non-nitrogenous solvents, mention may be made, by way of nonlimiting examples, of alcohols, ethers, esters, and other nonnitrogenous solvents compatible with the compositions such as they have just been described.
[0064] Among the nonnitrogenous additional solvents that can form a mixture with DMSO present in the compositions of the present invention, preference is given to monofunctional and/or difunctional esters, and more particularly alkyl esters, where “alkyl” denotes a linear or branched hydrocarbon-based chain comprising from 1 to 6 carbon atoms. These esters advantageously originate from linear-chain or branched-chain monocarboxylic and/or dicarboxylic acids comprising from 3 to 30 carbon atoms.
[0065] Most particularly preferred are methyl, ethyl, propyl and butyl esters of formic acid, acetic acid, propionic acid, butyric acid, maleic acid, succinic acid, glutaric acid, 2-methylglutaric acid, and the like, and also mixtures thereof in any proportions.
[0066] Thus, in one preferred embodiment, the invention relates to a composition comprising, and preferably consisting of:
from 50% to 95%, preferably from 60% to 97%, of a dimethyl sulfoxide (DMSO)/non-nitrogenous solvent mixture, said non-nitrogenous solvent being chosen from alcohols, ethers and esters; from 1% to 30%, preferably from 2% to 20%, of at least one amine; from 0% to 30% of water, preferably from 0% to 15%; and from 0% to 10%, preferably from 0% to 5%, of at least one additive.
[0071] According to another preferred embodiment, the invention relates to a composition comprising, and preferably consisting of:
from 50% to 95%, preferably from 60% to 97%, of a dimethyl sulfoxide (DMSO)/non-nitrogenous solvent mixture, said non-nitrogenous solvent being chosen from alcohols, ethers and esters; from 1% to 30%, preferably from 2% to 20%, of at least one amine; from 1% to 30% of water, preferably from 1% to 15%; and from 0% to 10%, preferably from 0% to 5%, of at least one additive.
[0076] In the compositions according to the invention which comprise a DMSO/non-nitrogenous solvent mixture, preference is given to those for which the DMSO/non-nitrogenous solvent weight ratio is between 99/1 and 30/70, preferably between 90/10 and 40/60, for example the weight ratio is approximately 50/50.
[0077] The compositions of the invention can be prepared according to any method known in the field, and for example by simple mixing of the various ingredients in any order. However, it is preferred to add the amines to the DMSO/water mixture, when said water is present in the composition. The optional additives are advantageously added to the final mixture of DMSO/amine(s) and optionally water.
[0078] According to another aspect, a subject of the present invention is the use of at least one of the compositions such as they have just been defined, for partially or totally dissolving polymers, and in particular for cleaning polymer residues.
[0079] The term “cleaning polymer residues” is intended to mean the partial or total dissolution of polymers with the compositions of the present invention.
[0080] The polymers which can thus be partially or totally dissolved are of any type, thermoplastic and thermosetting, in particular thermoplastic.
[0081] The polymers targeted in the use of the present invention are, for example, chosen, in a nonlimiting manner, from fluoropolymers, such as poly(vinyl difluoride) or PVDF, nitrogenous polycondensates, such as those bearing amide, imide, amido-amide, urethane or nitrile groups, sulfur-containing polycondensates, such as those bearing sulfone groups, and the like.
[0082] The compositions of the invention are particularly suitable for cleaning polymers chosen from polyurethanes, polyamides, polyamide-imides, polyethersulfones, polyacrylonitriles, and the like, and more particularly suitable for dissolving, for cleaning, polyurethanes.
[0083] The compositions of the invention are most particularly effective for cleaning polyurethane residues for which the solvent of choice to date was DMF, which is now prohibited, in particular by the European guidelines.
[0084] For cleaning polymer residues, the compositions of the present invention are used in a temperature range from ambient temperature to 90° C. The efficiency of the compositions according to the invention decreases rapidly when the temperature decreases, and, below ambient temperature, the time required for efficient cleaning can prove to be relatively long. Above 90° C., the cleaning composition can generate unpleasant vapors, but it is possible to work in a ventilated or closed chamber, thus making it possible to work at the boiling point of the cleaning composition.
[0085] However, it is preferred to use the compositions according to the invention at a temperature of between 30° C. and 70° C., for example between 50° C. and 65° C.
[0086] According to yet another aspect, the present invention relates to a process for cleaning polymer residues present on devices used in the transformation of plastics as previously defined, said process comprising at least one step of bringing the said device soiled with said polymer residues into contact with at least one composition according to the present invention, under the temperature conditions indicated above.
[0087] The term “bringing into contact” is intended to mean partial or total immersion of the device to be cleaned, with or without agitation, or spraying the device to be cleaned with a cleaning composition at various pressures, for example by means of a spray gun or brush, and the like. As a variant, the bringing into contact can simply be wiping with a cloth, a sponge or any other absorbing/desorbing material soaked in the cleaning composition.
[0088] The bringing into contact defined above can optionally be accompanied by physical cleaning, for example using tools, such as spatulas, scrapers, and the like.
[0089] The present invention is now illustrated by means of the examples which follow, which are in no way limiting in nature, and which consequently cannot be understood to be capable of restricting the scope of the invention as claimed.
Example 1: Dissolution of Polyurethane (PU) using DMF and DMSO
[0090] Polyurethane residues originating from shoe sole molds were used to carry out the tests illustrating the invention.
[0091] The reference solvent is DMF. To clean the molds, the molds are usually immersed for a few hours in a bath of DMF brought to 60° C.
[0092] The tests are in this case carried out in 20 ml glass flasks. 10 ml of the cleaning composition (e.g., DMF or DMSO alone) preheated in an incubator to approximately 60° C. are placed in each flask. A sample of polyurethane (PU) having a parallelepipedal shape (approximately 10×5×2 mm) is then placed in each flask. The flasks are closed and left, without agitation, in an incubator at 60° C.
[0093] Swelling of the samples is first of all observed after approximately 2 to 3 minutes of immersion. After 25 minutes, the PU is not dissolved in either the DMF or the DMSO. The difference in efficiency between the DMF and the DMSO is observed in the time: after 18 hours at 60° C., the PU begins to become soluble in the DMF, whereas nothing happens in the DMSO. DMF is therefore more effective than DMSO alone.
Example 2: Dissolution of Polyurethane (PU) in a DMSO/Nonnitrogenous Solvent Mixture
[0094] The same protocol as in example 1 is repeated using a mixture of DMSO (95.5%) and diacetone alcohol (4.5%). As in DMSO, swelling of the PU is observed in the DMSO/diacetone alcohol mixture, but no dissolution, even after 18 hours of immersion of the sample.
[0095] A comparable test was carried out with a DMSO/hexylene glycol mixture. Likewise, it is observed that the hexylene glycol provides no additional efficiency. This mixture acts like DMSO and is less efficient than DMF.
[0096] The addition of a non-nitrogenous, oxygen-containing solvent to DMSO does not make it possible to improve the efficiency of DMSO alone and remains a less effective solution than dissolution with DMF.
Example 3: Dissolution of Polyurethane (PU) in a DMSO/MEoA Mixture
[0097] The same protocol as in example 1 is repeated using a mixture of DMSO (95.5%) and monoethanolamine (4.5%), with immersion for 18 hours at 60° C.
[0098] It is observed, surprisingly, that the PU sample is completely dissolved in the DMSO/MEoA mixture, whereas, in DMF, the sample barely begins to dissolve.
[0099] A DMSO/MEoA mixture is therefore much more efficient than DMF alone.
Example 4: Dissolution of Polyurethane (PU) in a DMSO/MEoA Mixture, With and Without the Addition of Water
[0100] The same protocol as in example 1 is repeated while comparing a DMSO/MEoA (95.5%/4.5%) composition and a DMSO/MEoA/water (87.5%/4.5%/8%) composition.
[0101] After 4 h at 60° C., the PU is completely dissolved in the DMSO/MEoA/water mixture, whereas it is not dissolved in the DMSO/MEoA (95.5%/4.5%) mixture.
[0102] A DMSO/MEoA/water mixture is therefore much more efficient than a DMSO/MEoA mixture.
Example 5: Influence of the Proportion of Nitrogenous Solvent in the DMSO on the Dissolution of Polyurethane (PU)
[0103] Still according to the protocol described in example 1, PU-sample dissolution tests are carried out while varying the concentration of MEoA in the DMSO, from 1% to 5%.
[0104] It is observed that the greater the amount of MEoA in the DMSO, the faster the dissolution of the PU.
[0105] In addition, the DMSO+1% MEoA mixture is more efficient than DMF alone, since flakes of PU in suspension in the mixture have already begun to be seen after 1 hour at 60°, whereas no effect (other than swelling of the sample) is observed in either DMF or DMSO.
[0106] After 48 hours at 60° C., the PU is completely dissolved in the DMSO+1% MEoA mixture. The addition of MEoA to DMSO (from 1% to 5%) clearly increases the dissolution of PU compared with DMSO alone. The DMSO+MEoA mixture is more efficient than DMF.
Example 6: Lowering of the Crystallization Point in the Presence of Water in the DMSO-based Cleaning Compositions
[0107] The crystallization point of DMSO is 18.5° C., which often poses storage and handling problems during winter.
[0108] The crystallization point of a DMSO (95%)+MEoA (5%) mixture is approximately 15° C. This crystallization point can be further enhanced by adding water to the composition.
[0109] A test is carried out by adding 8% by weight of water to DMSO, and then the MEoA is added (5% by weight in the above mixture). The crystallization point of this mixture is measured at −2.9° C., whereas a DMSO/water (92%/8%) mixture has a crystallization point close to 0° C.
[0110] According to the protocol of the example, dissolution tests are carried out on this DMSO/MEoA/water (i.e. 87.6%/4.8%/7.6%) mixture.
[0111] After 3 hours at 60° C., the PU sample is completely dissolved in this mixture, whereas it is only beginning to be dissolved in the DMSO/MEoA (95%/5%) mixture and no dissolution is observed in DMF: the addition of water to the DMSO/MEoA mixture accelerates the dissolution of PU.
Example 7: Influence of the Water Content on the Dissolution of Polyurethane (PU) in a DMSO/MEoA/Water Mixture
[0112] The same protocol as example 1 is repeated while comparing DMSO/MEoA/water compositions with varying water contents.
[0113] After 7 hours at 60° C., the results are the following:
91.5% DMSO/4.5% MEoA/4% water: polymer not completely dissolved; 87.5% DMSO/4.5% MEoA/8% water: polymer completely dissolved; 80.5% DMSO/4.5% MEoA/15% water: very beginning of dissolution of the polymer; 70.5% DMSO/4.5% MEoA/25% water: no dissolution of the polymer; 45.5% DMSO/4.5% MEoA/50% water: no dissolution of the polymer.
[0119] It can therefore be concluded that a water content up to 15% significantly improves the dissolving efficiency of the DMSO/MEoA/water compositions.
Example 8: Dissolution of Polyurethane (PU) in a DMSO/Nonnitrogenous Solvent/MEoA/Water Mixture
[0120] The same protocol as in example 1 is repeated using a mixture of DMSO (50% by weight) and dimethyl glutarate (50% by weight). As in DMSO, swelling of the PU is observed in the DMSO/dimethyl 2-methylglutarate mixture, but no dissolution, even after 18 hours of immersion of the sample.
[0121] A comparable test was carried out with a DMSO/dimethyl 2-methylglutarate/MEoA/water (44.5%-44.5%-3%-8% by weight) mixture. After 18 hours of immersion of the PU sample, the latter is completely dissolved.
[0122] The addition of MEoA and of water, under the conditions of the invention, to a DMSO/nonnitrogenous solvent mixture makes it possible to clearly improve the effectiveness compared with the DMSO/nonnitrogenous solvent mixture alone.
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The present disclosure relates to a dimethyl sulfoxide composition suitable for cleaning polymer residue found on the devices used for processing plastic materials, in particular polyurethane.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application claims priority to German patent application number DE 10 2005 061 025.0 filed Dec. 19, 2005, and PCT/EP2006/011315, filed Nov. 25, 2006, the entire disclosure of which is incorporated by reference herein.
FIELD OF THE INVENTION
The present invention relates to a seat belt retractor for motor vehicles, comprising a vehicle-sensitive and/or belt webbing-sensitive controllable locking device for the belt shaft, with the retractor comprising a profiled head that acts as a support for a displaceably mounted locking member that locks the belt shaft in the housing, and a two-stage force limiting device that is equipped with two force limiting elements connected in series, the force limiting elements being switchable between a high level and a low level of force limitation via an interposed coupling that is controlled by means of a control device.
BACKGROUND OF THE INVENTION
A seat belt retractor having the above-mentioned characteristics is described in DE 200 15 402 U1. In addition to a torsion bar disposed between the belt shaft and the profiled head thereof, this seat belt retractor has two further force limiting devices connected in series in the form of two friction couplings, which are coupled to one another via an externally and internally toothed ring. The first friction coupling having a high level of force limitation acts between the belt shaft and/or the profiled head thereof and the toothed ring, and the second friction coupling between the toothed ring and the housing. In the initial state, the toothed ring is fixed to the housing via a catch that can be controlled by a control device, wherein, if necessary, the catch is controlled disengaged from the toothed ring by the control device such that the toothed ring can be rotated freely in relation to the belt retractor housing.
In the known belt retractor, the control of the force limiting elements is configured such that the toothed ring is fixed to the housing via the catch so that the higher level of force limitation acts first in case of an accident. If a signal emitted by the vehicle determines that based on the driver's height, weight or position, or based on the severity of the accident, the restraining force acting on the occupants is becoming too large, the catch is controlled disengaged from the toothed ring so that the toothed ring can be rotated freely in relation to the housing. Thus, a relative movement occurs between the housing and the toothed ring, wherein the second friction coupling located between the housing and the toothed ring acts as a force limiting device with a lower level of force limitation. Accordingly, the switching operation is accomplished from the high level of force limitation to the lower level of force limitation and is not reversible. Insofar, the known belt retractor has the disadvantage that the high level of force limitation acts first also on lower-weight or buckled-up persons, resulting in an accordingly strong increase in the restraining force. The level of force limitation is only reduced when the restraining force is too high. A further disadvantage is that the known seat belt retractor does permit consideration of the momentary changes in the sitting position by movements of the buckled-up occupants on the seat.
SUMMARY OF THE INVENTION
Therefore, the object of the present invention is to further develop a seat belt retractor of the general type such that the level of force limitation may be more flexibly and better adjusted to the occupants' conditions.
The solution of this task, including advantageous embodiments and refinements of the present invention, will become apparent from the claims appended to this description.
The present invention provides a control device for switching the coupling between the high level and low level of force limitation comprising a counter gear, which determines the amount of the respective belt webbing that is extended from the belt shaft, and that the coupling can be reversibly switched back and forth between the high and the low levels of force limitation.
The present invention has the advantage that, depending on the belt webbing extension at the moment of the accident, the level of force limitation is either adjusted to a high level or to a low level right from the start. Thus, not only is the belt webbing extension contingent upon the body measurements and respective clothing, but also the occupants' sitting position at the moment of the accident may be taken into consideration. If a small and therefore normally light-weight occupant, for whom a low level of force limitation is to be engaged according to prior art, bends forward shortly before the accident, the occupant will possibly be correspondingly near a vehicle part so that the longer belt webbing release path associated with the low level of force limitation may already endanger the occupant. However, in this case the seat belt retractor according to the present invention ensures that the high level of force limitation is immediately engaged via a belt webbing extension request, wherein, while accepting a higher belt webbing force, a potential forward displacement of the occupant is reduced. Therefore, the small occupant is better protected.
Further, the protection is advantageously improved for such persons, who are buckled-up with a belt webbing extension located shortly before the switching point, and for whom the low level of force limitation is adjusted in this regard. In case of an accident, the activation of the force limiting element having the low level of force limitation will cause a belt webbing extension, at which the switching position may be exceeded and the high level of force limitation be consequently engaged.
According to one embodiment of the present invention, the coupling comprises a toothed ring, which is rotatably mounted on the housing of the belt extractor and when locked can be engaged by the locking member of the profiled head, and a catch, which can be displaced back and forth between two switching positions by means of the control device, said catch releasing the toothed ring in the one switching position and locking it to the housing in the other switching position. As far as the use of a toothed ring for accomplishing the switching connection between two force limiting devices is known from DE 200 15 402 U1, a movement of the corresponding catch is only provided in one switching direction.
In a further embodiment, the force limiting elements are disposed with respect to the toothed ring such that the first force limiting stage having the low level of force limitation is implemented by a toothed ring that can rotate in relation to the housing, and the second force limiting stage having the high level of force limitation is implemented by the catch, which is controlled by the control device when engaged in the toothed ring, in the toothed ring that is fixed to the housing.
In a further embodiment of the present invention, the force limiting element defining the low level of force limitation is a torsion rod, which is disposed in the belt retractor housing outside the belt shaft, one end of the rod being fixed inside the housing and the other end being attached to the toothed ring by means of a connecting means such that the rotation of the toothed ring can be translated into a twisting motion of the torsion rod. EP091330041 describes a torsion rod disposed outside the belt shaft as a second force limiting element, which is connected directly to the belt shaft by means of a gear mechanism and thus rotates together with the belt shaft. In the event of an appropriate load case, the second torsion rod is locked so that a force limiting effect is added to the level of force limitation created by the first torsion rod disposed on the belt shaft. In contrast, according to the present invention, the torsion rod located outside the belt shaft is uncoupled from the second force limiting element, which likewise has the shape of a torsion rod disposed in the belt shaft, for example, by means of the rotatable toothed ring.
In a further embodiment of the present invention, the connecting means is made of a metal band having a predetermined length, one end of which is attached to the toothed ring and the other end of which is wound onto and attached to a winding spool, which is fixed to the torsion rod and rotatably disposed on the belt retractor housing. This is advantageous in that also at the low level of force limitation, the belt webbing release associated with the twisting motion of the torsion rod is limited to the length of the metal band to be unwound. If the metal band is completely unwound, the force is directly transmitted from the toothed ring to the twisted torsion rod, and consequently to the housing, such that a rigid system is created, which activates the higher level of force limitation of the further force limiting element even with a selected catch and a rotatable toothed ring. In this way, additional safety is provided for persons, for whom the control device only provides the low level of force limitation.
Regarding the design of the force limiting element defining the lower level of force limitation, an alternative embodiment provides that the force limiting element defining the low level of force limitation is a bending brake that is disposed on the belt retractor housing outside the belt shaft and comprises a pulling element, which is guided through a baffle fixed to the housing, and has one end attached to the toothed ring such that the rotation of the toothed ring can be translated by the baffle into an energy-absorbing pull-through of the pulling element. This has the advantage that the arrangement of a bending brake as an additional force limiting element is cost-effective. In this respect, the effectiveness of the force limitation may be easily adjusted via the length of the pulling element that is to be pulled through the baffle, which is to say the retained reserve thereof.
In this connection, different embodiments of the present invention provide that the free end, which forms the reserve, of the pulling element is disposed outside around the toothed ring, or that the free end, which forms the reserve, of the pulling element is disposed in a storage housing, which is rotatably mounted on the belt retractor housing, and may be pulled out of the storage housing.
The force path may advantageously be adjusted during force limitation by the selection of the width of the pulling element in that the pulling element has a uniform width across the length thereof, or in that the width of the pulling element varies across the length thereof as a function of the desired change in the level of force limitation.
In a further embodiment of the present invention, the counter gear comprises an externally toothed gear wheel that is connected to the belt shaft, a further externally toothed gear wheel that is fixed to the housing, and a third externally toothed gear wheel disposed on a rocker arm, which is pivotably mounted on the housing in two switching positions, wherein all three gear wheels mesh with one another, and switching points for the switching lugs that fix the rocker arm are disposed on the gear wheels, wherein in the predetermined unwinding state the lugs come in contact with one another and thus pivot the rocker arm between the switching positions. A counter gear of this type is known in principle from DE 41 32 876, namely as a retractor switch for the use of a seat belt retractor in a child seat. The counter gear switches the belt webbing-sensitive and/or vehicle-sensitive control system for locking the belt shaft when the retractor is used with a child seat. The known counter gear comprises two gear wheels with corresponding switching lugs that are disposed on a rocker arm, wherein the wheels mesh with the gear wheel that is connected to the belt shaft. As a result of the arrangement of the switching lugs on the individual gear wheels, the belt webbing must first be fully unwound from the belt shaft before a switching operation is possible, so that during a return motion of the belt webbing to an extended position that is suitable for the use of a child seat, the corresponding vehicle-based control system is switched off. The further return motion of the belt webbing up to the storage position then results in a new switching operation by engaging the belt webbing-sensitive and vehicle-sensitive control system.
A further embodiment of the present invention provides that the gear wheel connected to the belt shaft and the gear wheel mounted on the housing each comprise a switching lug, and that the gear wheel mounted on the rocker arm comprises two switching lugs to restrict the switching hysteresis. Thus, each of the two switching lugs disposed on the gear wheel mounted on the rocker arm interact with the switching lugs of the gear wheel fixed on the shaft and/or with the switching lugs of the gear wheel mounted on the housing such that both switching points may be adjusted via a very small angle of rotation of the belt shaft. In this way, the exact definition of the switching point for controlling the catch in the toothed ring is a function of the extension motion and also the winding motion of the belt webbing.
To the extent that the rocker arm controlled by the counter gear must control the catch in both of the switching positions, alternative embodiments of the present invention provide that the rocker arm directly controls the catch via a mechanical connection or indirectly via an interposed electrical or pneumatic switch.
In case of a direct mechanical control, an embodiment of the present invention provides that a control catch is disposed on the catch relatively displaceably thereto and interacting with the rocker arm, the control catch having a control cog that interacts with the outer gearing of the toothed ring. Such an embodiment ensures that via the engagement of the control catch, the catch is engaged in the outer gearing of the rotating toothed ring with precise fit without resulting in tooth-on-tooth locking. This applies not only to the switching operation for the belt extension when buckling up, or when the buckled-up person moves, but also to switching the level of force limitation, for example, when switching occurs due to the engagement of the catch in the outer gearing of the toothed ring as a result of the belt webbing extension related to the forward displacement of an occupant exposed in the first instance to the low level of force limitation.
A further embodiment of the present invention provides that the catch has a slotted mounting recess for the U-shaped control catch, with which the connecting member of said catch is inserted in the mounting recess allowing clearance for movement. With respect to the reversible configuration of the coupling, it may be provided that with regard to the retraction of the catch, said catch is pretensioned in the release position for the toothed ring by means of a spring.
A further embodiment of the present invention provides that the control catch is tensioned by a pretensioned spring in the direction of the engagement in the outer gearing of the toothed ring, and that the pretensioned spring is fixed in the release position of the control catch for the toothed ring by means of a separately controlled holding device, which releases the pretensioned spring when the control catch engages in the outer gearing of the toothed ring. This is advantageous in that in case of the dynamic engagement of the control catch in the outer gearing of the toothed ring at the beginning of the rotation of the toothed ring, the switching force of the control catch is increased by releasing the pretensioned spring. As a result of the increased actuating force accomplished in this way, as well as the subsequent meshing force of the control catch in the external gearing of the toothed ring, it is no longer possible to switch off the adjusted higher level of force limitation due to the locking of the toothed ring on the one hand, and on the other hand, as a result of the pretensioning by the spring, the control catch in addition acts as a retraction lock against undesired reversed rotation of the toothed ring.
In this connection, it may be advantageous that the holding device comprises a gate that may be displaced relative to the pretensioned spring between a holding position and a release position. For this purpose, an embodiment of the present invention provides that the gate is maintained in the holding position by means of a holding lever, which rests positively in a recess configured in the toothed ring and is released from the toothed ring on rotation of said toothed ring. Coupling the holding device to the rotation of the toothed ring ensures that no faulty activation and/or faulty operation occur because the release of the holding device is exclusively activated by the onsetting rotation of the toothed ring, wherein the toothed ring is then fixed by the immediately operative, load absorbing catch.
Insofar as an embodiment of the present invention provides that the pretensioned spring is disposed and oriented such that, in the release position of the control catch for the toothed ring, the spring force line extends via the pivot bearing of the control catch on the catch and, when the control catch is pivoted, the buckling thereof produces a torque in the engagement direction of the control catch in the toothed ring, this has the advantage that in the resting position of the pretensioned spring, no additional torque is present that would have to be absorbed by the holding device. Only when the control catch is pivoted will the intended torque become active.
BRIEF DESCRIPTION OF THE DRAWINGS
The drawings show exemplary embodiments of the present invention, which are described in more detail below: The drawings show:
FIG. 1 an overall view of a seat belt retractor in accordance with the present invention,
FIG. 2 the subject matter of FIG. 1 from a different angle,
FIG. 3 an exploded view diagram of the subject matter according to FIGS. 1 and 2 ,
FIG. 4 a top view of the control device configured as a counter gear in one of the switching positions of the rocker arm,
FIG. 5 the subject matter of FIG. 4 in the other switching position of the rocker arm,
FIG. 6 a detailed drawing of the toothed ring with the torsion rod having the lower level of force limitation connected thereto,
FIG. 7 an enlarged cut-out view of the catch with the associated control catch and toothed ring,
FIG. 8 an overall view of the catch with the control catch mounted thereto,
FIG. 9 the subject matter of FIG. 8 with a separate illustration of the catch and control catch,
FIGS. 10 a - c the process of engaging the catch into the outer gearing of the toothed ring,
FIG. 11 a - c the control catch with a pretensioned spring acting on it and the associated holding, device for the pretensioned spring in the different functional positions of the control catch,
FIG. 12 a side view of the toothed ring with the torsion rod having the lower level of force limitation connected thereto in the initial position,
FIG. 13 the subject matter of FIG. 12 with an unwound metal band,
FIG. 14 a side view of the toothed ring with a force limiting device configured as a bending brake having the lower level of force limitation,
FIG. 15 a modified embodiment of the subject matter of FIG. 14 .
DETAILED DESCRIPTION OF THE INVENTION
The seat belt retractor 10 illustrated in FIGS. 1 and 2 has a U-shaped housing 11 with lateral housing legs 12 in which a belt shaft 13 is mounted. The so-called spring side of the belt shaft is designated with numeral 14 , wherein a spring housing that is not illustrated may be disposed thereon for the winding up motion of the belt shaft, and also other functional elements, such as a tightening device, for example. Reference numeral 15 designates the end of a torsion rod disposed in the belt shaft 13 , said torsion bar forming the force limiting element having the high level of force limitation.
A second force limiting element having a level of force limitation that is lower in relation to the torsion rod 15 is provided as a second torsion rod 16 that is disposed outside the belt shaft 13 , the one end of said torsion rod being fixed in a positive locking manner on the associated housing leg 12 of the seat belt retractor housing 11 , and the other end being connected non-rotatably to a winding spool 17 rotatably mounted on the opposite housing leg 12 . A metal band 18 is wound onto the winding spool 17 and attached with the free end thereof to a toothed ring 19 that is mounted rotatably on the respective housing leg 12 . As is apparent from other drawings in the figure, the toothed ring 19 is provided with an outer gearing, which is associated with a force-transmitting catch 20 mounted on the housing leg 12 .
As is apparent from FIG. 2 , a bearing plate 28 is disposed on the outside of the housing leg 12 supporting the toothed ring 19 , said bearing plate having a counter gear 22 with a gear wheel 23 that is connected to the associated end of the belt shaft 13 , a gear wheel 24 mounted on the bearing plate 28 and a gear wheel 24 disposed on a rocker arm 25 mounted pivotably on the bearing plate 28 . The rocker arm 21 extends beneath the bearing plate 28 by means of an extension and interacts with the catch 20 in a manner described below.
FIG. 3 shows the above-described individual components of the seat belt retractor 10 in detail again, wherein it is apparent that a profiled head 26 is disposed at the end of the belt shaft 13 ; which engages in the bearing plate 28 , and is fixed to the torsion rod 15 extending inside the belt shaft 13 , an inertia controlled locking member 27 being disposed on the profiled head 26 , wherein the member may be engagable in the inner gearing 33 configured on the toothed ring 19 . In contrast, the catch 20 is configured for engagement in the outer gearing 34 of the toothed ring 19 .
As is further apparent from FIGS. 4 and 5 in an enlarged illustration of the counter gear 22 , the gear wheels 23 , 24 , 25 are disposed in relation to one another such that the gear wheel 25 mounted on the rocker arm 21 remains meshed with the shaft gear wheel 23 in each of the two possible switching positions of the rocker arm 21 on the one hand, and with the gear wheel 24 mounted on the bearing plate 28 , on the other hand. Switching lugs 30 and/or 31 are configured on each of the two gear wheels 23 and 24 . In contrast, two switching lugs 32 a, b are disposed offset from one another at an angle of rotation on the gear wheel 25 mounted on the rocker arm 21 , the switching lug 32 a meeting with the switching lug 30 of the shaft gear wheel 23 when the counter gear 22 is in the appropriate position ( FIG. 5 ), while the switching lug 32 b meets with the switching lug 31 of the gear wheel 24 mounted on the bearing plate when the rocker arm 21 is in a different position. When comparing FIGS. 4 and 5 , it is apparent that upon contact of the two switching lug combinations, the rocker arm 21 is respectively pivoted according to the two switching positions. Based on the two switching lugs 32 a, b located on the gear wheel 25 disposed on the rocker arm 21 , the corresponding switching point may be defined with a very small clearance of the angle of rotation, so that not only an exactly reproducible switching point in the unwinding direction as well as in the winding direction is created, but also both switching points are closely adjacent to one another in relation to the angle of rotation of the belt shaft 13 .
The interaction of the toothed ring 19 with the outer torsion rod 16 via the metal band 18 is apparent in detail from FIG. 6 , and the engagement of the catch 20 mounted on the housing leg 12 in the outer gearing 34 of the toothed ring 19 is apparent in detail from FIGS. 7 to 9 . In order to ensure the engagement of the catch 20 in the outer gearing 34 of the toothed ring 19 even when the toothed ring 19 is rotating, a separate control catch 29 is provided, which is configured as a U-shaped component with lateral legs 36 and an interposed connecting member 37 , the catch 20 having a slotted mounting recess 38 , in which the control catch 27 is inserted with the connecting member 37 thereof, so that the lateral legs 36 of the control catch 29 enclose the catch 20 between them. In this respect, the control catch 29 as such is mounted directly rotatably on the catch 20 allowing clearance for movement. This mounting is implemented such that a slightly protruding tilt edge 39 meshes with a receiving groove 40 at the bottom of the slotted mounting recess 38 of the catch 20 , so that the control catch 29 may be displaced with minor expenditure of energy in the catch 20 . A control cog 42 that is configured for the engagement into the outer gearing 34 of the toothed ring 19 is provided on the connecting member 37 . A leaf spring 35 engages on the catch 20 , by means of which in the resting position the catch 20 is kept disengaged from the outer gearing 34 of the toothed ring 33 .
FIGS. 10 a - 10 c show the implementation of the back and forth switching operation between the two levels of force limitation. As is apparent from FIG. 10 a at first, the catch 20 is disengaged from the outer gearing 34 of the toothed ring 19 ; the same also applies to the control catch 29 , which is maintained in the position illustrated in FIG. 10 a by means of an extension 41 of the rocker arm 21 that engages on said control catch. In this position, the control catch 27 mounted on the profiled head 26 is also disengaged from the inner gearing 33 of the toothed ring 19 . Thus, in this position of the involved components relative to one another, the belt shaft 13 can rotate freely. If, however, the control catch 27 engaged in the inner gearing of the toothed ring 23 is disengaged, the toothed ring 19 rotates together with the belt shaft in the direction of the belt extension, wherein the toothed ring 19 acts on the outer torsion rod 16 via the metal band 18 attached to the toothed ring, so that the low force limiting element becomes active on further rotation of the belt shaft.
FIG. 10 b shows a position of the control catch 29 , as implemented when switching the rocker arm 21 via the counter gear 22 , wherein the extension 41 of the rocker arm 21 now engages the control catch 29 in the motion path of the outer gearing 34 of the toothed ring 19 , so that the control catch 29 is grasped and pivoted when the rotation of the toothed ring 19 starts, wherein the pivoting of the control catch likewise pivots the catch 20 and definitely engages it in the outer gearing 34 of the toothed ring 19 and is entrained accordingly during engagement.
In the functional position shown in FIG. 10 b , the control catch 27 has not been engaged in the inner gearing 33 of the toothed ring 19 , so that the position according to FIG. 10 b exemplifies the switching position in which, on activation of the locking system and engagement of the control catch 27 , the toothed ring 19 is directly fixed in a force-transmitting manner on the housing leg 12 and/or housing 11 via the catch 20 . Thus, in this position the second torsion rod that is disposed outside the belt shaft cannot become active with the low level of force limitation. When the catch 20 is engaged in the outer gearing 34 of the toothed ring 19 , only the torsion rod 15 having the high level of force limitation disposed in the belt shaft 13 will in fact be engaged. In FIG. 10 c , this state is shown in a certain intermediate position before the catch 20 is fully engaged in the outer gearing 34 of the toothed ring 19 ; consequently, the catch 20 is “ready for coupling”.
According to the exemplary embodiment shown in FIG. 11 a - c , the arrangement of a pretensioned spring 50 , which pretensions the control catch 29 in the direction of the engagement thereof in the outer gearing 34 of the toothed ring 19 , ensures that when the control catch 29 is engaged in the gearing of the toothed ring 19 , an additional switching force and/or additional torque is created. For this purpose, the end of the control catch 29 is tensioned by the pretensioned spring 50 , which is supported oh a spring abutment 51 provided on the belt retractor housing 11 . The pretensioned spring 50 is disposed and oriented with respect to the control catch 29 such that, in the release position of the control catch 29 for the toothed ring 19 , the spring force line extends via the pivot bearing 56 of the control catch 29 on the catch 20 so that in this resting position of the control catch 29 , the pretensioned spring 50 does not create additional torque that would have to be absorbed by the associated holding device. This holding device comprises a gate 52 that is guided displaceably on the spring abutment 51 , wherein the gate fixes the pretensioned spring 50 in the initial position shown in FIG. 11 a . The gate 52 in turn interacts with a holding lever 53 rotatably mounted about a pivot point 54 , said holding lever being positively supported by means of a lever arm in a recess 55 that is configured on the toothed ring 19 . Hence, in the position shown in FIG. 11 a , the control catch 29 is held in the non-engaged position thereof with the outer gearing 34 of the toothed ring 19 .
When an operational demand causes a rotation of the toothed ring 19 is started, this rotation of the toothed ring 19 causes the holding lever 53 to be released from the recess 55 of the toothed ring 19 , pivoting as a result and displacing the gate 52 in the spring abutment 51 such that the pretensioned spring 50 is released, consequently acting upon the control catch 29 . This functional position is shown in FIG. 11 b.
When the position of the counter gear 22 is as described in FIG. 10 b , the control catch 29 is engaged in the motion path of the outer gearing 34 of the toothed ring 19 and is grasped and pivoted with the onsetting rotation of the toothed ring 19 . This engaging movement of the control catch 29 , prompted by the pivoting of the control catch 29 , is supported by the buckling pretensioned spring 50 that consequently exerts additional torque on the control catch 29 . In this way, the switching operation is made irreversible because as a result of the action of the pretensioned spring 50 the control catch is also kept engaged in the outer gearing of the toothed ring, and the control catch 29 at the same time acts as a return stop for the toothed ring 19 .
FIGS. 12 and 13 again show the connection of the second torsion rod 16 , which is disposed outside the belt shaft 13 , to the low level of force limitation and to the toothed ring 19 via the metal band 18 . From FIG. 12 it is apparent that upon rotation of the toothed ring 19 , the metal band 18 is unwound from the winding spool 17 , which, due to the torque-proof connection thereof to the torsion rod 16 , twists this torsion rod while absorbing a force. If, according to FIG. 13 , the metal band 18 is fully unwound from the winding spool 17 , a rigid system is created with respect to the force transmission via the rotatable toothed ring 19 as a result of the force-transmitting attachment of the metal band 18 to the torsion rod 16 .
In another embodiment for the arrangement of a force limiting element having a lower level of force limitation shown in FIGS. 14 and 15 , the function of the self-locking seat belt retractor is accomplished as described above. In the embodiment shown in FIGS. 14 and 15 , the additional torsion rod having the lower level of force limitation is merely replaced by a bending brake. This bending brake comprises a pulling element 60 , preferably in the form of a metal band made of a suitable material, which is attached with one end thereof to the toothed ring 19 and is guided by a baffle 61 that is fixed to the housing. With one free end 62 , which forms a reserve for the pulling movement of the pulling element 60 through the baffle 61 , the pulling element 60 protrudes the baffle 61 . In the embodiment shown in FIG. 14 , the free end 62 of the pulling element 60 is placed outside around the rotatable toothed ring 19 after the baffle 61 and is thus available as a reserve. In the exemplary embodiment shown in FIG. 15 , this free end 62 is inserted in a separate reserve housing 63 that is disposed rotatably on the belt retractor housing 11 and may be extracted from there on rotation of the toothed ring 19 .
The function of the belt retractor according to the present invention will again be explained with reference to the above-mentioned explanations of the functions of the individual components thereof.
If an occupant fastens the not illustrated seat belt webbing that is wound on the belt shaft 13 of the seat belt retractor 10 and thus extends it from the belt shaft 13 , the counter gear 22 records the extent of the belt webbing extension, wherein the switching lug 30 located on the shaft gear wheel 23 meets with the switching lug 32 a of the gear wheel 25 mounted on the rocker arm 21 after an appropriate number of revolutions of the belt shaft and switches the rocker arm 21 into a position illustrated in FIG. 10 b upon reaching this switching point. Reaching the switching point during belt extension means that an accordingly large occupant has fastened the seat belt and needs the corresponding amount of belt webbing. In case of an accident, only the large force limiting level will apply to such a large occupant so that upon reaching the prescribed switching point, the control catch 29 is placed in the rotation path of the outer gearing 34 of the toothed ring 19 . If during the accident the belt shaft 13 and toothed ring 19 are coupled by the engagement of the control catch 27 mounted on the profiled head 26 in the inner gearing 33 of the toothed ring 19 , the toothed ring 19 actuates the control catch 29 , which consequently engages the catch 20 in the outer gearing 34 of the toothed ring 19 , so that the toothed ring is fixed to the housing 11 . In this position, the second torsion rod 16 and/or the pulling element 60 having the low level of force limitation cannot become active. When the embodiment according to FIG. 11 a - c is implemented, the dynamic engagement of the control catch 29 with the catch 20 in the outer gearing 34 of the toothed ring 19 is supported by the pretensioned spring 50 .
If, on the other hand, a smaller occupant fastens the seat belt, the switching point between the switching lugs 30 and 32 a activated by the corresponding belt extension will not be reached, so that the rocker arm 21 remains in a position, in which, according to FIG. 10 a , it keeps the control clutch 29 disengaged from the outer gearing 34 of the toothed ring 19 . In this position, upon coupling to the belt shaft 13 , due to the disengagement of the control clutch 27 from the inner gearing 33 of the toothed ring 19 as a result of an accident, the toothed ring 19 may now rotate relative to the housing, unwinding the metal band 18 from the winding spool 17 ; the rotation of the winding spool 17 produces a force-absorbing twisting of the torsion rod 16 . As the level of force limitation of the torsion rod 16 is lower than the level of force limitation of the torsion rod 15 of the belt shaft 13 , only the low level of force limitation is active when the toothed ring 19 can be rotated, which is appropriate for a smaller occupant. This applies accordingly to the arrangement of the pulling element 60 as a force limiting element.
If upon buckling up an occupant has required such an amount of belt webbing that the corresponding switching point of the counter gear 22 has not been reached yet, it will first remain in the position described for FIG. 10 b . However, as an occupant buckled up in such a way moves, bends forward, for example, more belt webbing is extended, and as this belt extension exceeds the correspondingly adjusted switching point between the switching lugs 30 and 32 a , the rocker arm 21 will also be switched for this possibly short-term state, and in this respect a switching readiness in regard to switching only the torsion rod 15 is brought about. If in such a case the occupant straightens up again, the belt retraction associated with a back rotation of the belt shaft 13 causes the switching lug 32 b of the gear wheel 25 disposed on the rocker arm 21 to meet with the switching lug 31 of the gear wheel 24 disposed on the bearing plate 28 , and this results in a new switching motion of the rocker arm 21 into the position in which, according to FIG. 10 a , the rocker arm 21 keeps the control catch 29 disengaged from the toothed ring 19 so that the toothed ring is in turn freely rotatable. This back and forth switching is perceivable to the buckled-up occupant; however, it ensures that, depending on the sitting position at the moment of the accident, either the low level of force limitation, or directly the high level of force limitation is also switched with smaller occupants in order to prevent excessive forward displacement of the occupant in the latter case.
A similar switching state is also possible if, in case of an accident, the belt release related to the second torsion rod 16 becoming active results in the switching point being exceeded, wherein an occupant who in the this case is first subject to the low level of force limitation gets too close to a vehicle part. In such a case as well, in particular as a result of the arrangement of the control catch 29 , the catch 20 may be engaged in the rotating toothed ring 19 , thus activating the high level of force limitation according to FIG. 10 c.
The characteristics of the subject matter of the invention disclosed in the specification, claims, abstract and drawings can each be fundamental for the execution of the present invention in the different embodiments as such or in any combination thereof.
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A seat belt retractor for motor vehicles with a vehicle-sensitive or belt webbing sensitive controllable locking device, or both, for the belt shaft, having a profiled head that acts as a support for a displaceably mounted locking member that locks the belt shaft in the housing, and a two-stage force limiting device having two force limiting elements that are switchable between a high level and a low level of force limitation via an interposed coupling ( 19, 20 ) that is controlled by means of a control device having a countergear which determines an amount of belt webbing that is extended from the belt shaft.
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TECHNICAL FIELD
This invention relates to electrical engineering, and particularly to an arrangement by which desired electronic components of an electrical system may be given redundancy while not requiring redundancy of other parts of the system.
BACKGROUND OF THE INVENTION
There are electrical systems made up of plural components, some of which are inherently unlikely to fail, or impractical of replication, while others are of nature more susceptible of failure or of replication. Redundancy is an engineering principal by means of which the likelihood of system failure is reduced by replication of parts so that if any components fail, a duplicate may be substituted automatically or with slight delay.
For an example of a system where partial redundancy is desirable, consider the apparatus used to indicate the quantity or depth of fuel in the tanks of a large aircraft. The sensors or depth probes in the fuel tanks are physical structures not apt to any kind of failure, and the indicating devices observed by the pilot are likewise sturdy mechanical structures from which continued satisfactory performance may be expected. However, other components in such a system, which may be quite complex for a large aircraft and may include amplifiers, power supplies, multiplexers, microprocessors, and so on, are electronic in nature and statistical failure within a given period of time can be predicted with some certainty.
Difficulty has been experienced in the past, however, in providing electronic components which would not debase each other's accuracy when used concurrently, yet would be able to replace one another in case of failure. An example of this is operational amplifiers, which when connected in parallel to a current signal source divide the signal between themselves, so that neither gives an output correctly representative of the signal.
SUMMARY OF THE INVENTION
The present invention comprises circuitry by means of which two electronic components can be permanently connected physically to a single device in such a fashion that one of the components can be used as an accurate, independent device, yet upon failure of that one component the other can be quickly, safely and, if necessary, automatically substituted for the first one, to give redundancy of that portion of the system without requiring redundancy of other system components.
Various advantage and features of novelty which characterize the invention are pointed out with particularity in the claims annexed hereto and forming a part hereof. However, for a better understanding of the invention, its advantages, and objects attained by its use, reference should be had to the drawing which forms a part hereof, and to the accompanying descriptive matter, in which there is illustrated and described a preferred embodiment of the invention.
BRIEF DESCRIPTION OF THE DRAWING
The single FIGURE of the drawing shows the invention embodied in a practical indicating circuit.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In the drawing a measuring impedance 20 is shown as a capacitor of which the capacitance varies with a condition being measured, as for example the depth of liquid fuel in a tank. A first terminal of capacitor 20 is connected through conductor 21, a junction point 22, and conductor 23 to a excitation signal generator 24, which supplies a constant voltage between conductor 23 and a ground connection 25. The second terminal of capacitor 20 is connected, through conductor 26, a junction point 27, and conductor 30, to the inverting input terminal of a first operational amplifier 31 having a non-inverting input terminal grounded at 32 and supplying an output on a conductor 33 to a junction point 34. The second terminal of capacitor 20 is also connected, through conductor 26, junction point 27, conductor 35, a junction point 36, conductor 37, a junction point 40, and conductor 41 to the inverting input terminal of a second operational amplifier 42 having a non-inverting input terminal grounded at 43 and supplying an output on a conductor 44 to a junction point 48. It is intended that amplifiers 31 and 42 be mutually redundant.
A first feedback circuit 45 is associated with amplifier 31, and includes a capacitive feedback impedance 46 and a single pole double throw switch 47 having a movable contact 50 and first and second fixed contacts 51 and 52. Capacitor 46 is connected by conductors 53 and 54 to junction point 36 and movable contact 50. Fixed contact 51 is connected to junction point 34 by conductor 55. Fixed contact 52 is grounded at 56.
A second feedback circuit 57 is associated with amplifier 42, and includes a capacitive feedback impedance 60 and a single pole double throw switch 61 having a movable contact 62 and first and second fixed contacts 63 and 64. Capacitor 60 is connected through conductor 65, a junction point 66, and conductor 67 to junction point 40, and by conductor 70 to movable contact 62. Fixed contact 64 is connected to junction point 48 by conductor 71. Fixed contact 63 is grounded at 72.
Junction points 34 and 48 are connected to a selector 73 by conductors 74 and 75, which may include coupling impedances 76 and 77 if desired. The selector supplies one of the amplifier outputs on a conductor 80 to a utilization device 81 shown as operating an indicating needle 82. By way of illustration, a manual knob 83 is shown as operating selector 73 and switches 47 and 61 through mechanical connections 84, 85, 86, and 87.
A first rebalance circuit 90 is associated with amplifier 31, and includes a capacitive rebalance impedance 91, a single pole double throw switch 92 having a movable contact 93 and first and second fixed contacts 94 and 95, and a voltage divider 96 having a winding 97 and a movable contact 100. Winding 97 is energized from source 24 through conductor 23, junction point 22, an inverter 101, a junction point 102, and conductor 103, and through ground connections 25 and 104. Movable contact 100 is connected to first fixed switch contact 94 by conductor 105, second fixed switch contact 95 is grounded at 106, and capacitor 91 is connected between movable switch contact 93 and junction point 36 by conductors 107 and 110.
A second rebalance circuit 111 is associated with amplifier 42, and includes a capacitive rebalance impedance 112, a single pole double throw switch 113 having a movable contact 114 and first and second fixed contacts 115 and 116, and a voltage divider 117 having a winding 120 and a movable contact 121. Winding 120 is energized from source 24 through conductor 23, junction point 22, inverter 101, junction point 102, and conductor 122, and through ground connections 25 and 123. Movable contact 121 is connected to second fixed switch contact 116 by conductor 124, first fixed switch contact 115 is grounded at 125, and capacitor 112 is connected between movable switch contact 114 and junction point 66 by conductors 125 and 126.
Movable contacts 100 and 121 are actuated through mechanical connections 127 and 130 by utilization device 81 concurrently with needle 82. Movable switch contacts 93 and 114 are actuated simultaneously with those of switches 47 and and 61 by mechanical connections 131, 132, and 133. It will be appreciated that, if desired, selector 73 may include or be operated by a sensing and relay arrangement which goes into operation if conditions warrant it, as indicated below.
The circuit can be implemented quite easily with solid state components in place of the mechanical components. In such a system, utilization device 81 would be replaced by a comparator circuit connected to a microprocessor controlled successive approximation type Analog-to-Digital (A/D) converter which would be used to simultaneously acquire the binary code representing fuel depth and adjust the feedback voltage at 100 and 121. This adjustment would be accomplished by replacing voltage dividers 96 and 117 with Digital-to-Analog (D/A) converters. Then the mechanical feedback links 127 and 130 would be replaced with control lines from the output port of the microprocessor controller to select a bit pattern appropriate to supply the voltages at 100 and 124 to bring the amplifier 31 or 42 output to a null, i.e. zero volts. In like manner, the switches 47, 61, 92, 73 and 113 can be any of the solid-state type electronic analog switches and are controlled by logic circuitry connected to the microprocessor controller output ports, instead of mechanical linkages 84, 85, 86, 87, 131, 132 and 133.
OPERATION
Consider first the operation of the invention without rebalance circuits 90 and 111. The capacitance of capacitor 20 is at some value determined by the depth of fuel being measured, and excitation generator 24 supplies, through capacitor 20 a current determined by its capacitive reactance. Amplifiers 31 and 42 are current devices, and if simply connected in parallel would attempt to divide the current from capacitor 20, so that neither amplifier would give an output representative of the fuel depth. However, feedback capacitor 60 is grounded at 72 and capacitor 112 is grounded at 125. As is well known, a feedback current is supplied through capacitor 46 which is equal in magnitude and opposite in phase to that from capacitor 20, so that junction points 27, 36, 40 and 66 which define an input bus, are all maintained at ground potential. No voltage appears across capacitors 60 and 112 therefore no current flows through either capacitor and since the input impedance of amplifier 42 is large, essentially no signal current is drawn by it. The output voltage at junction point 34 is thus representative of the fuel depth which is proportional to capacitor 20's current, and is supplied through selector 73 to device 81.
Turning now to the rebalance circuits 90 and 111, movable contact 121 is disconnected at switch 113, but movable contact 100 is connected to junction point 36 through capacitor 91, and a current is supplied through capacitor 91 of the same phase as that supplied through capacitor 46. The output of amplifier 31 may now become zero, the current through feedback capacitor 46 decreasing as that from rebalance capacitor 91 increases, while maintaining the amplifier input at zero volts, until the current through capacitor 91 is exactly equal and opposite to that from capacitor 20, when needle 82 indicates the depth of fuel in the tank, and the amplifier input and output are both at zero volts.
Now suppose that selector 73 and switches 47, 61, 92, and 113 are reversed. The output of amplifier 31 is cut off from device 81 and that from amplifier 42 is substituted. The feedback circuit for amplifier 42 is now complete through capacitor 60, and amplifier 42 now operates instead of amplifier 31 to maintain the input bus at ground potential by supplying a feedback current, equal and opposite to that from capacitor 20 until it is replaced by current from rebalance voltage divider 117 through capacitor 112. Capacitors 91 and 46 are grounded, and comprise no load on capacitor 20 since the voltage across these capacitors is zero. The output of amplifier 42 may now become zero, and needle 82 again indicates the depth of fuel this time using amplifier 42 rather than amplifier 31.
It is clear that in this combination of amplifiers each is redundant to the other. If desired, components 73 or 81 may include a watch dog circuit continuously monitoring one of the amplifier outputs, and automatically actuating the switches and selector, if the monitored output fails to automatically substitute the other amplifier and perhaps perform an appropriate indicating function that shows failure has occurred, as is well known in redundancy arrangments.
Numerous characteristics and advantages of the invention have been set forth in the foregoing description, together with details of the structure and function of the invention, and the novel features thereof are pointed out in the appended claims. The disclosure, however, is illustrative only, and changes may be made in detail, especially in matters of shape, size, and arrangement of parts, within the principle of the invention, to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed.
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A redundancy circuit comprising, in combination: a first measuring impedance; a plurality of operational amplifiers having inverting input terminals, non-inverting input terminals, and output terminals; a source of excitation voltage with respect to ground, the source being connected to the measuring impedance thus supplying signal current to the inverting input terminals, and the non-inverting input terminals being grounded; a like plurality of further impedances having first terminals connected respectively to the inverting terminals of the amplifier; and a switching arrangement having a plurality of conditions in each of which a selected one of the further impedances is connected between the output terminal and the inverting input terminal of a selected one of the amplifiers, and the remaining further impedances are connected between the inverting input terminals of the remaining amplifiers and ground.
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BACKGROUND OF THE INVENTION
The present invention relates to cable trays for use with electrical cables.
Cable trays are used to support electrical cables which run through factories and other structures. Cable trays may have straight and (horizontally and vertically) curved sections to accommodate the installation requirements of a particular setting.
One type of known cable tray has a pair of parallel side rails or stringers that are interconnected with a plurality of transverse rungs at predetermined intervals along the length of the parallel side rails. Cables are laid on top of the rungs. The rungs are typically attached to the side rails by fasteners, or are welded to the side rails. The parallel side rails may be joined end-to-end by a splice plate or a connecting bar. However, since these cable trays generally do not secure the cables in spaced relation to each other, they may be unsuitable for use with high power cables where there may be a need to keep the cables cool, or to prevent the cables flailing in the event of a fault or short circuit.
A cable tray more suited to high power cables is disclosed in U.S. Pat. No. 3,618,882 to Podedworny. In Podedworny, two abutting support blocks with semi-circular cut-outs on adjacent faces provide a housing with cylindrical openings that confine the cables in spaced relation in the cable tray. The blocks are secured to each other and to a rung by bolts extending vertically through the blocks and into the rung.
To install the type of cable tray disclosed by Podedworny, lower support blocks may be placed on rungs with their semi-circular face facing upwardly and the lower support blocks may be temporarily held in place by bolts. Cables may then be laid into the semi-circular channels without risk of the support blocks shifting or falling over. Next, the bolts may be removed, the upper support blocks set in place and the bolts again inserted to complete the assembly. This manner of assembly is time consuming and may become difficult where the tray has a large vertical curve. More specifically, with a large vertical curve, as it becomes hard to keep a lower support block properly positioned while the bolts are inserted and there is also a risk of the lower support block shifting when the bolts are removed preparatory to installing the upper support blocks.
SUMMARY
The present invention seeks to provide a cable tray which is easier to install.
In accordance with an embodiment of the present invention, a cable tray has a pair of opposed side rails with a pair of aligned through bores. One or more stacked cable support blocks extend between the opposed side rails. A lower rung extends between the rails at the pair of aligned through bores. The lower rung has an upwardly opening channel extending along its length receiving the bottom edge of a lowermost one of the cable support blocks. The lower rung also has at least one opening extending through the lower rung in alignment with the pair of aligned through bores. A fastener extends through at least one opening of the lower rung and through at least one of the pair of aligned through bores in the side rails.
These and other features, aspects, and advantages of the present invention will become better understood with reference to the following description in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
In the figures which illustrate example embodiments of the invention:
FIG. 1 is a perspective view of a cable tray made in accordance with this invention;
FIG. 2 is a front view of the cable tray of FIG. 1 ;
FIG. 3 is a cross-sectional view along the lines 3 - 3 in FIG. 2 ;
FIG. 3A is a magnified view of FIG. 3 ;
FIGS. 4 , 5 , and 6 are exploded fragmentary views of a portion of the cable tray of FIG. 1 illustrating assembly of the cable tray;
FIG. 7 is a cross-sectional view along the lines 7 - 7 in FIG. 6 ; and
FIG. 8 is a fragmentary perspective view of a portion of a cable tray made in accordance with another embodiment of the invention.
DESCRIPTION
Referring to FIG. 1 , a cable tray 10 has a pair of opposed side rails 12 a and 12 b to which are attached opposed pairs of lower and upper rungs 14 L, 14 U. A plurality of cable support blocks 26 , 28 are held in place by each pair of rungs, and cables 32 extend through cylindrical openings formed by the support blocks. Vented covers 17 may be attached to the upper and lower rungs 14 U, 14 L.
Turning to FIGS. 2 , 3 , and 3 A, each of rungs 14 L and 14 U has a U-shaped profile which provides a central channel 16 along the length of each rung. An opening 34 extends along the length of each of the two side arms 19 of each rung. The lowermost support block 26 L is fitted into the central channel 16 of the lower rung 14 L and the uppermost support block 26 U is fitted into the central channel 16 of the upper rung 14 U. Each rung is positioned so that its openings 34 are aligned with aligned through bores 50 ( FIG. 4 ) in opposed side rails 12 a , 12 b . A rod 18 runs through each opening 34 in the rungs and through the through bore 50 ( FIG. 4 ) in each of the side rails 12 a , 12 b . The rods are threaded and a flange nut 20 is threaded to either end of each rod to attach the rungs to the side rails.
Cable support blocks 26 L and 26 U are identical in configuration but oriented oppositely. Thus, each of the support blocks 26 L, 26 U has one straight face 42 (which for block 26 L is the lower face and which for block 26 U is the upper face) and one face 44 with four semi-circular cut outs 45 (which for block 26 L is the upper face and which for block 26 U is the lower face). It is the straight face 42 of each block 26 L, 26 U which is fitted into the channel 16 in a rung 14 L, 14 U.
Cable support blocks 26 L, 26 U sandwich cable support blocks 28 L, 28 U. Cable support blocks 28 L and 28 U are identical in configuration but oriented oppositely. Thus, each of support blocks 28 L and 28 U has one face 70 with four semi-circular cut outs 45 (which for block 28 L is the lower face and which for block 28 U is the upper face) and an opposite face 72 with five semi-circular cut outs 45 (which for block 28 L is the upper face and which for block 28 U is the lower face). As best illustrated in FIG. 3A , the faces 44 , 70 , and 72 are radiused at the semi-circular cut-outs to prevent cutting or chafing of the cable insulation. The semi-circular cut-outs in adjacent blocks align to form offset rows of cylindrical openings 60 for receiving cables.
Turning to FIG. 4 , side rails 12 a , 12 b have opposed inwardly facing channels 46 at the ends of each rung 14 L which receive the ends of the support blocks 26 , 28 . In this regard, as illustrated in FIG. 7 , the cable support blocks 26 , 28 have a length greater than the spacing between the opposed side rails 12 a , 12 b but less than the spacing between the bottoms of opposed channels 46 of the side rails.
A pair of inwardly facing depressions 52 extend along each side rail 12 a , 12 b from each end of each side rail. In consequence, the depressions of a side rail 12 b line up with like depressions in a side rail 12 b ′ placed end-to-end with side rail 12 b , resulting in extended length depressions. Within each depression 52 of a side rail, a through bore 54 extends through the side rail. A splice plate 22 has a pair of protuberances 56 of complementary width to that of the extended length depressions, with longitudinally extending slots 58 extending through the splice plate at the protuberances. These protuberances of the splice plate may be fit into the extended length depressions with the slots 58 aligning with through bores 54 . Bolts 24 (with lock washers—not shown) and grommet nuts 30 may then be joined through each of the aligned through bores 54 and slots 58 to join the splice plate to the side rails 12 b , 12 b ′. The bores 54 may be positioned such that when the end-to-end side rails are joined by a splice plate, there is a gap between the side rails. This gap between the side rails, along with the longitudinally extending slots 58 allows for thermal expansion.
To assemble cable tray 10 , with reference to FIGS. 3A and 4 , lower rungs 14 L are first joined to side rails 12 a , 12 b by positioning each lower rung so that rods 18 may be inserted through a pair of adjacent through bores 50 in one side rail, through C-shaped openings 34 in the lower rung and out the pair of through bores 50 in the opposite side rail. Flange nuts 20 may then be threaded to the ends of the rods. Next, for each installed lower rung, a lower cable support block 26 L may be slid down opposed channels 46 of the side rails 12 a , 12 b and into channel 16 of the lower rung. Optionally, at this stage, cover sections 17 ( FIG. 1 ) could be installed on the bottom of the partially assembled cable tray. The cable tray, thus far assembled, may then be moved to its installed position and secured in position in any suitable fashion. This may be repeated with an adjacent section of cable tray and the adjacent section joined to the first section by splice plates 22 .
With all of the sections of cable tray secured in position, a first row of cables 32 may be laid into the cable trays such that each cable is received by the semi-circular cut 45 outs of the lower block 26 L. Turning to FIG. 5 , a cable support block 28 L may then be slid down opposed channels 46 in the side rails at each lower rung into abutment with block 26 L. In this position, the semi-circular cut outs 45 in block 28 L form, with semi-circular cut outs 45 in block 26 L, cylindrical openings 60 which confine each cable 32 in the first row of cables. Turning to FIG. 6 , a second row of cables 32 may then be laid into the semi-circular cut outs 45 in the top face of block 28 L. Thereafter, a cable support block 28 U may then be slid down opposed channels 46 in the side rails at each lower rung and into abutment with block 28 L. In this position, the semi-circular cut outs 45 in block 28 U form, with semi-circular cut outs 45 in block 28 L, cylindrical openings 60 which confine each cable 32 in the second row of cables. A third row of cables may then be laid into the semi-circular cut outs 45 in the top face of block 28 U. Thereafter, a cable support block 26 U may be slid down opposed channels 46 in the side rails at each lower rung and into abutment with block 28 U. In this position, the semi-circular cut outs 45 in block 26 U form, with semi-circular cut outs 45 in block 28 U, cylindrical openings 60 which confine each cable 32 in the third row of cables. Lastly, for each block 26 U, an upper rung 14 U is positioned so that the top face 42 of block 26 U is received by the channel 16 of the upper rung. The upper rung is then joined to side rails 12 a , 12 b by inserting rods 18 through a pair of adjacent through bores 50 in one side rail, through openings 38 in the upper rung and out the pair of through bores 50 in the opposite side rail. Flange nuts 20 may then be threaded to the ends of the rods. The result is that the support blocks 26 , 28 are clamped in place between the rungs 14 L, 14 U and the blocks 26 , 28 hold the cables in place. Lastly, cover sections 17 ( FIG. 1 ) may be installed.
As is apparent from FIG. 2 , adjacent rows of cables are staggered in a trefoil formation which balances the electromagnetic fields produced by the power cables thereby lowering system impedance and reducing power losses in addition to optimizing load sharing amongst the cables. Further, this improves heat dissipation of the assembly and reduces the prospects of a flailing cable impacting (and shorting to) another cable. The radiusing of the edges of the openings 60 also help to prevent cable damage.
It will be apparent from the foregoing that cable trays according to this invention ease installation in the field. For instance, assembly does not require any step of partial disassembly and the support blocks will stay in place even in vertically curved cable tray sections.
Numerous modifications may be made without departing from the spirit of the invention.
For example, with wider side rails, a greater number of blocks 28 could be used to increase the number of rows of cables. Also, with narrow side rails, only blocks 26 L, 26 U could be used to construct a cable tray with one row of cables. Indeed, in a relatively low power application where there is little concern for flailing cable in the event of an electrical fault and where only one row of cables is needed, it may be possible to install only the lower rungs 14 L and lower support blocks 26 L and simply set the one row of cables into the semi-circular cut outs of the top face of the lower support blocks 26 L.
While not preferred, the joining wall of the U-shaped rungs could be thickened and be provided with a single opening in place of openings 38 in the side arms 19 of the rungs. In such instance, the rungs would have a tendency to rotate until stabilized by a support block 26 L or 26 U being fitted into their central channels 16 .
The rungs could have other profiles which provide a channel to support the support blocks and openings to receive the rods.
While the openings 38 have been described as C-shaped, they could have other shapes and could, for example, be cylindrical bores through the rungs. However, a drawback with long bores through the rungs is that any foreign material that found its way into the long bores could jam the rods during installation.
While rods 18 have been described as threaded at both ends to receive nuts, the rods could equally be in the nature of long bolts such that nuts need be threaded to only one end of the rods. Further, a nut with a lock washer could be substituted for the described flange nuts. Alternatively, the rods could clamp the side rails with other mechanisms, such as cams.
In the alternate embodiment the rungs 14 L, 14 R do not have openings 34 and the long rods 18 are not used. Instead, as shown in FIG. 8 , the rungs 114 L have ears 190 at each end with through bores 192 . Each through bore 192 aligns with a bore 50 ( FIG. 4 ) in a side plate and a bolt 194 extends through the bore 50 ( FIG. 4 ) and the aligned bore 192 and is held in place by a flange nut 196 . Top rung is similarly configured. Alternatively, vertical slots could be cut into rungs 14 L, 14 R proximate their ends so that the modified rungs could be used with bolts 194 and nuts 196 . However, these options considerably complicate installation of the top rung, especially where, as is often the case, the cable tray is proximate the ceiling. Further, this reduces the strength of the assembly. Yet further, in an industrial setting subject to significant vibration, any necessary re-tightening of the nuts 196 as preventative maintenance would be difficult.
Other modifications will be apparent to those skilled in the art and, therefore, the invention is defined in the claims.
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A cable tray has a pair of opposed side rails with a pair of aligned through bores. One or more stacked cable support blocks extend between the opposed side rails. A lower rung extends between the rails at the pair of aligned through bores. The lower rung has an upwardly opening channel extending along its length receiving the bottom edge of a lowermost one of the cable support blocks. The lower rung also has at least one opening extending through the lower rung in alignment with the pair of aligned through bores. A fastener extends through at least one opening of the lower rung and through at least one of the pair of aligned through bores in the side rails.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Priority is claimed with respect to Application No. 100 07 268.2-26 filed in Germany on Feb. 17, 2000, the disclosure of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] The invention relates to a carding machine for the parallel arrangement of fibers by clothing guided along a carding track and having combing structures that engage in the fibers.
[0003] A carding machine of this type is used for the parallel alignment of fibers, in particular cotton fibers. The fibers are transported in bundles to a main carding cylinder in the shape of a cylindrical roller which is horizontally positioned. The fiber bundles are aligned in the circumferential direction of the main carding cylinder while positioned on the surface of the carding cylinder along the longitudinal length thereof.
[0004] Specifically, the fibers are transported in the circumferential direction on the main carding cylinder and engage in clothing fitted onto a carding track and guided over a cylinder arrangement. The clothing consists of individual flexible material strips with combing structures in the form of metal needles on the top.
[0005] The clothing extends in the longitudinal direction of the main carding cylinder, directly above its surface, so that the fibers are combed with these combing structures and are aligned in the circumferential direction of the main carding cylinder.
[0006] The clothing is fastened to respective flat bars guided along the carding track on the carding machine, wherein the dimensions of the flat bars are adapted to the dimensions of the clothing.
[0007] With known carding machines, the clothing rests on top of the flat bars. The flat bars are wider at the upper end and have a rectangular cross-sectional profile, wherein the clothing rests on the complete upper front of the profile. Parts made of sheet metal or the like are attached to the side walls of the flat bars for reinforcement. These parts project slightly over the upper edge of the profile with the clothing, as well as over the lower edge of the profile. The projecting ends of the sheet metal parts are bent through beading, so that they fit against the top and bottom side of the profiles and thus secure the respective clothing on a profile.
[0008] The individual clothing is subject to relatively high wear and thus must be exchanged within a predetermined time interval. The clothing is removed for replacement from the carding machine, along with the fixedly attached flat bars. Subsequently, the clothing assembly is mechanically treated in a machine shop or servicing station in order to separate the clothing secured with the beading on the flat bars from these flat bars. New clothing is then attached to the flat bars and secured in place through beading of the sheet metal parts affixed to the side.
[0009] The disadvantage of this type of arrangement is that the assembly for replacing the clothing is extremely involved. Particularly disadvantageous is the fact that changing the clothing requires corresponding mechanical tools, so that the replacement cannot be made at the location of the carding machine, but must be made in a machine shop or servicing station. Thus, the replacement of clothing not only requires considerable time for the assembly, but also results in a considerable expenditure due to transport time and transport costs.
SUMMARY OF THE INVENTION
[0010] It is an object of this invention to provide a carding machine of the aforementioned type in such a way that the replacement of clothing is made as simple as possible.
[0011] The above and other objects are accomplished according to the invention by the provision of an arrangement for a carding machine for parallel arrangement of fibers, including: a carding track; a plurality of flat bars arranged for being guided along the carding track; clothing positioned respectively on each flat bar, the clothing including clothing structure that engages in the fibers; and means for releaseably fastening the clothing to each flat bar.
[0012] The essential advantage of fastening the clothing in this way to the flat bars is that the clothing can be fastened and repeatedly released by using simple tools. The clothing can therefore be replaced easily and quickly at the location of the carding machine. It is particularly advantageous in this case that the fastening mechanism can be attached to the flat bars, and can be are reversibly detached or released so that the mechanism can be reused after the clothing has been replaced.
[0013] The clothing of one particularly advantageous embodiment of the invention is attached to a rigid base support, for example a sheet metal part.
[0014] The sheet metal part with attached clothing forms a stable structural unit that can be mounted flexibly and easily to a flat bar. In particular the flexible clothing is protected in that case against mechanical damage or being pulled out of shape. Furthermore, it is advantageous that the dimensionally stable structural unit, consisting of base support and clothing, can be positioned easily and safely on the flat bar, thus making it easier to attach to the flat bar.
[0015] According to one preferred embodiment, brackets are used as means for securing the clothing to a flat bar. In that case, the clothing with base support is positioned on the top front of the flat bar. The brackets are then fitted from the side onto the flat bar and the clothing that rests on top.
[0016] The fastening means for another advantageous embodiment are guides in the flat bars, into which the clothing secured on the base support can be inserted.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] The invention is explained in the following with the aid of the accompanying drawings.
[0018] [0018]FIG. 1 is a schematic representation of an end view of a carding machine for the parallel arrangement of fibers.
[0019] [0019]FIG. 2 is an enlarged, detailed view of a portion of the carding machine according to FIG. 1, showing clothing attached to flat bars and engaged in fibers.
[0020] [0020]FIGS. 3 a and 3 b are schematic end views which show first and second exemplary embodiments, respectively, of a base support for the clothing.
[0021] [0021]FIG. 4 is a schematic end view of a first exemplary embodiment of the fastening mechanism for fastening clothing to a flat bar.
[0022] [0022]FIG. 5 is a schematic end view of a second exemplary embodiment of the fastening mechanism for fastening clothing to a flat bar.
DETAILED DESCRIPTION OF THE INVENTION
[0023] [0023]FIG. 1 shows an exemplary embodiment of a carding machine 1 for the parallel alignment of fibers 2 , in particular cotton fibers.
[0024] The carding machine 1 comprises a main carding cylinder 3 in the shape of a cylindrical roller, for which the longitudinal axis is positioned horizontally. The main carding cylinder 3 is positioned so as to rotate around a rotational axis that extends in the longitudinal direction and is made to rotate by means of non-depicted drives.
[0025] A carding track 4 that is driven by a system of rollers 5 adjoins the top of the surface of main carding cylinder 3 . The rollers 5 are arranged such that the carding track 4 is guided at a short distance from the surface, via an angular section of nearly 180°, wherein the carding track extends in the circumferential direction of the main carding cylinder 3 .
[0026] The fibers 2 are fed to the main carding cylinder 3 with the aid of an insertion device with insertion fitting or shoe 6 . The fibers 2 are guided as fiber bundles in the circumferential direction, while resting on the surface and in the longitudinal direction of the main carding cylinder 3 .
[0027] The sectional detail of carding machine 1 , shown in FIG. 2, shows that the fibers 2 are guided between the surface of the main carding cylinder 3 and the clothing 8 that is positioned on the fronts of flat bars 7 . The flat bars 7 are positioned on the carding machine.
[0028] The flat bars 7 are arranged as traveling flat assemblies on the carding track 4 , one after another and at a short distance to each other. The longitudinal axes of flat bars 7 extend in the longitudinal direction of the main carding cylinder 3 .
[0029] The dimensions for clothing 8 are approximately the same as for the flat bars 7 , and the clothing is composed of strip-type, elongated, web-like material layers 9 with comb structures 10 projecting from the top. The comb structures 10 are metal needle combs, which extend across nearly the complete surface of clothing 8 .
[0030] The comb structures 10 engage in the fibers 2 that are guided on the main carding cylinder 3 . As a result, the fibers are combed in the circumferential direction of the main carding cylinder 3 and are thus aligned parallel.
[0031] According to the invention, fastening means are provided for securing the clothing 8 to the flat bars 7 , which means are reversibly detachable. Thus, these means can preferably be fastened and released repeatedly from the flat bars with the aid of simple tools.
[0032] For this, the clothing 8 is not mounted directly on the flat bars 7 . Rather, the clothing 8 is secured on base supports 11 . A base support 11 with clothing 8 respectively forms a dimensionally stable structural unit, which can be positioned easily and precisely on a flat bar 7 .
[0033] [0033]FIGS. 3 a and 3 b show different embodiments for a base support 11 of this type, preferably consisting of sheet metal parts or thin metal profiles. In any case, the base support 11 is dimensionally stable and rigid, so that it can provide the flexible clothing 8 positioned thereon with a secure hold.
[0034] The exemplary embodiment shown in FIG. 3 a shows a base support 11 , for which the surface area is identical to the surface area of clothing 8 . The base support 11 in this case has a level surface upon which the clothing 8 rests.
[0035] The base support 11 shown in FIG. 3 b has a level surface, analog to the exemplary embodiment according to FIG. 3 a, on which the clothing 8 rests. In addition, the base support 11 is provided along its two longitudinal edges with edge strips 12 , which project from the top and secure the clothing 8 on the side. The height for edge strip 12 in this case is adjusted to the structural height of clothing 8 . The edge strips 12 preferably form one piece with the base body 11 a of base support 11 .
[0036] The clothing 8 is secured to the base support 11 , wherein the clothing 8 is preferably screwed on or glued to the base support.
[0037] The structural unit thus formed by securing the clothing 8 to the base support 11 is then releaseably fastened to the respective flat bar 7 .
[0038] In principal, the base support 11 can be attached to the flat bar 7 by screwing or gluing it to the top of the flat bar.
[0039] [0039]FIG. 4 shows fastening means for securing the clothing 8 with base support 11 to a flat bar 7 , thus making the assembly particularly easy, time-saving and cost-effective.
[0040] [0040]FIG. 4 shows that the flat bar 7 is provided at its upper end with a widening 7 a in the form of a rectangular cross-sectional profile, which is followed by the narrow back end 7 b of the flat bar 7 .
[0041] As a result, the flat bar 7 has two offsets 7 ′ a and 7 ′ b at the lower end of the profile, which are joined by two vertically extending side walls 7 ′ c and 7 ′ d and the level top 7 ′ e of the flat bar 7 .
[0042] For the assembly, the clothing 8 together with its base support 11 is placed on the top 7 ′ e of flat bar 7 , wherein the side walls 11 b and 11 c of base support 11 end flush with the side walls 7 ′ c and 7 ′ d of the profile for the flat bar 7 .
[0043] Brackets 13 that serve as means for fastening the flat bar 7 are snapped from the side onto the profiles. The brackets 13 consist of sheet metal parts or the like and have level support surfaces 13 a, which fit flush against the side walls 7 ′ c and 7 ′ d of the profile for flat bar 7 and the base support 11 resting thereon. A projection 14 projects from the supporting surface on the top and bottom side of each bracket 13 . The projection 14 on the top of bracket 13 rests against the top of base support 11 , or the top of projection 12 thereof, while the projection 14 on the underside of bracket 13 fits against the profile offset 7 ′ a, 7 ′ b of flat bar 7 . Thus, the brackets 13 secure the clothing 8 with base support 11 against being detached from the flat bar 7 . The brackets 13 can preferably be snapped without tools onto the base support 11 and the flat bar 7 and can also be released from these, without the brackets 13 being destroyed in the process.
[0044] The brackets 13 of one preferred embodiment are designed as rail-type elements, wherein each bracket 13 extends over the total length of flat bar 7 .
[0045] Alternatively, several individual brackets 13 can be arranged one after the other along the flat bar 7 .
[0046] [0046]FIG. 5 shows another embodiment of the means for securing the base support 11 with clothing 8 on the flat bar 7 . In this case, the fastening means consist of a guide in the flat bar 7 , wherein the guide preferably is designed as dovetail guide defining a groove 16 . The dovetail guide extends in the longitudinal direction of the flat bar 7 . The dovetail guide forms one piece together with the flat bar 7 and consists of two guide rails 15 , which respectively stop at a longitudinal edge on the top of flat bar 7 .
[0047] The heights of these guide rails 15 are adapted to the structural height of the base support 11 with clothing 8 positioned thereon.
[0048] In addition, the spacing between the guide rails 15 is adapted to the width of the base support 11 with clothing 8 positioned thereon, so that the base support 11 with clothing 8 fits tightly against the insides of the guide rails 15 .
[0049] The base support 11 with clothing 8 is inserted from the front or back end of flat bar 7 into the guide opening until the base support 11 with its total length rests on the top of flat bar 7 .
[0050] In order to secure the base support 11 on the flat bar 7 , threaded bores that are not depicted here can be provided in the side walls of guide rails 15 and the base support 11 . Screws for fastening the base support 11 to the guide rails 15 are inserted into these threaded bores.
[0051] Alternatively or in addition, the base support 11 with clothing 8 that is positioned in the guides, can be secured by closing off the end parts of the guides at the front and back end with a fastener that is not shown here. It is necessary in that case that the length of base support 11 matches exactly the length of flat bar 7 , so that the base support 11 fits tightly against the front and back end between the fasteners.
[0052] The fasteners can be plates, for example, onto which the front and back sides of the flat bar 7 are screwed. End caps or the like can also be provided alternatively as fasteners, which are attached to the flat bar 7 by snapping them in.
[0053] In a modification of the exemplary embodiment according to FIG. 5, the guides and the base body for flat bar 7 can also have a multi-part design.
[0054] For example, the base body for flat bar 7 can have a level top, on which the base support 11 with clothing 8 rests. The base support 11 again extends over the complete length of flat bar 7 . However, the top of flat bar 7 is wider than the width of the base support 11 . The edge strips that project over the clothing 8 contain bores for fastening.
[0055] Guide rails 15 are fitted onto these edge strips in order to secure the base support 11 . Screws extending through the fastening bores are used to secure the guide rails to the base body of flat bar 7 .
[0056] The invention has been described in detail with respect to preferred embodiments, and it will now be apparent from the foregoing to those skilled in the art, that changes and modifications may be made without departing from the invention in its broader aspects, and the invention, therefore, as defined in the appended claims, is intended to cover all such changes and modifications that fall within the true spirit of the invention.
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An arrangement for a carding machine for parallel arrangement of fibers, includes a carding track; a plurality of flat bars arranged for being guided along the carding track; clothing positioned respectively on each flat bar, the clothing including clothing structure that engages in the fibers; and a mechanism for releaseably fastening the clothing to each flat bar.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Application No. 60/036,704, filed on Jan. 31, 1997, the disclosure of which is hereby incorporated by reference herein.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to modifying zeolite minerals in order to increase their affinity for arsenic species, and their use in removing arsenic species from an aqueous medium.
2. Description of the Background Art
Arsenic is a shiny, gray, brittle element possessing both metallic and non-metallic properties. It is stable in its elemental form, but is most commonly found in the trivalent form (Arsenite) and pentavalent form (Arsenate). Its compounds may be organic or inorganic. The dominant forms of arsenic present in natural waters at common pH (6-8) are the monovalent H 2 AsO 4 - and the divalent HAsO 2- forms of arsenate and the uncharged form of arsenite, arsenious acid HAsO 2 .
Inorganic arsenic is highly toxic to mammals and aquatic species. When ingested, it is readily absorbed from the gastrointestinal tract, the lungs, and to a lesser extent from the skin, and becomes distributed throughout the body. Trivalent inorganic forms of arsenic are more toxic than the pentavalent forms. Recently, arsenic in water supplies has been linked to arsenical dermatosis and skin cancer.
Naturally occurring ubiquitous arsenic is present in the environment and makes of 0.00005% of the earth's crust. Hence it is found in trace quantities in many ground and surface waters. However, arsenic has many industrial uses such as hardening of copper and lead alloys, pigmentation in paints and fireworks, and the manufacture of glass, cloth, and electrical semiconductors. Arsenic is also used extensively in the production of agricultural pesticides, which includes herbicides, insecticides, desiccants, wood preservatives and feed additives. Runoff from these uses and the leaching of arsenic from waste generated from these uses have resulted in increased levels of various forms of soluble arsenic in water. Because of recent studies further revealing its toxicity, the United States Environmental Protection Agency (EPA) has classified arsenic as a human carcinogen (Group A) and is considering lowering its maximum contaminant level from its present requirement 50 parts per billion (ppb) to 5 ppb or less.
In order to keep the water supply safe for human consumption, and affordable to all, water utilities are presently examining methods of treating water in order to reduce levels of arsenic in the water to 5 ppb. One such method is adsorption, which is the bonding of an aqueous species to the surface of a solid grain. The solid grain is called the sorbent while the aqueous species is called the sorbate. The nature of the sorbent, including functional groups and the surface area available for adsorption, affects the affinity of the sorbent for specific contaminants. Also, the chemical character, shape, and configuration of the sorbate, its water solubility, its acidity, the polarity of the molecule, its molecular size and polarizability all affect its ability to sorb onto the reactive media.
One method for removing arsenic species from an aqueous medium is through the use of an alumina sorbent. U.S. Pat. No. 5,556,545 (Konstantin, et al.), which is incorporated by reference herein, discloses the use of activated alumina sorbent having a particulate size below 200 micrometers diameter and with sufficient porosity and pore diameters above 100 Angstroms to remove arsenic from water. This method is done using a slurry of the activated alumina sorbent and water. After a certain period of time, the activated alumina sorbent is removed and the water is recovered. The spent activated alumina sorbent is then regenerated and recycled.
However, the use of activated alumina as sorbent contains some inherent limitations. For example, in order to make the removal of arsenic with activated alumina sorbent an economically feasible process, rejuvenation and conditioning of the sorbent for subsequent use is necessary. Rejuvenation and conditioning of the sorbent is a process wherein the sorbent is made to release its adsorbed arsenic. Therefore, this rejuvenation process creates a hazardous solution which requires further treatment and ultimately expensive disposal costs.
Another limitation connected with the use of activated alumina as a sorbent to remove arsenic species from water involves the regeneration of the sorbent. More specifically, some sorbent is lost in every regeneration due to the strong alkaline solution necessary to remove the adsorbed arsenic. Hence, lost activated alumina sorbent must continuously be replaced which substantially increases the cost of using activated alumina as a method for removing arsenic from an aqueous medium.
Another method for removing arsenic species from an aqueous medium is through the use of activated carbon. Activated carbon is available in powdered (PAC) and granular (GAC) forms. The powdered form is generally utilized in a batch process, most often in conjunction with another unit process. Studies have shown that the addition of a powdered activated carbon to a lime softening process can enhance arsenic removal (Dutta, A. and M. Chaudhuri. "Removal of arsenic from groundwater by lime softening with powdered coal additive." Aqua, vol. 40, no. 1 (1991) pp. 25-29). Lime softening and PAC alone were found to remove 90% and 15%, respectively of the aqueous arsenic species present.
However, the use of activated carbon to remove arsenic species from an aqueous medium has inherent limitations in that activated carbon has a limited natural capacity for adsorbing arsenic species. Further, activated carbon has a high cost making it less attractive as a chosen method for removing arsenic species from an aqueous medium.
Yet another method for removing arsenic species from an aqueous medium is through the use of fly ash. Fly ash is a waste product produced in large quantities at coal power stations. It is composed primarily of calcium oxide, CaO, but also may contain magnesium, aluminum and iron oxides.
However, the properties of fly ash produced by a particular power station are dependent upon the fuel used at that power station. Hence, quality control and the fly ash's capacity for arsenic species are difficult to maintain. Moreover, fly ash is produced only in a powdered form, and therefore has limited application in column separation.
Still another presently known method to remove arsenic species from an aqueous medium is ion exchange. Ion exchange is essentially a sorption process. Arsenic anions enter the exchanger structure and replace labile anions. One of the disadvantages of this process is that the ion-exchangers utilized are mostly synthetic resins and hence are expensive. Further, few arsenic selective resins presently exist. Consequently, ubiquitous anions such as sulfates compete for the ion-exchange sites in the resin. Chromatographic peaking of toxic arsenic levels can occur in this situation.
In general, ion-exchange is not a feasible method of removing arsenic from an aqueous medium if the medium contains a high level of dissolved solids or sulfate concentrations. Ion exchange resins are generally regenerated with a sodium chloride solution. As is the case with activated alumina, the spent regenerant will require treatment prior to reuse or disposal.
Another method for removing arsenic species from an aqueous medium is through the use of a membrane process. A membrane process involves passing the aqueous medium through the membrane to filter the selected material. For example, reverse osmosis has been shown to reject arsenic in commercial and household (point of use treatment) applications (please see Connell, P. J. and T. A. Marr. "Emergency response spill cleanup of wood treating waste." Water Pollution Research Journal of Canada, vol. 25, no. 3 (1990), pp. 265-273; Fox, Kim R. and Thomas L. Song. "Controlling arsenic, fluoride and uranium by point-of-use treatment." Journal of the American Water Works Association (1987); Fox, Kim R. "Field experience with point-of-use treatment systems for arsenic removal." Journal of the American Water Works Association, vol. 81, no. 2 (1989), pp. 94-101; Rozelle, Lee T. "Point-of-use and point-of-entry drinking water treatment." Journal of the American Water Works Association (1987); Stass, A. A. "Osmose water purification system to remove CCA contaminants from water." Arsenic and mercury workshop on removal, recovery, treatment, and disposal, EPA/600/R-92/105. U.S.E.P.A., Cincinnati, (1992), pp. 30-32). Discharge levels of 0.05 mg/l have been met.
However, membrane processes are similar to the ion exchange process described herein due to the fact that they both require treatment of the concentrated waste stream (reject) in order to dispose of the arsenic contaminant. Therefore, membrane processes are costly as a method for removing arsenic species from an aqueous medium.
The present invention employs modified zeolite minerals as a method for removing arsenic species from an aqueous medium. Zeolite minerals are inexpensive minerals composed of crystalline hydrated aluminosilicates of group I and II metals in the periodic table. The isomorphous substitution of aluminum ions for silica ions into the component polyhedra causes a residual charge on the oxygen framework. Zeolites have a generally open framework which contain channels that can accommodate water molecules, and the cations necessary for charge balancing.
As stated hereinabove, zeolite minerals are very inexpensive compared to synthetic resins, and are readily available. Hence it is not economically necessary to remove adsorbed arsenic from them and reuse them. Further, the present invention for a method of removing arsenic species from an aqueous medium using modified zeolite minerals can remove arsenic from an aqueous medium to 50 ppb or less within about 2 hours of treatment.
Hence, one object of the present invention is to modify naturally occurring zeolite minerals with a concentrated ferrous aqueous solution in order to increase the zeolite mineral's affinity for aqueous arsenic species in an aqueous medium.
Therefore, the primary object of the present invention is to provide a method of removing arsenic species in the form of both arsenate and arsenite from an aqueous medium with modified zeolite minerals that does not possess the shortcomings of the prior art and offers the advantages of being able to achieve the removal of arsenic in the form of both arsenate and arsenite and is less expensive to use than the methods disclosed in the prior art.
Another object of the present invention is provide a method of removing aqueous arsenic species from an aqueous medium to a detection level for arsenic species of 5 ppb.
Yet another object of the present invention is to provide an inexpensive sorbent material to remove aqueous arsenic species from an aqueous medium which does not need to be reused in order to be economically applicable.
Yet still another object of the present invention is to provide an inexpensive sorbent material to remove aqueous arsenic species from an aqueous medium which will not leach aqueous arsenic species and can be readily disposed of as non-hazardous waste.
Another object of the present invention is provide a method of removing aqueous arsenic species from natural water.
Yet another object of the present invention is provide a method of removing aqueous arsenic species from natural water having a pH range from 5 to 8.
A further object is to provide a method of removing arsenic species from an aqueous medium using modified zeolite minerals comprising: providing an aqueous medium containing arsenic species in the form of both arsenate and arsenite; contacting the aqueous medium with an iron (II) laden zeolite mineral so that arsenic in the form of both arsenate and arsenite contained in the aqueous medium can be adsorbed onto the iron (II) laden zeolite mineral forming an arsenic adsorbed iron (II) laden zeolite mineral; and separating the arsenic adsorbed iron (II) laden zeolite mineral from the aqueous medium.
The foregoing has outlined some of the pertinent objects of the invention. These objects should be construed to be merely illustrative of some of the more prominent features and applications of the intended invention. Many other beneficial results can be attained by applying the disclosed invention in a different manner or modifying the invention within the scope of the disclosure. Accordingly, other objects and a more comprehensive understanding of the invention may be obtained by referring to the summary of the invention, and the detailed description of the preferred embodiment in addition to the scope of the invention defined by the claims.
SUMMARY OF THE INVENTION
The present invention is defined by the appended claims with the specific embodiment shown in the attached drawings. This invention satisfies the need for an inexpensive and safe method for removing arsenic species from an aqueous medium to be compliance with federal safety standards.
For the purpose of summarizing this invention, this invention comprises providing an aqueous medium containing arsenic species in the form of at least one of arsenate and arsenite whereby the aqueous medium is brought in contact with an iron (II) laden zeolite mineral. The iron (II) laden zeolite mineral adsorbs the arsenic species contained in the aqueous medium. The iron (II) laden zeolite mineral is then separated from the aqueous medium upon saturation level of the arsenic species through adsorption onto the iron (II) laden zeolite mineral.
The modification of zeolite minerals involves exposing them to concentrated ferrous aqueous solutions so that ferrous ions in the concentrated ferrous aqueous solution are absorbed onto the zeolite mineral to form an iron (II) laden zeolite mineral. Based upon research conducted by applicant and reported herein, this modification of the zeolite mineral increases its affinity for arsenic so that it can be used efficiently to remove the level of arsenic species in an aqueous solution to a level of 5 ppb.
Therefore, it can be readily seen that the present invention provides a method of removing arsenic species from an aqueous medium using modified zeolite minerals that can cost effectively and safely remove arsenic from an aqueous medium. Thus, a method of removing arsenic species from an aqueous medium using modified zeolite minerals provides capabilities that would be appreciated.
The foregoing has outlined rather broadly, the more pertinent and important features of the present invention. The detailed description of the invention that follows is offered so that the present contribution to the art can be more fully appreciated. Additional features of the invention will be described hereinafter. It should be appreciated by those skilled in the art that the conception and the disclosed specific embodiment disclosed may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes of the present invention. It should also be realized by those skilled in the art that such equivalent constructions do not depart from the spirit and scope of the invention as set forth in the appended claims.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Chabazite was the zeolite mineral used as the starting material in the preferred embodiment of the present invention. However, it may be possible that any presently known or subsequently discovered zeolite mineral can be used as the starting material.
In the preferred embodiment, the chabazite starting material, marketed by GSA Resources as ZC400H, had a particle size of 20×60 U.S. mesh. The chabazite was washed by mixing it with distilled/de-ionized (DI) water. The chabazite was allowed to settle and the DI water decanted off. This procedure was repeated five (5) times. The chabazite was then placed in a ceramic crucible and dried in an oven at 103° C. for approximately two (2) hours.
Subsequently, 10 g of the dried chabazite was removed and mixed with a 1 L solution of 0.2 M FeSO 4 and exposed in a mixer for twenty-four (24) hours to form iron (II) laden chabazite.
After 24 hours of contact with the 0.2 M FeSO 4 aqueous solution in the mixer, the iron (II) laden chabazite/FeSO 4 mixture was filtered to separate the iron (II) laden chabazite solid phase from the liquid phase. The solid phase of the iron (II) laden chabazite/FeSO 4 mixture was retained, whereas, the liquid phase the iron (II) laden chabazite/FeSO 4 mixture was discarded.
The iron (II) laden chabazite solid was transferred to the contacting jar in the mixer and rinsed with DI water. The rinsing cycle was repeated five times. The iron (II) laden chabazite was then dried in an oven at 103° C.
A. Determination of the Ability of the Iron (II) Laden Chabazite to Remove Arsenate from an Aqueous Medium
After drying, the iron (II) laden chabazite was tested with an aqueous solution containing arsenic species to determine its affinity for arsenate relative to the arsenate affinity of unmodified chabazite. In this test, twelve 150 ml aliquots of 5 mg/l of As (V) were pipetted into individual 250 ml NALGENE® bottles. Iron (II) laden chabazite was added to the bottles in doses ranging from 0 to 500 mg. One bottle was kept as a control (no sorbent added). The bottles were then capped and placed on a constant temperature water bath/shaker operating at 1405 cm excursions/min and a temperature of 25° C.
After shaking for twenty-four (24) hours, the bottles were removed from the water bath, the pH of each bottle was measured on a FISHER SCIENTIFIC® pH meter. A 35 ml sample was then removed from each bottle and individually filtered through a 0.45 μm filter. The filtrates were then analyzed for arsenic with the Standard Method 3500-As C. Silver Diethyldithiocarbamate method, which has been approved by the EPA. The different concentrations of iron (II) laden chabazite examined here were tested in duplicates. All samples were analyzed for arsenic concentration, pH, and the results were recorded. The same procedures were used with untreated chabazite as a control. The iron (II) laden chabazite made pursuant to the present invention has a much greater capacity for arsenate in an aqueous solution than does untreated chabazite.
Moreover, applicant had a Toxicity Characteristic Leaching Procedure (TCLP) test conducted on a sample of arsenic loaded iron (II) laden zeolite mineral from the top portion of a column containing iron (II) laden zeolite mineral used to treat drinking water. This test is designed to determine whether arsenic loaded iron (II) laden zeolite mineral would leach arsenic species if disposed of in a non-hazardous waste landfill. The protocol for TCLP is promulgated by the EPA and is published in the Federal Register at 55 FR 26986.
Applicant had the above referenced TLCP test performed on some arsenic loaded iron (II) laden zeolite mineral produced pursuant to the present invention. According to the results of this test, arsenic was not detected in any of the leachate from the arsenic loaded iron (II) laden zeolite mineral. The detection limit for arsenic was 5 μg/L. A scanning electron microscopy (SEM) analysis of the sorbent indicated an arsenic concentration of 13 mg/gram.
The ability of the iron (II) laden chabazite to remove arsenate was also evaluated in a fixed bed application. In particular, the dried chabazite was loaded into two clear PVC columns which were connected in series. The sorbent bed depth of the column was 25 inches, and the diameter was two inches. A concentrated ferrous solution was then run through the column in order to convert the dried chabazite into iron (II) laden chabazite. A 1 mg/L arsenate solution was then prepared by spiking potable water with arsenic acid, Na 2 HAsO 4 . The solution was fed in the columns containing the iron (II) laden chabazite at a rate of 3.65 gpm/ft 2 .
Samples of the effluents from both columns were taken and sent to Quanterra Environmental Services, a laboratory certified by the Florida Department of Environmental Protection having a principal place of business at 5910 Breckenridge Parkway, Suite H, Tampa, Fla. 33610. Quanterra used Method SW846 6010A (Trace Inductively Coupled Plasma) to assay the column effluent for arsenate. This assay has an arsenate detection limit of 5 μg/L (0.005 mg/L).
According to the results of this assay, over 235 bed volumes of the arsenate spiked potable water were treated with the iron (II) laden chabazite before arsenate was detected in the effluent.
B. Determination of the Application of Iron (II) Laden Chabazite to Remove Arsenite from an Aqueous Medium in a Batch Equilibrium Study
In the batch equilibrium studies, different quantities of iron (II) laden chabazite were placed in individual 250 ml NALGENE® bottles and exposed to identical volumes of a 5 mg/L arsenite solution prepared by dissolving NaAsO 2 in DI water deoxygenated with Na 2 SO 3 . The iron (II) laden chabazite was allowed to equilibrate with the arsenite solution in the individual bottles for 24 hours at 25° C. in a constant temperature water bath shaker.
After shaking for 24 hours, the pH of the mixture in each bottle was measured on a FISHER SCIENTIFIC® pH meter. A 35 ml sample was then removed from each bottle and individually filtered through a 0.45 μm filter. The individual filtrates from the samples were then analyzed for arsenic with the Standard Method 3500-As C. Silver Diethyldithiocarbamate method, which has been approved by the EPA. The different concentrations of iron (II) laden chabazite examined here were tested in duplicates. The sample filtrates were also analyzed for pH, and dissolved oxygen (DO) content, and the results of these assays were recorded. This procedure was repeated using untreated chabazite sorbent. The iron (II) laden chabazite made pursuant to the present invention have a much greater capacity for arsenite in an aqueous solution than does untreated chabazite.
In addition, an equilibrium study was run utilizing a powdered form of iron (II) laden chabazite. The results of this equilibrium study indicate that this powder form exhibited an even higher capacity for arsenite than did iron (II) laden chabazite in granular form.
Many other variations and modifications of the invention will be apparent to those skilled in the art without departing from the spirit and scope of the invention. The above-described embodiments are, therefore, intended to be merely exemplary, and all such variations and modifications are intended to be included within the scope of the invention as defined in the appended claims.
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A method for removing arsenic species from an aqueous medium with modified zeolite minerals comprising providing an aqueous medium containing arsenic species in the form of both arsenate and arsenite, contacting the aqueous medium with an iron (II) laden zeolite mineral so that arsenic in the form of at least one of arsenate and arsenite contained in the aqueous medium can be adsorbed onto the iron (II) laden zeolite mineral forming an arsenic adsorbed iron (II) laden zeolite mineral, and separating the arsenic adsorbed iron (II) laden zeolite mineral from the aqueous medium.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is based upon and claims the benefit of priority from U.S. Provisional Application No. 61/331,439, filed May 5, 2010 in the United States Patent and Trademark Office, the disclosure of which is incorporated herein in its entirety by reference.
BACKGROUND
[0002] 1. Field
[0003] The invention is related to an interferometer adapter cap which can easily be incorporated attached to a fiber inspection device, such as a microscope. It could also be used to examine the “flatness” of the end of any small object with a suitable holder.
[0004] 2. Related Art
[0005] A number of interferometer products tailored to the inspection of fiber optic connector ferrule end faces exist today. They are typically bench style units intended for production or laboratory use. Most are “non-contact” types which do not require physical contact with the connector under inspection. Some are “contact” types which are intended for the inspection of bare optical fiber cleave angles, which are crucial for successful fusion splicing.
[0006] The non-contact interferometers tend to be expensive due primarily to the high cost of the specialized optics and motion systems which they contain. Examples of these interferometers include the Micro Enterprises “Optispec” line and the Norland CC6000 “Connect-Chek” models.
[0007] Problems with the current interferometers include cost, ease of use and physical form factors. For example, interferometers typically exhibit high sensitivity to mechanical vibration, placing restrictions on the work area. They are also very expensive and require a high end PC for data processing at the time of this writing.
[0008] Therefore, there is a need for a lower cost apparatus that can be used to inspect connector ferrules. Portable microscopes are one such apparatus. They are typically in the shape of a hand held probe so that during normal use, they can be held in a variety of positions to probe large panels of connectors, such as in a networking room.
[0009] In order to use such a portable microscope, some mechanism for attaching the connector ferrules to the microscope is needed. Therefore, one objective of the invention is to provide an apparatus that allows for the low cost testing of connector end-face geometry, in the field or office, with low sensitivity to environmental factors (vibration, movement, etc.).
SUMMARY
[0010] Exemplary implementations of the present invention address at least the above problems and/or disadvantages and other disadvantages not described above. Also, the present invention is not required to overcome the disadvantages described above, and an exemplary implementation of the present invention may not overcome any of the problems listed above.
[0011] A first embodiment of the adapter cap includes a cap body; a slot in the cap body, wherein the slot is configured to hold an optical flat, an attachment mechanism configured to attach the cap to an inspection device, and an alignment hole in the cap body, wherein the alignment hole is configured to hold an optical connector ferrule.
[0012] Another feature of the adapter cap is that the alignment hole is further configured such that an axis of the hole is perpendicular to a plane of the optical flat.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1A is a top perspective view of an embodiment of the invention.
[0014] FIG. 1B is a bottom perspective view of an embodiment of the invention.
[0015] FIG. 2 is a side view of an embodiment of the invention.
[0016] FIG. 3 a diagram showing how the invention is used with a microscope.
[0017] FIGS. 4 and 5 are illustrations of images that could be captured by an inspective microscope that uses an embodiment of the invention.
DETAILED DESCRIPTION
[0018] The following detailed description is provided to assist the reader in gaining a comprehensive understanding of the methods, apparatuses and/or systems described herein. Various changes, modifications, and equivalents of the systems, apparatuses and/or methods described herein will suggest themselves to those of ordinary skill in the art. Descriptions of well-known functions and structures are omitted to enhance clarity and conciseness.
[0019] Hereinafter, the exemplary embodiments will be described with reference to accompanying drawings.
[0020] The invention is a low cost interferometer adapter “cap,” which can easily be incorporated into many or all of the portable fiber inspection microscopes on the market today, or those yet to come, and those microscopes which uses a monochromatic light source. In a preferred embodiment, a blue monochromatic light is used. In many cases, only a method of holding the elements of the invention in proper mechanical orientation for the basic design of the microscope would be required. This is similar to the process, by which the adapter caps required for the varied optical fiber connectors in use today, are created for this type of inspection microscope.
[0021] FIG. 1A shows an embodiment of the inventive adapter cap 1 . The cap 1 includes a narrow slot 10 in the side of the cap body 11 with an inner diameter and outer diameter. The inner diameter is sized so that the adapter can be attached to a microscope. In this exemplary embodiment, the inner diameter of the cap is secured to a microscope with a ⅞ inch×28 female thread and the outer diameter is approximately 1.25 inches. While the cap body 11 in this exemplary embodiment is cylindrical in shape, the cap body does not have to be cylindrical, as long as the adapter can be attached to a microscope. In addition, while the narrow slot 10 in this embodiment is offset from an axis of an alignment hole 13 , the slot could be center with respect to the axis as well.
[0022] An optical flat 12 , which could be a simple glass microscope slide, slides into the narrow slot 10 in the side of the cap body 11 . Contact of the optical flat and the adapter cap is critical and is maintained by mechanical pressure similar to that provided by biological microscope stage clips. Only enough pressure to prevent movement during use is required. Because the optical flat can be removed from the adapter cap, it can be provided as a consumable item to help insure that it is always in good condition. The adapter cap also includes an alignment hole 13 , into which a connector ferrule under inspection is inserted.
[0023] A bottom view of the adapter cap is shown in FIG. 1B . This embodiment contains screw threads 14 that can be used to attach the adapter cap to a fiber optic inspection microscope. The attachment mechanism can take many alternate forms such as a tapered fit, straight or tapered fit with clamping mechanism, straight or tapered fit with a latching mechanism (for example, an indented ball and spring). In addition, in this embodiment, an elevated portion 16 can act as a guide for an optical flat that is inserted into the slot 10 .
[0024] FIG. 2 is a side view of the embodiment which shows the critical 90 degree angle of the axis of the alignment hole for the connector ferrule to the plane of the optical flat.
[0025] Next, the use of the adapter cap will be described. A fiber optic connector ferrule, previously inspected for cleanliness (possibly by the same inspection system), is inserted into the alignment hole 13 of a precise diameter and perpendicularity to a flat optical plate so that the connector ferrule can be held in the hole. This hole is coaxially aligned with the optical axis of the microscope by design. The fiber optic connector is then brought into physical contact with the optical flat. The adapter cap is then attached to the microscope 15 . FIG. 3 is a schematic representation showing a connector in the adapter cap and the adapter cap 1 attached to the microscope 15 , which may include an objective lens, beamsplitter and illumination source.
[0026] A series of Newton's rings are produced by this contact which are visible on the optical or video inspection end of the microscope (eye lens or video monitor). The rings have periodic light and dark values which are a result of the curvature manufactured into the end of the connector. The spacing of the rings is related to the radius of curvature of the connector and gross imperfections are readily observed as a disturbance in the circular shape of the rings. The phenomenon of Newton's rings was first described in 1664 by Robert Hooke and later analyzed by Sir Isaac Newton.
[0027] FIG. 4 is an illustration of an image that could be captured by an inspection system that uses the adaptive cap. The gray circle is the optical fiber end face, appearing against the white background of the connector ferrule. The concentricity of the rings indicates at a glance that the end radius of the connector is uniform in curvature. The darker black circle is caused by mechanical limitations of the lab-built prototype. On a properly finished connector, the dark circle would coincide with the gray circle that appears to protrude from beneath it, see for example FIG. 5 .
[0028] Although a few exemplary embodiments of the present invention have been shown and described, it would be appreciated by those skilled in the art that changes may be made in this embodiment without departing from the principles and spirit of the invention, the scope of which is defined in the claims and their equivalents.
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An adapter cap including a cap body, a slot in the cap body, wherein the slot is configured to hold an optical flat, an attachment mechanism configured to attach the cap to an inspection device, and an alignment hole in the cap body, wherein the alignment hole is configured to hold an optical connector ferrule.
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FIELD OF THE INVENTION
This invention relates to the field of polyhydroxyalkanoate polymers, articles made therefrom and melt processing methods. More specifically, the invention pertains to melt processing and cast film extrusion of polyhydroxyalkanoates which contain a novel combination of nucleant and plasticizer for enhancing chain mobility, crystallization rates in order to improve processibility in conventional melt processes.
BACKGROUND OF THE INVENTION
Polyhydroxyalkanoates (PHAs) and other thermoplastic polyesters represent potential raw materials for a myriad of useful products. Examples include melt-spun fibers from which non-woven products can be produced for medical gowns and masks, blown and cast films for compostable grocery and garbage bags, injection-molded bottles for health and personal care products and extrusion coatings on paper/paperboard for biodegradable/compostable fast-food containers. In the processes to produce PHA products, it is crucial to achieve line speeds, cycle times, and other processing parameters that are economically desirable.
Polyhydroxyalkanoate copolymers are extremely sticky when melt processed due, at least in part, to extremely slow crystallization rates of their crystalline phase domains. This sticky or “tacky” behavior leads to an inability to process the polymer through any melt processing equipment, including extrusion, compounding, film and fiber operations. Unmodified polymer has a strong tendency to stick to all pieces of machinery, regardless of the material of construction. The polymer also has a strong tendency to stick to itself and to human skin when touched. The stickiness or tackiness gradually disappears in a matter of minutes to hours. However, this time frame is significantly long for any conventional processing techniques, which generally require the polymer to become non-tacky within a matter of a few seconds.
Previous work has shown that addition of a crystallization nucleant to some compositions of polyhydroxyalkanoate copolymers can increase crystallization rates to a point where melt processibility is acceptable. In addition, such nucleants can sometimes improve the physical and mechanical properties of the processed articles. Conventional nucleating agents include, for example, talc, micronized mica, calcium carbonate, boron nitride (see, for example, EP 0291024) and ammonium chloride (see, for example, WO 9119759).
U.S. Pat. No. 5,296,521 describes polyester compositions having increased crystallization rates comprising thermoplastic polyester resins and 0.5 to about 5 weight percent of nucleating agent of the formula RO[P(O)(Ph)(CH 2 ) m O] n H where R is an alkali or alkaline earth metal; m is 1, 2, or 3; n takes an average value within the range of 1 to 5. The nucleating agent can be optionally mixed with the acid or ester form providing at least 50 mole percent of the nucleating agent is in the salt form. The nucleating agent is preferably in the form of the sodium salt (e.g., sodium salt of hydroxymethylphenyl phosphonic acid or sodium salt of oligomethylene phenyl phosphinic acid).
U.S. Pat. No. 4,536,531 describes use of carboxylic salts of metals of Group I and II in the Periodic Table as nucleating agents for polyesters exemplified by metal salts of aliphatic monocarboxylic acids such as acetic acid, propionic acid, caproic acid, palmitic acid, stearic acid, oleic acid, behenic acid and montanic acid. Suitable metals are sodium, potassium, lithium, magnesium, calcium, barium and zinc. In these carboxylic acid salts, it is unnecessary that all the carboxylic groups be converted into salt form, but a part of the carboxyl group may be in a salt form and the remaining groups may be in a free acid or ester form.
Several references disclose the use of organophosphorous compounds as nucleants. U.S. Pat. No. 5,061,743 discloses a preferred polyhydroxyalkanoate nucleant made by dry blending cyclohexylphosphonic acid and zinc stearate with polyhydroxybutyrate-co-valerate. The nucleant is disclosed as particularly advantageous for the nucleation of polyhydroxybutyrate-co-valerate having high hydroxyvalerate content. WO 9905208 discloses that organophosphorous compounds having at least two phosphonic acid moieties can be used as nucleants for polyhydroxyalkanoates and other thermoplastic polyesters.
Although many of these compounds have shown effectiveness in increasing the nucleation density of polyhydroxyalkanoate, and therefore crystallization rates, certain disadvantages have been associated with their use. Dispersion of particulate nucleants, for example, has been problematic because agglomeration frequently occurs during processing which can generate regions of stress concentration and inhomogeneity in molding. In addition, nucleants such as boron nitride have been found to act as pigments in some situations, particularly in films and injection moldings, giving rise to opaque products where transparent products are generally desired. Further, some nucleant systems include constituents which may be environmentally and toxicologically undesirable.
Furthermore, the polymers of the previous references tend to be copolymers that do not contain a comonomer that effectively increases the amorphous character or decreases crystallization rates of the polymer. The resulting polymers are often brittle and lead to undesirable properties. Polyhydroxyalkanoate copolymers that contain more modifying comonomers, which lead to a significant amount of amorphous phase, tend to be more desirable polymers because they exhibit a high level of toughness and elastic resilience. However, the large amount of amorphous phase contained in these polymers is not conducive to good crystal formation or rapid crystallization rates. Furthermore, addition of nucleants to these polymers generally does not increase the amount of crystallization or the crystallization rate enough to make melt processing of these polymers feasible. Thus, there is a need for benign and cost-effective nucleant systems which allow for the production of polyhydroxyalkanoate resins having moderate to high crystallinity, excellent moldability, mechanical strength and dimensional stability.
The problem to be solved, therefore, is to provide a polymeric composition that produces tough, flexible polyhydroxyalkanoates that can be readily and quickly processed into film-based products. Another objective of this invention is to provide a method for continuous melt extrusion of these polyhydroxyalkanoates. Yet another object of the present invention is to provide a method for continuous cast film production using these polyhydroxyalkanoates.
SUMMARY OF THE INVENTION
The invention provides a polyhydroxyalkanoate copolymer composition which can be processed into film-based products, extruded and molded articles, and coatings, comprising: (a) a polyhydroxyalkanoate copolymer; (b) a nucleant; and (c) a plasticizer, and a method of making same.
In a preferred embodiment, unique combinations of either poly-3-hydroxy(butyrate-co-octanoate) or poly-3-hydroxy(butyrate-co-hexanoate) are polymerized with polyhydroxybutyrate (nucleant) and either methyl laurate or dibutylmaleate (plasticizer).
DETAILED DESCRIPTION OF THE INVENTION
Applicants have solved the problem by providing combinations of nucleant and plasticizer to polyhydroxyalkanoate (“PHA”) copolymers. Addition of the nucleant and plasticizer to PHA copolymers allows crystallization processes to occur in a time frame which enables practical melt processing. The instant invention is applicable to any situation in which accelerated crystallization rates are desired. In particular, the nucleants and plasticizer are used for improved production of PHA and other thermoplastic polyester products by decreasing the cycle times normally required for producing films, extruded and molded articles, and coatings.
In this disclosure, a number of terms and abbreviations are used. The following definitions are provided.
“Poly(3-hydroxybutyrate-co-3-hydroxyoctanoate)” which is also known as “poly-3-hydroxy(butyrate-co-octanoate)” is abbreviated P3HBO.
“Poly-3-hydroxy(butyrate-co-hexanoate)” which is also known as “poly-3-hydroxy(butyrate-co-hexanoate)” is abbreviated P3HBH.
“Polyhydroxyalkanoate” is abbreviated PHA.
“Polyhydroxybutyrate” is abbreviated PHB.
Polyhydroxyalkanoates
Polyhydroxyalkanoates (“PHA”s) of this invention include naturally derived polymers such as polyhydroxybutyrate (PHB), including homopolymers of 3-hydroxybutyrate and 4-hydroxybutyrate. They also include copolymers of PHB with hydroxy acids, for example copolymers of PHB with 3-hydroxyhexanoate, 3-hydroxyoctanoate, or longer chain hydroxy acids (e.g. C 9 -C 12 hydroxy acids) and copolymers thereof. PHAs of this invention can also be synthetically derived from hydroxy carboxylic acids. Furthermore, the PHA can be predominantly of R(−) configuration, predominantly of S(+) configuration, or a random, block, or other combination of R(−) and S(+) configuration. As will be understood by the skilled artisan, the R(−) and S(+) isomers refer to the ability of the repeat unit of the polymer to rotate plane polarized light in the counterclockwise or clockwise direction, respectively. A racemic copolymer consists of both R(−) and S(+) repeat units within the polymer which can be arranged in any combination, including random or block configurations.
Preferred examples of polyhydroxyalkanoate copolymers used in this invention are poly-3-hydroxy(butyrate-co-octanoate) (y=3) (P3HBO)
and poly-3-hydroxy(butyrate-co-hexanoate) (y=1) (P3HBH). These block copolymers have the generalized structure shown below.
m=0.7-0.97 and n=0.3-0.03, where m+n=1.0
In general, block copolymers can be prepared having various architectures. For example, an A-B diblock copolymer has a block of polymer A segments coupled to a block of B polymer segments. An A-B-A triblock copolymer has a block of B segments coupled to a block of A segments at each of its terminal ends. An -(A-B) n - multiblock copolymer has alternating sequences of A and B segments where n is a positive integer greater than 1. Especially preferred are random block copolymers in which the PHB segments comprise from 85 to about 95 weight percent of the copolymer. For use in the present invention, PHAs have a weight average molecular weight of about 600,000 to greater than 1,000,000; the number average molecular weight ranges from about 280,000 to 500,000 grams/mole.
PHAs are generally difficult to process by conventional melt processes into films, fibers, filaments, rods, tubes or other forms having physical integrity. Conventional melt processes include continuous melt extrusion processes, cast film extrusion, blown film extrusion, melt spinning processes and other methods generally known to those skilled in the art. By “polymer difficult to melt process”, it is meant that the polymer exhibits an effective melt strength and/or set time that detracts from the ability to form products having physical integrity by a conventional melt extrusion process.
The “effective melt strength” refers to the resistance of a molten polymer to be drawn-down to a desired dimension such as thickness (in the case of films), or diameter or denier (in the case of fibers or filaments). A polymer having a low effective melt strength is unable to withstand the minimum strain that is required to draw the polymer melt to a desired dimension. For example, the polymeric material may exhibit instabilities such as breakage, sagging or draw resonance. The resultant products tend to be highly non-uniform in physical integrity.
The “set time” refers to the time period required, under a given set of process conditions, for the molten polymer material to achieve a substantially non-tacky or non-sticky physical state. The set time is important because blocking may occur if the polymer does not set within a suitable time during processing. Thus, the polymeric material having residual tack may stick to itself and/or to processing equipment even after cooling to room temperature or below. Such residual tack may restrict the speed at which the product can be processed or prevent the product from being collected in a form of suitable quality.
The set time is influenced by the polymer material and the processing equipment and conditions. In general, the set time should be on the order of seconds under conventional process conditions. Such conditions typically include temperatures ranging from that of chill rolls, such as are known in the art, to the melt temperature of the material being processed, which may be up to about 150° C., (preferably 120 to 135° C.). In general, longer process cycle times (e.g. from the point of melt extrusion to the point of take-up of collection) tend to accommodate longer set times.
The term “tack” or “tackiness” is known to those skilled in the art to mean sticky or the amount of stickiness. Tack is generally a subjective measurement made by touching the film surface with a finger. If the surface is “tacky”, or sticky, then it has the property of “tack”. Tack may be measured subjectively by means of many scales, but to illustrate the concept, fly paper may be considered the high point of the scale with a Teflon® sheet (polytetrafluoroethylene) (from E. I. du Pont de Nemours and Company, Wilmington, Del.) as having no tack. For the purpose of this invention, tack was subjectively measured by a single operator after pressing a film of the appropriate polymer blend between two sheets of Teflon® coated aluminum foil five times. After the fifth pressing, the sample film was cooled for 10 seconds at room temperature, and the relative force required to first remove the film from the Teflon® sheets was noted. Additionally, the force required to peel the film apart from itself after folding it over on itself was also subjectively monitored along with the force required to peel the polymer from the gloves of the operator. A result of “no tack” was recorded when no apparent additional force was required to remove the film from the Teflon® sheet or from itself after folding. The subjectively graded scale of “slight tack” to “moderate tack” indicates that more force was required to pull the film from the Teflon® sheet and itself in each respective category. The category of “tacky” indicates that generally the film was extremely difficult to remove from the Teflon® sheet and virtually impossible to separate from itself after folding when cooled under the standard time of 10 seconds.
Nucleants
“Nucleants” or “nucleating agents” are compounds used to artificially introduce nucleation sites for the process of polyhydroxyalkanoate crystallization from the molten state. A description is set forth in U.S. Pat. No. 5,534,616, starting at column 1, line 36. The reference is hereby incorporated by reference. Nucleants help to compensate for the slow rate of crystallization of many PHAs due to their low nucleation density. The preferred amount of nucleant in the composition is from about 1% to about 10%, based on the total weight of the composition. The nucleant in the preferred composition is polyhydroxybutyrate and is used in an amount ranging from about 0.005% to about 20%, more preferably from about 0.05% to about 10% and most preferably from about 0.5% to about 5%, based on the total weight of the composition.
Plasticizers
Plasticizers are used in the instant composition to modify the mechanical properties of products formed and to improve the processability of the composition. In general, a plasticizer tends to lower the modulus and tensile strength, and to increase the ultimate elongation, impact strength, and tear strength of the polymeric product. The plasticizer may also be used to lower the melting point of the composition to thereby enable melt processing at lower temperatures. In this invention the plasticizer is used to lower the glass transition temperature as an aid to increase the rate at which a non-tacky product will be attained.
External plasticizers known in the art include glycerol, ethylene glycol, and low molecular weight polyethylene glycols. Preferred plasticizers for the PHAs examined include di(2-ethylhexyl)(dioctyl)maleate, paraffin, dodecanol, olive oil, soybean oil, polytetramethylene glycols, methyl oleate, n-propyl oleate, tetrahydofurfuryl oleate, epoxidized linseed oil, 2-ethylhexyl epoxytallate, glycerol triacetate, methyl linoleate, dibutyl fumarate, methyl acetyl ricinoleate, acetyl tri(n-butyl) citrate, acetyl triethyl citrate, tri(n-butyl) citrate, triethyl citrate, bis(2-hydroxyethyl) dimerate, butyl ricinoleate, glyceryl tri-(acetyl ricinoleate), methyl ricinoleate, n-butyl acetyl rincinoleate, propylene glycol ricinoleate, diethyl succinate, diisobutyl adipate, dimethyl azelate, di(n-hexyl) azelate and tri-butyl phosphate. Most preferred plasticizers for the PHAs examined include methyl laurate and di-n-butyl maleate. The preferred amount of plasticizer in the composition is from about 5% to about 35%, and more preferably from about 12% to about 20%, based on the total weight of the composition.
Methods of Melt Extrusion
Conventional melt extrusion methods are used to produce extruded and molded articles of the present invention. Such melt extrusion methods involve blending of polymeric components followed by extrusion of the blend. In a preferred embodiment, the strands of PHA polymer are extruded at about 120-160° C., more preferably from 130-145° C., through the die plate into a water bath having a temperature of about 30-40° C.
In a preferred melt extrusion process of the present invention, pellets of the polymeric components are first prepared. The PHA nucleant and plasticizer can be first dry blended and then melt mixed in the film extruder itself. Alternatively, if insufficient mixing occurs in the melt extruder, the ingredients can be first dry blended and then mixed in a pre-compounding extruder followed by pelletization prior to film melt extrusion.
The PHA films of the present invention may be processed using conventional methods and are used for producing single or multilayer films on conventional film-making equipment. The cast or blown film extrusion methods used to make the PHA films of the present invention are more fully described in U.S. Pat. No. 6,027,787, hereby incorporated by reference, and described in Plastics Extrusion Technology—2 nd Ed., by Allan A. Griff (Van Nostrand Reinhold, 1976). In a preferred embodiment, the PHA polymer continuous film is extruded at about 120-160° C., more preferably from 120-140° C., onto rollers having a temperature of about 30-45° C., more preferably of about 40° C.
“Film” refers to a continuous piece of extruded material having a high length to thickness ratio and a high width to thickness ratio. While there is no requirement for precise upper or lower limits of thickness, a preferred film thickness of the present invention is from about 0.05 to about 50 mil, and a more preferred film thickness is from about 0.5 to about 15 ml. The films of the present invention can comprise one, two or more layers.
The PHA compositions of the present invention can also be made into certain selected molded articles by conventional injection molding techniques.
EXAMPLES
The present invention is further defined in the following Examples. It should be understood that these Examples, while indicating preferred embodiments of the invention, are given by way of illustration only. From the above discussion and these Examples, one skilled in the art can ascertain the essential characteristics of this invention, and without departing from the spirit and scope thereof, can make various changes and modifications of the invention to adapt it to various usages and conditions.
The meaning of abbreviations is as follows: “h” means hour(s), “min” means minute(s), “sec” means second(s), “d” means day(s), “mL” means milliliter(s), “L” means liter(s), “ft” means foot or feet, “lb” means pound(s) and “g” means gram(s).
General Methods
Poly-3-hydroxy(butyrate-co-octanoate) (P3HBO) was obtained from Procter and Gamble Company, Inc. (Cincinnati, Ohio). Poly-3-hydroxy(butyrate-co-hexanoate) (P3HBH) was obtained from Proctor and Gamble Company, Inc. (Cincinnati, Ohio) (Jiangmen Center for Biotechnology Development and Tsinghua University (China). PHB was supplied by Aldrich Chemical Company, Inc. (St. Louis, Mo.).
Example 1
Identification of “Active” Nucleant and Plasticizer Combinations
Screening of nucleant and plasticizer combinations was conducted as follows: a melt blend of the nucleant PHB and a PHA, specifically, either P3HBO or P3HBH were prepared by first tumble blending powders of the appropriate amounts of PHB and either P3HBO or P3HBH. Generally, 1 wt % PHB (0.75 g) was added to the P3HBO (74.25 g) polymer and 3 wt % PHB (2.25 g) was added to the P3HBH (72.75 g) polymer. (Percent nucleant addition was determined by anti-stick performance in preliminary experiments.) After tumble blending the appropriate ingredients, the powder was fed into a small 16 mm PRISM twin screw extruder set to a maximum temperature of 155° C. The polymer was melt extruded through a single hole {fraction (3/16)}-inch die into a water bath and onto a water-cooled “non-stick” belt. The polymer tended to stick to the belt and was cut into 2 to 3 ft lengths and draped over a rack to allow time for crystallization to occur. After 20 min to 1 hr, the polymer strands had crystallized sufficiently to be hand cut with scissors or run through a blade cutting machine to produce small (2 to 8 mm long) pellets. The pellets were then pressed into film under the following conditions: press temperature (140° C.); pressure (1000 psi); minutes in press (2 min); cooling temperature (25° C.). The resulting film was then cut into 2 to 5 mm wide strips to be used in the screening process.
Because good mixing facilities were not available for blending very small quantities of polymer and plasticizer, the following methodology was developed and followed to screen melt blends of polymer, nucleant and plasticizer. Into a small test tube was added 0.4 g of the desired plasticizer. The test tube containing the plasticizer was placed into a Wood's metal bath heated to 160° C. and held there for 10 min. After the plasticizer was pre-heated, 1.6 g of the appropriate PHA film strips containing the PHB nucleant (prepared as described above) were added to the test tube. The entire content of the tube was then heated at 160° C. for an additional 50 min. The tube was then removed from the heating bath and allowed to cool at room temperature for at least 1 h. The resulting polymer blend was removed from the test tube (breaking the tube if necessary). The resulting polymer and any liquid contents were put onto a Teflon® coated aluminum foil sheet (commercially available from E. I. du Pont de Nemours and Company, Wilmington, Del.) and pressed into a film. The film was then removed from the sheet, folded over onto itself and pressed again into a film. The film pressing process was repeated 5 times to ensure good blending of the three ingredients and to evaluate the effectiveness of the nucleant plasticizer combination. Film processing conditions were generally as follows: press temperature (140° C.); press pressure (1000 psi); press time (2 min); cool temperature (room temperature); cool pressure (5 lb plate); and cool time (10 sec). Immediately after the final film was pressed and cooled for 10 sec, the sample was peeled from the Teflon® coated sheet and evaluated for tack to the Teflon® coated sheet, to itself, and to the operator's gloves. If the sample exhibited no stickiness or tackiness, as defined herein, to any of the surfaces to which it was exposed, it was given a rating of “no tackiness”. All other ratings indicate some level of tack. The sample was then wiped of any remaining plasticizer and weighed. Percent incorporation of plasticizer was determined by comparing final polymer weight to theoretical weight and back calculating plasticizer content assuming only plasticizer loss. A sample calculation follows:
Ingredients added:
1.6 g (nucleant+polymer) as film
0.4 g plasticizer
Total ingredients processed=1.60 g+0.40 g=2.00 g
Theoretical % plasticizer=(0.40 g/2.00 g)×100%=20%
General Example:
Actual final weight of film=X g
Assumed final weight of plasticizer=X g−1.60 g=Y g
Actual % plasticizer=(Y g/X g)×100%
Specific Example:
Actual final weight of film=1.86 g
Assumed final weight of plasticizer=1.86 g−1.60 g=0.26 g
Actual % plasticizer present=(0.26 g/1.86 g)×100%=14%
It should be noted that in no case was a film of less than 1.60 g ever produced, indicating that in all cases some plasticizer was incorporated into the polymer.
Table 1 (examples 1-44) summarizes the nucleant and plasticizer screening done with both P3HBO and P3HBH, respectively, that showed results of no tack. Table 2 (examples 45-60) summarizes comparative examples that do exhibit tack. The abbreviation Tg used in Table 1 and Table 2 represents glass transition temperature (° C.);
In general, for those samples that produced a rating of “no tackiness”, the samples that retained more plasticizer tended to perform better (show even less tack) than those that retained less plasticizer. Occasionally, tack was still evident when some films were cooled at room temperature. If these same films were cooled at 65° C., some of them then exhibited no tack. These films were given a rating of no-tack; however, they are considered inferior to those that exhibit no tack after 10 sec of room temperature cooling. The samples that exhibit rapid elimination of tack were considered to be candidates for melt processing via injection molding, film extrusion and fiber extrusion.
Example 2
Demonstration of Continuous Melt Extrusion of Poly-3-hydroxy(butyrate-co-hexanoate) into Strand and On-Line Pelletizing
Blending of Ingredients (di-n-butylmaleate plasticizer): Into a 35 gallon fiberpak was added 15088.6 g of powdered P3HBH, and 588.5 g of powdered PHB. To this powder mixture was slowly added 3923.0 g of di-n-butylmaleate at such a rate that the liquid plasticizer was immediately imbibed into the powder. The fiberpak was then placed onto a barrel tumbler and tumbled for six h to ensure good mixing.
Extrusion of Polymer Strand and Pelletizing (di-n-butylmaleate plasticizer): After tumbling the polymer ingredients as described, the resulting mixture was fed into a 30 mm twin screw extruder at a rate of approximately 10 lb/h. The extruder temperatures were set to maintain a gradient barrel temperature of 120° C. to 160° C. Screw RPM was maintained at 100. The resulting molten polymer was extruded through a {fraction (3/16)} inch die into a 12-foot long water trough kept at a temperature of 34° C. to 38° C. The polymer was cut at a rate of 6 to 8 ft/min and fed directly into a Conair polymer cutter. A total of 40.9 lb of pellets were collected.
The resulting polymer strand exhibited some tacky behavior within the first 6 feet of the quench trough. After the strand became non-tacky in the water trough, the polymer exhibited no tacky behavior at any time during the processing operation or in subsequent processing operations.
Example 3
Demonstration of Continuous Melt Extrusion of Poly-3-hydroxy(butyrate-co-hexanoate) into Strand and On-Line Pelletizing
Blending and Extrusion of Polymer Strand and Pelletizing (methyl laurate plasticizer): In a process similar to that described for polymer blended with di-n-butylmaleate in Example 2, the following ingredients were blended: 11,793 g of P3HBH, 459.5 g of PHB, and 3063 g of methyl laurate. The resulting mixture was then fed into a 30 mm extruder as previously described set to maintain a gradiated barrel temperature between 120° C. to 160° C. The screw RPM was maintained at 100 and polymer was extruded through a {fraction (3/16)} inch die into a 12-foot water trough maintained at 34° C. to 38° C. The polymer was cut at a rate of approximately 12 ft/min by a Conair polymer cutter. The polymer quench time (the time at which no further tackiness was observed) was approximately 25 sec. A total of approximately 32 lb of non-tacky pellets were collected. It was noted that methyl laurate promoted faster quench times, thus allowing faster cutting rates.
Example 4
Demonstration of Continuous Cast Film Production Using Poly-3-hydroxy(butyrate-co-hexanoate) with Methyl Laurate Plasticizer
P3HBH pellets plasticized with methyl laurate and nucleated with PHB as prepared in the previous examples were fed into a single screw extruder equipped with a 14 inch film die and set to maintain a gradiated barrel/die temperature of 140° C. to 120° C. The resulting polymer extrudate was cast onto 12 inch diameter stainless steel rolls set at a temperature of 40° C. The extruded film was taken up onto the quench rolls and then onto packaging rolls at speeds ranging from 2 ft/min to 13 ft/min to produce films of thicknesses ranging from 1 mil to 10 mil. The film exhibited no tack and the following properties summarized in Table 3, (measured according to ASTM D 882-95a—Standard Test Method for Tensile Properties of Thin Plastic Sheeting):
TABLE 3
Young's
Thickness
Mod.
Strain at
Stress at
Toughness
Direction
(mil)
(MPa)
Break (%)
Break (MPa)
(J/in 3 )
Machine
1.7
187
562
10.3
745
Cross
1.7
147
524
8.2
623
TABLE 1
COMPOSITION
EX. #
(+NUCLEANT)
PLASTICIZER
WT % PLASTICIZER
FILM QUALITY
1
PHBO/PHB (99:1)
di(2-ethylhexyl)(dioctyl)maleate
12
no tackiness
2
PHBO/PHB (99:1)
paraffin
3.6
no tackiness
3
PHBO/PHB (99:1)
dodecanol
7
no tackiness
4
PHBO/PHB (99:1)
polyethylene glycol 600
7
no tackiness
5
PHBO/PHB (99:1)
polyethylene glycol 8000
11
no tackiness
6
PHBO/PHB (99:1)
olive oil
2.4
no tackiness
7
PHBO/PHB (99:1)
soybean oil
4.8
no tackiness
8
PHBO/PHB (99:1)
TERETHANE 650
14
no tackiness
9
PHBO/PHB (99:1)
methyl oleate
14
no tackiness
10
PHBO/PHB (99:1)
n-propyl oleate
12
no tackiness
11
PHBO/PHB (99:1)
tetrahydrofurfuryl oleate
13
no tackiness
12
PHBO/PHB (99:1)
epoxidized linseed oil
9
no tackiness
13
PHBO/PHB (99:1)
2-ethylhexyl epoxytallate
11
no tackiness
14
PHBO/PHB (99:1)
dibutyl fumarate
20
no tackiness
15
PHBO/PHB (99:1)
glycerol triacetate
18
no tackiness
16
PHBO/PHB (99:1)
methyl laurate
12
no tackiness
17
PHBO/PHB (99:1)
methyl linoleate, 75%
9
no tackiness
18
PHBO/PHB (99:1)
di-n-butyl maleate
17
no tackiness
19
PHBO/PHB (99:1)
methyl acetyl ricinoleate
11
very good
20
PHBO/PHB (99:1)
acetyl tri(n-butyl) citrate
19
very little tack
21
PHBO/PHB (99:1)
acetyl triethyl citrate
20
very little tack
22
PHBO/PHB (99:1)
tri(n-butyl) citrate
20
very little tack
23
PHBO/PHB (99:1)
triethyl citrate
20
very little tack
24
PHBO/PHB (99:1)
bis(2-hydroxyethyl) dimerate
7
very little tack
25
PHBO/PUB (99:1)
butyl ricinoleate
19
OK
26
PHBO/PHB (99:1)
glyceryl tri-(acetyl ricinoleate)
6
OK
27
PHBO/PHB (99:1)
methyl ricinoleate
18
OK
28
PHBO/PHB (99:1)
n-butyl acetyl ricinoleate
13
OK
29
PHBO/PHB (99:1)
propylene glycol ricinoleate
17
OK
30 (control)
PHBO/PUB (99:1)
high tack
31
PHBH/PHB (97:3)
paraffin
2.4
no tackiness
32
PHBH/PHB (97:3)
dodecanol
8
no tackiness
33
PHBH/PHB (97:3)
dibutyl fumarate
17
non stick
34
PHBH/PHB (97:3)
methyl laurate
18
non stick
35
PHBH/PHB (97:3)
methyl linoleate
17
non stick
36
PHBH/PHB (97:3)
di-n-butyl maleate
19
non stick
37
PHBH/PHB (97:3)
methyl ricinoleate
18
non stick
38
PHBH/PHB (97:3)
diethyl succinate
17
non sticky
39
PHBH/PHB (97:3)
diisobutyl adipate
19
non tacky
40
PHBH/PHB (97:3)
dimethyl azelate
19
non tacky
41
PHBH/PHB (97:3)
di(n-hexyl) azelate
17
non tacky
42
PHBH/PHB (97:3)
tri-butyl phosphate
20
non-tacky
43
PHBH/PHB (97:3)
di(2-ethylhexyl)(dioctyl)maleate
17
OK
44
PHBH/PHB (97:3)
TERETHANE 650
15
OK
TABLE 2
EX. #
COMPOSITION (+NUCLEANT)
PLASTICIZER
WT % PLASTICIZER
FILM QUALITY
45
PHBO − CONTROL
tacky
46
PHBH − CONTROL
tacky
47
PHBH/PHB (97:3)
tacky
48
PHBO/PHB (97:3)
tacky
49
PHBO/MICROCRYSTALLINE CELLULOSE
tacky - removed easily from
(97:3)
teflon when hot - tacky as it
cooled
50
PHBO/NUCREL 1214 (95:5)
tacky
51
PHBO/paraffin (95:5)
worse than control
52
PHBO/PO2G (95:5)
tacky
53
PHBO/POLYETHYLENE GLYCOL 8000 (97:3)
slightly tacky
54
PHBO/POLYLACTIC ACID (97:3)
tacky
55
PHBO/SURLYN 8020 (95:5)
tacky
56
PHBH/PHB (97:3)
butyl oleate
8
tacky
57
PHBH/PHB (97:3)
ditridecyl adipate
15
slightly tacky
58
PHBH/PHB (97:3)
dodecanol
8
slightly tacky
59
PHBH/PHB (97:3)
epoxidized linseed oil
13
slightly tacky
60
PHBH/PHB (97:3)
olive oil
2
slightly tacky
61
PHBH/PHB (97:3)
soybean oil
3
tacky
62
PHBH/PHB (97:3)
triethyl citrate
18
tacky
63
PHBO/PHB (99:1)
chloroparaffin, 50% Cl
9
tacky
64
PHBO/PHB (99:1)
n-butyl stearate
6
some tackiness
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The present invention is directed to a polyhydroxyalkanoate copolymer composition that can be readily and quickly processed into extruded and molded articles and film-based products. More specifically, the invention pertains to melt processing of polyhydroxyalkanoates which contain a novel combination of nucleant and plasticizer for enhancing crystallization rates thus causing improved processibility.
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This is a continuation of application Ser. No. 08/378,124, filed Jan. 24, 1995, now abandoned.
TECHNICAL FIELD
The present invention relates generally to compositions for cleaning and priming EPDM and butyl roofing and waterproofing membranes and priming metal for bonding with butyl adhesives. More specifically, the present invention relates to low VOC cleaner/primer compositions for field use in removing talc residue from such membranes and removing soil and contaminants from metal.
BACKGROURD OF THE INVENTION
As will be appreciated by those skilled in the art, membrane roofing materials are flat sheets of either single-ply or multiple-ply sheets formed of polymeric materials such as ethylene propylene diene monomer or isobutylene diene copolymer. These roofing and waterproofing membranes are typically produced by laminating unvulcanized sheets and rolling the laminated sheets onto a steel curing mandrel. In order to prevent the layers of the roll from bonding together on the mandrel as they are cured, a coating of talc is applied to the sheets. The talc typically comprises hydrous magnesium silicate powder and serves as an excellent blocking agent for the unvulcanized Rubber sheets. After the sheets are vulcanized on the mandrel, they are removed and separated. A thin residue of talc remains adhered to the sheets.
Roofing sheets are typically provided in large rolls of material of standard widths. After a section of sheeting material is applied to a roof surface, a second section is laid down next to and partially overlapping the first section. In order to create a water-tight seal between the adjacent, overlapping roofing sheets, it is necessary to create a bond at the splice or lap-joint. This is generally achieved by placing an adhesive material between the two roofing sheets at the region of overlap.
In some applications, a contact adhesive is applied to one or more of the roofing sheets at the lap-joint and is allowed to dry. Alternatively, pressure-sensitive adhesive roofing tape is used to bond the lap-joint. These tapes are designed to take the place of liquid roofing adhesives. Conventional tapes are provided as a roll having a release liner. The tape is separated from the liner material and is applied to the surface of the roofing sheet at the region where the lap-joint is formed. The tape is placed between the overlapping surfaces of the roofing sheets along the entire length of the joint.
After the liquid adhesive or roofing tape has been applied, the sheets are overlapped and pressure is applied to cause the two sheets to bond together. After the two sheets are joined in this manner, a caulking material may be used along the edge of the top layer at the joint in order to provide additional protection to the lap-joint against water.
As will be appreciated by those skilled in the art, however, the talc residue which remains on the sheets interferes with the bonding of the adhesive to the roofing sheets. This in turn decreases the bond strength of the lap-joint. Accordingly, the talc residue is removed prior to applying the adhesive to the roofing sheet typically with a solvent-based cleaner or splice wash. These cleaning solutions comprise 96-100% organic solvent blend in admixture with small amounts of colorants and/or adhesion promoters. They are high VOC compositions (700+g/l) and their use is regulated in many areas due to environmental and health concerns. For example, some government regulations restrict the VOC content of cleaners, washes and primers for roofing membrane applications to less than 250 g/l. Although some solvents such as methylene chloride and methyl chloroform have been exempted from these restrictions, in most instances this has been a temporary exemption. The VOC cleaners are utilized in the field as a scrubbing solution to wash away the talc residue prior to applying the roofing adhesive.
It would therefore be desirable to provide a roofing membrane cleaner/primer which does not contain an excessive concentration of volatile organic compounds.
It would further be desirable to provide such a composition which promotes adhesion of the roofing adhesive to the roofing sheets and contributes to the bond strength of the lap-joint.
As will be appreciated by those skilled in the art, it is often necessary to secure such single-ply roofing membranes to metal substrates such as pipes, roof units, or metal wall flashings. It is desirable to use the same material to clean and prime both the rubber membrane and the metal surface.
It would further be desirable to provide such a composition which does not contain an excessive concentration of volatile organic compounds and which does promote adhesion of the roofing adhesive to both the roofing membrane and the metal substrate, and which contributes to the bond strength of the lap-joint.
It is therefore an object of the present invention to provide a primer/cleaner composition in which the majority of the VOC content is replaced by non-VOC components.
It is a further object of the invention to provide a low VOC cleaner/primer which serves to promote adhesion between bonding surfaces.
SUMMARY OF INVENTION
In one aspect the present invention provides a cleaner/primer which contains partially cross-linked halogenated butyl rubber, a tackifier, a low viscosity, high volatility petroleum oil and a curing agent for cross-linking the halogenated butyl rubber. In another aspect, the composition of the present invention contains partially cross-linked brominated butyl rubber, a high melting point tackifying resin, a low viscosity, high volatility petroleum oil, and an isophorone diisocyanate curing agent, where the composition has a very high loading of the brominated butyl rubber and tackifier components.
In still another aspect, the present invention provides a method of forming a bond between overlapping sheets of roofing or waterproofing materials such as EPDM and butyl rubber membranes. The method comprises the steps of applying a thin film of a roofing cleaner/primer containing partially cross-linked halogenated butyl rubber, a tackifier, a low viscosity, high volatility petroleum oil and a curing agent for cross-linking the halogenated butyl rubber to the surface of a roofing or waterproofing sheet having a talc residue at the region of overlap. An adhesive material, either a liquid adhesive or a roofing tape, is then placed on the cleaned/primed surface of the roofing sheet and the sheets are overlapped. Pressure is applied to firmly bond the two sheets together. After the two sheets are joined, a caulking material may be used at the edge of the joint to provide additional protection against water. Thus, when applied to dust covered membranes the cleaner/primer effectively displaces the dust and leaves behind a primer film which is conducive to adhesive bonding by either splicing tape or solvent-based adhesives.
These and other objects and advantages of the invention will be more fully appreciated in connection with the following detailed description of the preferred embodiments of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The cleaner/primer of the present invention is an oil-based, solvent free, low VOC liquid which provides a primed surface on a variety of substrates, including EPDM and butyl rubber-type roofing sheets. In its preferred embodiment the cleaner/primer contains partially cross-linked halogenated butyl rubber, a tackifier, a low viscosity, high volatility petroleum oil and a curing agent for cross-linking the halogenated butyl rubber.
The halogenated butyl rubber component provides a binder for the resin and is most preferably brominated isoprene-isobutylene copolymer, although other halogenated isoprene-isobutylene copolymers may be suitable or desirable in a particular application such as chlorinated butyl rubber. One particularly preferred brominated butyl rubber for use herein is sold under the trade name "Bromobutyl X-2" by Miles, Inc. As will be appreciated by those skilled in the art, the isoprene units comprise about 3% of the bromobutyl polymer. The bromobutyl polymer contains about 2% bromine by weight, with all of the bromine atoms being attached to the isoprene units. Most preferred for use herein is a pre-cross-linked butyl rubber master containing from about 93% to about 96% by weight brominated isoprene-isobutylene copolymer, from about 1% to about 2% zinc oxide, from about 1% to about 5% phenolic curing resin and from about 0.1% to about 1% magnesium oxide. It is preferred that the brominated isoprene-isobutylene copolymer have a Mooney viscosity (ML1+8 at 125 Degrees Celsius) of from about 41 to about 51.
Halogenated isoprene isobutylene-copolymer comprises from about 3% to about 8% by weight of the cleaner/primer composition of the present invention and more preferably from about 5% to about 7.5% by weight of the composition.
The cleaner/primer of the present invention further includes a tackifying agent. The tackifier acts as a reinforcing agent and provides heat resistance, viscosity control and tack to the cleaner/primer. The preferred tackifier is a thermoplastic hydrocarbon resin having a Ring and Ball melting point temperature (Tm) of between about 135° C. to about 185° C. and more preferably from about 175° C. to about 180° C. The most preferred tackifier for use in the present invention is a low molecular weight (from about 900 Mn to about 1100 Mn) thermoplastic resin having an acid number less than 1, a density (at 25 degrees C.) of from about 1.0 to about 1.1 kg/l, a melt viscosity (100 poises) of between about 208° C. and about 216° C. and a Tg (softening point) of above about 160° C. One suitable tackifier is sold under the trade name Piccovar AB180 by Hercules Inc.
Tackifier comprises from about 10% to about 25% by weight and more preferably from about 20% to about 22% by weight of the cleaner primer composition of the present invention.
The carrier component of the present invention comprises a petroleum oil. Preferably the oil carrier is a low viscosity, high volatility petroleum oil having a viscosity (SSU at 100 degrees F., ASTM test method D2161) of less than 40 and preferably from about 31 to about 36; a specific gravity (ASTM D1298) of about 0.78 to 0.85; a flash point (ASTM D92 C.O.C.) of from about 84 to 110; a distillation range (ASTM), with initial boiling point, 190°-210° degrees C., 50%, 220°-230° degrees C., and dry point, 240°-322° degrees C. The preferred oil has a volatile content (ASTM D2369) of 20-35%. Preferred petroleum oils for use in the present invention are SUNPAR LW 003 sold by Sun Company, Inc., and TELURA 401 sold by Exxon Company, U.S.A.
Petroleum oil comprises from about 60% to about 80%, and more preferably from about 70% to about 75% by weight of the cleaner/primer of the present invention.
The present invention further includes a curing agent for cross-linking the halogenated butyl rubber component. A number of curing agents are suitable for this purpose. Preferred curing systems are polyfunctional isocyanates including hexamethylene diisocyanate, polymethylene polyphenyl isocyanate, isophorone diisocyanate, and diphenyl methane diisocyanate among others. Particularly suited for use in the present invention are polyfunctional aliphatic polyisocyanates based on isophorone diisocyanate dissolved in Aromatic 100 solvent. The most preferred curing agent is sold under the trade name DESMODUR Z-4370/Z by MILES, INC. Additional components may be added to the curing system such as accelerators and inhibitors.
Curing agent comprises from about 2% to about 4%, and more preferably from about 2.5% to about 3.5% by weight of the cleaner/primer composition of the present invention.
Other components may also be present in the cleaner/primer composition of the present invention such as heat and UV stabilizers and the like.
The following table sets forth the preferred formulations for the present invention:
______________________________________ Preferred Most preferred % by WT. % by WT.______________________________________Brominated Butyl Rubber: 3-8 5High MP Tackifier Resin: 10-25 22Low Visc. High Vol. Oil: 60-80 70Curing Agent: 2-5 3.7______________________________________ (cleaner/primer VOC less than about 250 grams per liter)
The compositions of the present invention are prepared by adding the dry components (bromobutyl rubber and tackifier, in crushed solid form) to the liquid components (oil and curing agent) The mixture is then stirred until the dry components are uniformly dispersed.
In the method of the present invention, the cleaner/primer composition is applied to the surface of a material such as a talc covered surface of an EPDM roofing sheet with a cloth rag or an abrasive cleaning pad. A thin film, between about 1 and about 3 mils, is applied to the surface. It will be understood by those skilled in the art that the cleaner/primer composition of the present invention dries more slowly than conventional high VOC cleaners. As a result the present invention has a greater coverage rate, particularly in high temperature environments, than conventional compositions. Use of an abrasive applicator is not necessary but has been found to loosen surface dust and deliver an even coat of the material. The cleaner/primer wets out the surface of the membrane and is readily absorbed into the membrane surface. After the cleaner/primer composition has dried it remains partially tacky. The roofing adhesive is then applied and a second roofing sheet is overlapped in the conventional manner to form a lap-joint. Pressure through the use of a roller or the like may be applied to increase the contact between the materials. The resultant bond has high bond strength and is resistant to degradation by environmental forces such as thermal fluctuations and the like. It has also been found that the cleaner/primer of the present invention is useful in priming metal surfaces to form metal/rubber laminates.
Thus it is apparent that there has been provided in accordance with the invention a method and composition that fully satisfies the objects, aims and advantages set forth above. While the invention has been described in connection with specific embodiments thereof it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art in light of the foregoing description. Accordingly, it is intended to embrace all such alternatives, modifications and variations that fall within the spirit and broad scope of the appended claims.
EXAMPLES
The following examples are intended to further illustrate the invention and are not intended to limit the full scope of the patent claims.
Example 1
Primer of the Invention Versus Solvent Based Splice Cleaner
A. Primer of the invention
B. Commercially available splice cleaner/primer
Subject primers were used to clean and prime dusted EPDM membrane which was subsequently bonded by use of commercially available pressure-sensitive butyl splice tape.
______________________________________A phr______________________________________Crosslinked rubber stock 105.8Piccovar AB-180 resin 500Desmodur Z4370/2 66Sun LW003 oil 1560Total 2231.8______________________________________ VOC = 240 grams/liter (as measured by ASTM Method D2369)
Test Results
______________________________________ 180° Peel-A 180° Peel-B Test (Primer of the (solvent basedAging Period Temperature invention) primer)______________________________________1 day @ RT RT 4.0 3.3 70° C. 0.6 0.37 days @ RT RT 4.3 4.0 70° C. 0.6 0.47 days @ RT + 14 @ RT 4.6 6.070° C. 70° C. 1.3 1.530 days @ RT RT 4.5 4.7 70° C. 1.0 0.630 days @ 70° C. RT 3.6 5.0 70° C. 1.1 1.5______________________________________
This example shows that the low VOC primer's performance is comparable to that of a commercially available solvent based product both at room temperature and under elevated temperature conditions.
Example 2
Use of Various Oils in Low VOC Primer
______________________________________Formulas, phr A B C D______________________________________Partially crosslinked rubber stock 105.8 105.8 105.8 105.8Piccovar AB-180 resin 500 500 500 500Desmodur Z4370/2 66 66 66 66Sun LW003 1560Telura 401 1560Calsol 804 1560Witsol 420 1560Total 2231.8 2231.8 2231.8 2231.8______________________________________
A. Peel adhesion of commercially available pressure-sensitive butyl tape to dusted EPDM roofing membrane cleaned and primed with primers of this example.
______________________________________ Test Solvent basedAging Period Temp A B C D cleaner/primer______________________________________7 days @ RT RT 7.6 5.6 5.4 4.9 4.0 70° C. 2.1 1.2 1.1 1.5 0.47 @ RT + 14 RT 6.9 5.6 5.9 4.9 6.6days @ 70° C. 70° C. 2.1 2.0 2.2 2.1 1.5______________________________________
B. Peel adhesion of commercially available butyl contact adhesive to dusted EPDM roofing membrane cleaned and primed with primers of this example.
______________________________________ Test Solvent basedAging Period Temp A B C D cleaner/primer______________________________________7 days @ RT RT 4.0 4.4 5.9 4.4 6.8 70° C. 0.5 0.5 0.6 0.6 0.67 @ RT + 14 RT 4.3 4.8 5.9 4.1 6.9days @ 70° C. 70° C. 2.2 2.0 2.3 1.8 3.0______________________________________
The oils used in this comparison display a variety of boiling ranges and volatility characteristics but still provide equivalent performance with either pressure-sensitive tape or solvent based adhesive when compared either to each other or to a solvent based cleaner primer (Carlisle Sure-Seal Splice Cleaner) control.
Example 3
Use on Metal
A. Formula A of example 2 used to clean and prime galvanized metal
______________________________________ Test Solvent basedAging Period Temp Adhesive A cleaner/primer______________________________________1 day @ RT RT Butyl P.S. Tape 7.6 pli 3.3 pli 70° C. 1.4 0.47 days @ RT RT Butyl P.S. Tape 6.7 3.3 70° C. 1.6 0.47 @ RT + 14 RT Butyl P.S. Tape 6.1 3.3days @ 70° C. 70° C. 1.2 0.87 @ RT + 30 RT Butyl P.S. Tape 5.0 2.8days @ 70° C. 70° C. 0.8 0.6______________________________________
The primer of the invention provides clearly superior adhesion to metal when compared to the commercially available solvent based primer. The superiority of the invention is particularly apparent after 1 and 7 days aging at room temperature, the most important time frame in terms of field installation of the splice tape system.
Example 4
Variations of Resin with Different Softening Points and Chemical Compositions
______________________________________Formulas A B C D______________________________________Partially crosslinked rubber stock 105.8 105.8 105.8 105.8Piccovar AB-180 resin 500Desmodur Z4370/2 66 66 66 66Sun LW003 1560 1560 1560 1560LX1035 500Arkon P140 500Petrorez PR140 500Dabco T-12 2 2 2 2Total 2231.8 2231.8 2231.8 2231.8______________________________________
Test Data
I. Peel strength of commercially available pressure-sensitive butyl splicing tape used to bond dusted, non-reinforced EPDM roofing membrane primed with the primers of the example.
______________________________________ Peel Strength, pliAging Period Test Temp A B C D______________________________________7 days @ RT RT 5.1 5.4 3.0 4.1 70° C. 0.8 2.0 0.3 2.07 @ RT + 14 RT 7.4 5.4 6.0 5.8days @ 70° C. 70° C. 2.1 2.0 2.3 1.9______________________________________
II. Peel strength of commercially available solvent based Butyl contact cement used to bond dusted, non-reinforced EPDM roofing membrane primed with the primers of the example.
______________________________________Aging Period Test Temp A B C D______________________________________7 days @ RT RT 3.1 3.9 5.3 5.1 70° C. 0.8 0.8 0.9 0.97 @ RT + 14 RT 4.3 6.4 5.7 5.5days @ 70° C. 70° C. 1.2 2.2 1.7 2.1______________________________________
This example illustrates the variety of tackifying resins which can be used to yield acceptable adhesion properties in this invention
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A low VOC cleaner/primer for EPDM and butyl roofing and waterproofing membranes. Highly volatile solvents are replaced with a carefully chosen petroleum oil and a blend of hydrocarbon resin and partially cross-linked halo-butyl rubber. The cleaner/primer contains halo-butyl rubber, a high softening point resin tackifier, a low viscosity, high volatility petroleum oil and a curing agent. When applied to a dust covered membrane the cleaner/primer effectively displaces dust and leaves behind a primer film which is conducive to adhesive bonding by either splicing tape or solvent based adhesive. When applied in a thin coating to metal surfaces the cleaner/primer effectively primes the metal to enhance the adhesion of butyl rubber based splicing tape or solvent based butyl adhesives.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is based upon and claims benefit of priority under 35 USC §119 from the Japanese Patent Application No. 2004-303100, filed on Oct. 18, 2004, the entire contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to a semiconductor device and a method of fabricating the same.
[0003] A memory cell of a DRAM includes one transistor and one capacitor. Recently, to reduce the dimensions of the capacitor of this DRAM memory cell while maintaining the capacitance of the capacitor, a trench capacitor type DRAM memory cell in which a capacitor is formed in the direction of depth of a semiconductor substrate is developed.
[0004] In this trench capacitor type DRAM memory cell, a trench is formed in the surface of a semiconductor substrate, and an insulating film is formed on the inner surfaces of the lower portion of this trench. After that, arsenic-doped polysilicon which is polysilicon in which arsenic (As) is doped is buried in the trench, thereby forming a trench capacitor which uses the semiconductor substrate and arsenic-doped polysilicon as an electrode.
[0005] In addition, after an insulating film called a collar oxide film is formed on the inner surfaces of the upper portion of the trench, arsenic-doped polysilicon is further buried in this trench to form a conductive layer.
[0006] Also, a MOS transistor is formed on the semiconductor substrate, and a drain region of this MOS transistor is formed in the surface portion of the semiconductor substrate so as to be adjacent to the collar oxide film. Furthermore, on the surface of the semiconductor substrate, a conductive layer called a surface strap is formed to electrically connect the drain region of the MOS transistor and the conductive layer formed in the trench.
[0007] In this trench capacitor type memory cell having the above structure, an electric current flows between the drain region of the MOS transistor and the trench capacitor via the surface strap formed on the semiconductor substrate surface and the conductive layer formed in the trench in order.
[0008] Note that an element isolation insulating film for isolating adjacent trench capacitors is formed near the upper portion of the trench.
[0009] Since the collar oxide film is formed on the inner surfaces of the upper portion of the trench, the area of the interface in which the surface strap formed on the semiconductor substrate surface and the conductive layer formed in the trench are in contact with each other decreases by the film thickness of this collar oxide film. This poses the problem that the resistance of the interface increases.
[0010] One method of reducing the resistance of the interface is to increase the area of the interface between the surface strap and the conductive layer by partially removing the collar oxide film formed near this interface.
[0011] In this method, however, when annealing for forming, e.g., a source region and drain region is performed after the trench capacitor and conductive layer are formed in the trench, arsenic diffuses into the semiconductor substrate from the arsenic-doped polysilicon forming the conductive layer in the trench, thereby forming an impurity diffusion layer whose junction depth is larger than that of the drain region of the MOS transistor.
[0012] This decreases the gate threshold voltage of the MOS transistor, and causes a short-channel effect which increases a leakage current between the source region and drain region.
[0013] A reference concerning the trench capacitor is as follows.
[0014] Japanese Patent Laid-Open No. 11-214651
SUMMARY OF THE INVENTION
[0015] According to one aspect of the invention, there is provided a semiconductor device comprising:
[0016] a gate electrode formed via a gate insulating film selectively formed on a predetermined region of a semiconductor substrate;
[0017] a source region and drain region formed in a surface portion of said semiconductor substrate on two sides of a channel region positioned below said gate electrode;
[0018] a capacitor insulating film formed in the surface portion of said semiconductor substrate to cover an inner surface near a bottom portion of a trench formed adjacent to one of said source region and drain region;
[0019] a capacitor electrode formed to be buried in said trench covered with said capacitor insulating film;
[0020] an insulating film formed to cover an inner surface of said trench, which is not covered with said capacitor insulating film;
[0021] a conductive layer containing a predetermined impurity and formed in said trench so as to be buried in a portion covered with said insulating film on said capacitor electrode;
[0022] a surface connecting layer formed on the surface of said semiconductor substrate to electrically connect said conductive layer and one of said source region and drain region; and
[0023] an impurity diffusion inhibiting film formed to cover the inner surface of said trench to a predetermined depth from an interface between said surface connecting layer and conductive layer, and having a film thickness smaller than that of said insulating film.
[0024] According to one aspect of the invention, there is provided a semiconductor device comprising:
[0025] a gate electrode formed via a gate insulating film selectively formed on a predetermined region of a semiconductor substrate;
[0026] a source region and drain region formed in a surface portion of said semiconductor substrate on two sides of a channel region positioned below said gate electrode;
[0027] an insulating film formed in the surface portion of said semiconductor substrate to cover an inner surface of a trench formed adjacent to one of said source region and drain region, except for a portion near the surface of said semiconductor substrate and a portion near a bottom portion of said trench;
[0028] an impurity diffusion inhibiting film formed to cover the inner surface of said trench and said insulating film, and having a film thickness smaller than that of said insulating film;
[0029] a conductive layer containing a predetermined impurity and formed to be buried in said trench in which said impurity diffusion inhibiting film is formed; and
[0030] a surface connecting layer formed on the surface of said semiconductor substrate to electrically connect said conductive layer and one of said source region and drain region.
[0031] According to one aspect of the invention, there is provided a semiconductor device fabrication method comprising:
[0032] forming a trench by removing a desired region of a surface portion of a semiconductor substrate;
[0033] forming a capacitor insulating film to cover an inner surface near a bottom portion of the trench;
[0034] forming a film by depositing a conductive material containing a first impurity so as to fill the trench covered with the capacitor insulating film, thereby forming a capacitor electrode;
[0035] forming an insulating film so as to cover an inner surface of the trench, which is not covered with the capacitor insulating film;
[0036] forming, in the trench, a film by depositing the conductive material containing a second impurity so as to fill a portion covered with the insulating film on the capacitor electrode, thereby forming a first conductive layer;
[0037] forming an impurity diffusion inhibiting film having a film thickness smaller than that of the insulating film, so as to cover an inner surface of the trench near the surface of the semiconductor substrate;
[0038] forming, in the trench, a film by depositing the conductive material containing a third impurity so as to fill a portion covered with the impurity diffusion inhibiting film on the first conductive layer, thereby forming a second conductive layer;
[0039] forming a gate electrode on a predetermined region of the semiconductor substrate via a gate insulating film;
[0040] forming a source region and drain region in the surface portion of the semiconductor substrate, such that one of the source region and drain region is adjacent to the trench; and
[0041] forming, on the surface of the semiconductor substrate, a surface connecting layer which electrically connects the second conductive layer and one of the source region and drain region.
[0042] According to one aspect of the invention, there is provided a semiconductor device fabrication method comprising:
[0043] forming a trench by removing a desired region of a surface portion of a semiconductor substrate;
[0044] sequentially forming first and second films so as to cover an inner surface of the trench;
[0045] forming a first resist film having a desired height from a bottom portion of the trench by coating a first resist material so as to fill the trench in which the first and second films are formed;
[0046] removing the second film having an exposed surface, and removing the first resist film remaining in the trench;
[0047] forming a first insulating film by oxidizing the first film having an exposed surface;
[0048] sequentially removing the second and first films remaining in the trench;
[0049] forming a second resist film lower than the surface of the semiconductor substrate by coating a second resist material so as to fill the trench in which the first insulating film is formed;
[0050] removing the first insulating film having an exposed surface;
[0051] removing the second resist film remaining in the trench;
[0052] forming a second insulating film having a film thickness smaller than that of the first insulating film, on the inner surface of the trench and on the surface of the first insulating film;
[0053] forming a film by depositing a conductive material containing a predetermined impurity so as to fill the trench in which the first and second insulating films are formed, thereby forming a conductive layer;
[0054] forming a gate electrode on a predetermined region of the semiconductor substrate via a gate insulating film;
[0055] forming a source region and drain region in the surface portion of the semiconductor substrate, such that one of the source region and drain region is adjacent to the trench; and
[0056] forming, on the surface of the semiconductor substrate, a surface connecting layer which electrically connects the conductive layer and one of the source region and drain region.
BRIEF DESCRIPTION OF THE DRAWINGS
[0057] FIG. 1 is a longitudinal sectional view showing the sectional structure of a device in a predetermined step of a semiconductor device fabrication method according to the first embodiment of the present invention;
[0058] FIG. 2 is a longitudinal sectional view showing the sectional structure of a device in a predetermined step of the semiconductor device fabrication method;
[0059] FIG. 3 is a longitudinal sectional view showing the sectional structure of a device in a predetermined step of the semiconductor device fabrication method;
[0060] FIG. 4 is a longitudinal sectional view showing the sectional structure of a device in a predetermined step of the semiconductor device fabrication method;
[0061] FIG. 5 is a longitudinal sectional view showing the sectional structure of a device in a predetermined step of the semiconductor device fabrication method;
[0062] FIG. 6 is a longitudinal sectional view showing the sectional structure of a device in a predetermined step of the semiconductor device fabrication method;
[0063] FIG. 7 is a longitudinal sectional view showing the sectional structure of a device in a predetermined step of the semiconductor device fabrication method;
[0064] FIG. 8 is a longitudinal sectional view showing the sectional structure of a device in a predetermined step of the semiconductor device fabrication method;
[0065] FIG. 9 is a longitudinal sectional view showing the sectional structure of a device in a predetermined step of the semiconductor device fabrication method;
[0066] FIG. 10 is a longitudinal sectional view showing the sectional structure of a device in a predetermined step of the semiconductor device fabrication method;
[0067] FIG. 11 is a longitudinal sectional view showing the sectional structure of a device in a predetermined step of the semiconductor device fabrication method;
[0068] FIG. 12 is a longitudinal sectional view showing the sectional structure of a device in a predetermined step of a semiconductor device fabrication method according to the second embodiment of the present invention;
[0069] FIG. 13 is a longitudinal sectional view showing the sectional structure of a device in a predetermined step of the semiconductor device fabrication method;
[0070] FIG. 14 is a longitudinal sectional view showing the sectional structure of a device in a predetermined step of the semiconductor device fabrication method;
[0071] FIG. 15 is a longitudinal sectional view showing the sectional structure of a device in a predetermined step of the semiconductor device fabrication method;
[0072] FIG. 16 is a longitudinal sectional view showing the sectional structure of a device in a predetermined step of a semiconductor device fabrication method according to the third embodiment of the present invention;
[0073] FIG. 17 is a longitudinal sectional view showing the sectional structure of a device in a predetermined step of the semiconductor device fabrication method;
[0074] FIG. 18 is a longitudinal sectional view showing the sectional structure of a device in a predetermined step of the semiconductor device fabrication method;
[0075] FIG. 19 is a longitudinal sectional view showing the sectional structure of a device in a predetermined step of the semiconductor device fabrication method;
[0076] FIG. 20 is a longitudinal sectional view showing the sectional structure of a device in a predetermined step of a semiconductor device fabrication method according to the fourth embodiment of the present invention;
[0077] FIG. 21 is a longitudinal sectional view showing the sectional structure of a device in a predetermined step of the semiconductor device fabrication method;
[0078] FIG. 22 is a longitudinal sectional view showing the sectional structure of a device in a predetermined step of the semiconductor device fabrication method;
[0079] FIG. 23 is a longitudinal sectional view showing the sectional structure of a device in a predetermined step of the semiconductor device fabrication method;
[0080] FIG. 24 is a longitudinal sectional view showing the sectional structure of a device in a predetermined step of the semiconductor device fabrication method;
[0081] FIG. 25 is a longitudinal sectional view showing the sectional structure of a device in a predetermined step of the semiconductor device fabrication method; and
[0082] FIG. 26 is a longitudinal sectional view showing the sectional structure of a device in a predetermined step of the semiconductor device fabrication method.
DETAILED DESCRIPTION OF THE INVENTION
[0083] Embodiments of the present invention will be described below with reference to the accompanying drawings.
(1) First Embodiment
[0084] FIGS. 1 to 11 show a method of fabricating a memory cell of a trench capacitor type DRAM according to the first embodiment of the present invention. First, as shown in FIG. 1 , LPCVD (Low Pressure Chemical Vapor Deposition) is used to form a silicon oxide (SiO 2 ) film (not shown) about 2 nm thick on a semiconductor substrate 100 , form a silicon nitride (SiN) film 120 about 220 nm thick, and form a BSG film 130 about 1,600 nm thick which is a silicon oxide film in which boron (B) is doped.
[0085] The BSG film 130 , silicon nitride (SiN) film 120 , and silicon oxide (SiO 2 ) film (not shown) are sequentially patterned by lithography and RIE (Reactive Ion Etching). Then, the BSG film 130 is used as a mask to etch the semiconductor substrate 100 , thereby forming trenches (DTs) 140 about 8 μm deep from the surface of the semiconductor substrate 100 .
[0086] As shown in FIG. 2 , after the BSG film 130 is removed by wet etching, an NO film 150 about 5 nm thick which is a stacked film of a silicon nitride (SiN) film and silicon oxide (SiO 2 ) film is formed on the entire surfaces of the semiconductor substrate 100 and silicon nitride (SiN) film 120 by LPCVD. In addition, arsenic-doped polysilicon which is polysilicon as a conductive material in which arsenic (As) is doped as an impurity is deposited on the entire surface, thereby forming an arsenic-doped polysilicon film 160 about 200 nm thick. Note that it is also possible to dope another impurity such as phosphorus (P), instead of arsenic (As).
[0087] The arsenic-doped polysilicon film 160 is then removed by RIE to a depth of about 1 μm from the surface of the semiconductor substrate 100 . After that, the NO film 150 which is exposed by the removal of the arsenic-doped polysilicon film 160 is removed by wet etching.
[0088] In this manner, a capacitor insulating film made of the NO film 150 is formed, and capacitor electrodes made of the arsenic-doped polysilicon film 160 as a conductive layer are formed, thereby forming trench capacitors made of the semiconductor substrate 100 , NO film 150 , and arsenic-doped polysilicon film 160 .
[0089] As shown in FIG. 3 , a silicon oxide (SiO 2 ) film (not shown) about 8 nm thick is formed on the entire inner surfaces of the exposed trenches 140 and on the entire surface of the arsenic-doped polysilicon film 160 . On the entire surface of this silicon oxide (SiO 2 ) film (not shown), a collar oxide film 180 about 35 nm thick made of, e.g., a silicon oxide (SiO 2 ) film is formed by LPCVD. After that, an insulating film made of the collar oxide film 180 is formed on the inner surfaces of the upper portions of the trenches 140 by RIE.
[0090] As shown in FIG. 4 , arsenic-doped polysilicon is deposited on the entire surfaces of the arsenic-doped polysilicon film 160 , collar oxide film 180 , and silicon nitride (SiN) film 120 to form a arsenic-doped polysilicon film 190 about 200 nm thick. After that, the arsenic-doped polysilicon film 190 is removed by RIE to a depth of about 100 nm from the surface of the semiconductor substrate 100 , thereby forming a conductive layer made of the arsenic-doped polysilicon film 190 .
[0091] As shown in FIG. 5 , the collar oxide film 180 is removed by wet etching to a depth of about 80 nm from the surface of the arsenic-doped polysilicon film 190 .
[0092] As shown in FIG. 6 , a silicon nitride (SiN) film 200 about 2 to 7 nm thick is formed by LPCVD on the entire surfaces of the collar oxide film 180 , arsenic-doped polysilicon film 190 , and silicon nitride (SiN) film 120 . After that, an impurity diffusion inhibiting film made of the silicon nitride (SiN) film 200 is formed on the inner surfaces of the upper portions of the trenches 140 by RIE.
[0093] An arsenic-doped polysilicon film 210 is formed by depositing arsenic-doped polysilicon about 200 nm thick on the entire surfaces of the collar oxide film 180 , silicon nitride (SiN) film 200 , arsenic-doped polysilicon film 190 , and silicon nitride (SiN) film 120 . As shown in FIG. 7 , the arsenic-doped polysilicon film 210 is removed by RIE to a depth of about 30 nm from the surface of the semiconductor substrate 100 , thereby forming a conductive layer made of the arsenic-doped polysilicon film 210 .
[0094] As shown in FIG. 8 , a silicon oxide (SiO 2 ) film 220 about 250 nm thick is deposited, and a trench 230 about 300 nm deep from the surface of the semiconductor substrate 100 is formed by lithography and RIE.
[0095] As shown in FIG. 9 , the silicon oxide (SiO 2 ) film 220 is remove by wet etching, and a thermal oxide film (not shown) about 4 nm thick made of a silicon oxide (SiO 2 ) film is formed on the entire surface. After that, a silicon oxide (SiO 2 ) film 250 about, e.g., 400 nm thick is formed on the entire surface of the thermal oxide film.
[0096] Then, the silicon oxide (SiO 2 ) film 250 formed in a position higher than the surface of the silicon nitride (SiN) 120 is removed by planarization. In addition, the silicon oxide (SiO 2 ) film 250 is removed by wet etching to a height of about 30 nm from the surface of the semiconductor substrate 100 .
[0097] The silicon nitride (SiN) film 120 is removed by wet etching to form an STI (Shallow Trench Isolation) film 250 as an element isolation insulating film for electrically isolating adjacent trench capacitors.
[0098] As shown in FIG. 10 , a silicon oxide (SiO 2 ) film (not shown) about 2.5 nm thick, for example, is formed on the surface of the semiconductor substrate 100 . After that, a phosphorus-doped polysilicon film 270 about 200 nm thick in which phosphorus (P) is doped is formed, and a silicon nitride (SiN) film 280 about 100 nm thick is also formed.
[0099] The silicon nitride (SiN) film 280 and phosphorus-doped polysilicon film 270 are patterned by lithography and RIE to form a gate insulating film made of the silicon oxide (SiO 2 ) film (not shown) and gate electrodes made of the phosphorus-doped polysilicon film 270 .
[0100] Then, phosphorus (P), for example, is ion-implanted in the surface of the semiconductor substrate 100 to form a source extension region and drain extension region (neither is shown).
[0101] Silicon nitride (SiN) about 70 nm thick is deposited on the entire surface of the semiconductor substrate 100 , and gate electrode side walls made of a silicon nitride (SiN) film 310 are formed by RIE on the side surfaces of the phosphorus-doped polysilicon film 270 and silicon nitride (SiN) film 280 .
[0102] In addition, phosphorus (P), for example, is further ion-implanted in the surface of the semiconductor substrate 100 to form a source region 290 and drain region 300 .
[0103] As shown in FIG. 11 , a silicon oxide (SiO 2 ) film 320 about 500 nm thick serving as an interlayer dielectric film is formed on the entire surface of the semiconductor substrate 100 , and etched by lithography and RIE to form contact holes 330 .
[0104] In this step, end portions 250 A of the STI film 250 , which are in contact with the silicon nitride (SiN) film 200 are partially removed to expose portions of the arsenic-doped polysilicon film 210 formed on the lower surfaces of the end portions 250 A of the STI film 250 .
[0105] After a phosphorus-doped polysilicon film (not shown) is formed by depositing phosphorus-doped polysilicon on the entire surface so as to fill the contact holes 330 , and etched by RIE to form surface straps 340 serving as surface connecting layers.
[0106] FIG. 11 shows the structure of a memory cell 400 of a trench capacitor type DRAM fabricated by the above method.
[0107] The phosphorus-doped polysilicon film 270 as a gate electrode is formed via the silicon oxide (SiO 2 ) film (not shown) as a gate insulating film on a predetermined region of the semiconductor substrate 100 . Additionally, the silicon nitride (SiN) film 280 as a cap insulating film is formed on the phosphorus-doped polysilicon film 270 .
[0108] The silicon nitride (SiN) films 310 as gate electrode side walls are formed on the side surfaces of the phosphorus-doped polysilicon film 270 and silicon nitride (SiN) film 280 .
[0109] In the surface portion of the semiconductor substrate 100 , the source region 290 and drain region 300 are formed on the two sides of each channel region 350 positioned below the phosphorus-doped polysilicon film 270 as a gate electrode.
[0110] The trenches 140 are formed adjacent to the drain regions 300 in the surface portion of the semiconductor substrate. The NO film 150 as a capacitor insulating film is formed on the inner surfaces near the lower portion of each trench 140 . Also, the arsenic-doped polysilicon film 160 which is a conductive layer serving as a capacitor electrode is formed to bury the NO film 150 .
[0111] As described above, the semiconductor substrate 100 , NO film 150 , and arsenic-doped polysilicon film 160 form a trench capacitor.
[0112] The collar oxide film 180 as an insulating film is formed on the inner surface near the upper portion of each trench 140 so as to be adjacent to the NO film 150 . The arsenic-doped polysilicon film 190 as a conductive layer is formed to bury the collar oxide film 180 . In addition, the arsenic-doped polysilicon film 210 as a conductive film is formed to bury the collar oxide film 180 and arsenic-doped polysilicon film 190 .
[0113] The surface straps 340 are formed on the surface of the semiconductor substrate 100 . Each surface strap 340 is a surface connecting layer for electrically connecting the drain region 300 of the MOS transistor and the conductive layer made of the arsenic-doped polysilicon film 210 in the trench 140 .
[0114] In the memory cell 400 of the trench capacitor type DRAM having the above structure, an electric current flows between the drain region 300 of each MOS transistor and the arsenic-doped polysilicon film 160 as a capacitor electrode of each trench capacitor via the surface strap 340 and the conductive layers 210 and 190 in order.
[0115] The silicon nitride (SiN) film 200 as an impurity diffusion inhibiting film thinner than the collar oxide film 180 is formed on the inner surface of each trench 140 near the interface between the surface strap 340 and arsenic-doped polysilicon 210 .
[0116] The interface between the surface strap 340 and arsenic-doped polysilicon 210 is positioned at a depth of about 20 nm from the surface of the semiconductor substrate 100 . The silicon nitride (SiN) film 200 as an impurity diffusion inhibiting film is formed to a depth of about 30 to 60 nm from this interface.
[0117] Note that the STI film 250 for electrically isolating adjacent trench capacitors is formed near the upper end corners of the trenches 140 , on the side of the semiconductor substrate 100 where the drain regions 300 are not formed.
[0118] The silicon oxide (SiO 2 ) film 320 as an interlayer dielectric film is formed on the semiconductor substrate 100 and silicon nitride (SiN) film 280 .
[0119] In this embodiment as described above, the silicon nitride (SiN) film 200 as an impurity diffusion inhibiting film thinner than the collar oxide film 180 is formed on the inner surface of each trench 140 near the interface between the surface strap 340 and the arsenic-doped polysilicon film 210 which forms a conductive layer.
[0120] This makes it possible to inhibit arsenic from diffusing into the semiconductor substrate 100 from the arsenic-doped polysilicon film 210 in each trench 140 , thereby suppressing a short-channel effect caused by a decrease in gate threshold voltage.
[0121] In addition, the area of the interface between the surface strap 340 and arsenic-doped polysilicon film 210 can be made larger than that when the collar oxide film 180 thicker than the silicon nitride (SiN) film 200 is formed near this interface. Accordingly, a resistance produced in the interface between the surface strap 340 and arsenic-doped polysilicon film 210 can be reduced.
(2) Second Embodiment
[0122] FIGS. 12 to 15 show a semiconductor device fabrication method according to the second embodiment of the present invention. Note that the steps shown in FIGS. 1 to 5 of the first embodiment are the same as in the second embodiment, so an explanation thereof will be omitted.
[0123] As shown in FIG. 12 , a silicon nitride (SiN) film 200 about, e.g., 2 to 7 nm thick is formed by LPCVD on the entire surfaces of a collar oxide film 180 , arsenic-doped polysilicon film 190 , and silicon nitride (SiN) film 120 . After that, a polysilicon film 410 about 28 to 33 nm thick for protecting the silicon nitride (SiN) film 200 is formed.
[0124] Then, the polysilicon film 410 and silicon nitride (SiN) film 200 are etched by RIE to form a silicon nitride (SiN) film 200 serving as an impurity diffusion inhibiting film on the inner surfaces of exposed trenches 140 . A polysilicon film 410 is also formed as a protective film.
[0125] Note that the silicon nitride (SiN) film 200 is a thin film about 2 to 7 nm thick. Therefore, if the silicon nitride (SiN) film 200 is etched in the step shown in FIG. 6 of the first embodiment, the end portion of the silicon nitride (SiN) film 200 may be removed. In this embodiment, however, the silicon nitride (SiN) film 200 is protected by the polysilicon film 410 , so the end portion of the silicon nitride (SiN) film 200 is not removed even when it is etched.
[0126] As shown in FIG. 13 , an arsenic-doped polysilicon film 210 about 200 nm thick is formed by depositing arsenic-doped polysilicon on the entire surfaces of the silicon nitride (SiN) film 200 , polysilicon film 410 , arsenic-doped polysilicon film 190 , and silicon nitride (SiN) film 120 . After that, as shown in FIG. 14 , the arsenic-doped polysilicon film 210 is removed by RIE to a depth of about 30 nm from the surface of a semiconductor substrate 100 .
[0127] Note that the upper portion of the polysilicon film 410 is etched at the same time the arsenic-doped polysilicon 210 is etched. Since, however, the silicon nitride (SiN) film 200 is protected by the polysilicon film 410 , etching of the silicon nitride (SiN) film 200 can be suppressed when compared to the first embodiment.
[0128] After that, the same steps as shown in FIGS. 8 to 11 of the first embodiment are executed to fabricate a memory cell of a trench capacitor type DRAM. FIG. 15 shows the structure of a memory cell 500 of the trench capacitor type DRAM according to this embodiment. Note that the same reference numerals as in FIG. 11 denote the same elements as shown in FIG. 11 , and an explanation thereof will be omitted.
[0129] In this embodiment, as shown in FIG. 15 , the polysilicon film 410 for protecting the silicon nitride (SiN) film 200 is formed on its surface to a position slightly higher than the interface between a surface strap 340 and the arsenic-doped polysilicon 210 .
[0130] In this embodiment as described above, the silicon nitride (SiN) film 200 as an impurity diffusion inhibiting film thinner than the collar oxide film 180 is formed on the inner surface of each trench 140 near the interface between the surface strap 340 and the arsenic-doped polysilicon 210 which forms a conductive layer.
[0131] This makes it possible to inhibit arsenic from diffusing into the semiconductor substrate 100 from the arsenic-doped polysilicon film 210 in each trench 140 , and thereby suppress a short-channel effect caused by a decrease in gate threshold voltage.
(3) Third Embodiment
[0132] FIGS. 16 to 19 show a semiconductor device fabrication method according to the third embodiment of the present invention. Note that the steps shown in FIGS. 1 to 5 of the first embodiment are the same as in the third embodiment, so an explanation thereof will be omitted.
[0133] As shown in FIG. 16 , a silicon nitride (SiN) film 200 about, e.g., 2 to 7 nm thick is formed by LPCVD on the entire surfaces of a collar oxide film 180 , arsenic-doped polysilicon film 190 , and silicon nitride (SiN) film 120 . After that, a BSG film 510 as a silicon oxide film in which boron (B) is doped is formed.
[0134] Then, the BSG film 510 and silicon nitride (SiN) film 200 are etched by RIE to form a silicon nitride (SiN) film 200 serving as an impurity diffusion inhibiting film on the inner surfaces of exposed trenches 140 . In addition, a BSG film 510 for protecting the silicon nitride (SiN) film 200 is formed.
[0135] Note that the silicon nitride (SiN) film 200 is a thin film about 2 to 7 nm thick. Therefore, if the silicon nitride (SiN) film 200 is etched in the step shown in FIG. 6 of the first embodiment, the end portion of the silicon nitride (SiN) film 200 may be removed. In this embodiment, however, the silicon nitride (SiN) film 200 is protected by the BSG film 510 , so the end portion of the silicon nitride (SiN) film 200 is not removed even when it is etched.
[0136] As shown in FIG. 17 , after the BSG film 510 is removed by wet etching, an arsenic-doped polysilicon film 210 about 200 nm thick is formed by depositing arsenic-doped polysilicon on the entire surfaces of the collar oxide film 180 , arsenic-doped polysilicon film 190 , and silicon nitride (SiN) film 120 . As shown in FIG. 18 , the arsenic-doped polysilicon film 210 is removed by RIE to a depth of about 30 nm from the surface of a semiconductor substrate 100 .
[0137] After that, the same steps as shown in FIGS. 8 to 11 of the first embodiment are executed to fabricate a memory cell of a trench capacitor type DRAM. FIG. 19 shows the structure of a memory cell 600 of the trench capacitor type DRAM according to this embodiment. Note that this structure is the same as the memory cell 400 of the trench capacitor type DRAM according to the first embodiment shown in FIG. 11 , so an explanation thereof will be omitted.
[0138] In this embodiment, as in the first embodiment, the silicon nitride (SiN) film 200 as an impurity diffusion inhibiting film thinner than the collar oxide film 180 is formed on the inner surface of each trench 140 near the interface between a surface strap 340 and the arsenic-doped polysilicon 210 which forms a conductive layer.
[0139] This makes it possible to inhibit arsenic from diffusing into the semiconductor substrate 100 from the arsenic-doped polysilicon film 210 in each trench 140 , thereby suppressing a short-channel effect caused by a decrease in gate threshold voltage.
[0140] Also, in this embodiment, no polysilicon film 410 for protecting the silicon nitride (SiN) film 200 is formed unlike in the second embodiment, so the area of the interface between the surface strap 340 and arsenic-doped polysilicon film 210 can be made larger than that in the second embodiment. Accordingly, a resistance produced in the interface between the surface strap 340 and arsenic-doped polysilicon film 210 can be made lower than that in the second embodiment.
(4) Fourth Embodiment
[0141] FIGS. 20 to 26 show a semiconductor device fabrication method according to the fourth embodiment of the present invention. Note that the step shown in FIG. 1 of the first embodiment is the same as in the fourth embodiment, so an explanation thereof will be omitted.
[0142] As shown in FIG. 20 , after a BSG film 130 is removed by wet etching, a polysilicon film 610 about 16 nm thick and a silicon nitride (SiN) film 620 about 10 nm thick are sequentially formed on the entire surfaces of a semiconductor substrate 100 and silicon nitride (SiN) film 120 by LPCVD. Subsequently, the silicon nitride (SiN) film 620 is coated with a resist material so as to fill trenches 140 , thereby forming a resist film 630 .
[0143] As shown in FIG. 21 , the resist film 630 is etched away by CDE (Chemical Dry Etching) to a depth of about 1.3 nm from the surface of the semiconductor substrate 100 . Then, the exposed silicon nitride (SiN) film 620 is removed by CDE.
[0144] As shown in FIG. 22 , the resist film 630 remaining in the lower portions of the trenches 140 is removed by wet etching. After that, the exposed polysilicon film 610 is oxidized in a high-temperature furnace at about 950° C. to form a silicon oxide (SiO 2 ) film 640 about 45 nm thick.
[0145] After the silicon nitride (SiN) film 620 remaining in the lower portions of the trenches 140 is removed by wet etching, the polysilicon film 610 exposed by the removal of the silicon nitride (SiN) film 620 is removed by CDE.
[0146] As shown in FIG. 23 , the semiconductor substrate 100 and silicon oxide (SiO 2 ) film 640 are coated with a resist material so as to fill the trenches 140 , thereby forming a resist film 650 . The resist film 650 is then removed by CDE to a depth of about 60 nm from the surface of the semiconductor substrate 100 .
[0147] A collar oxide film 660 is formed by removing the exposed silicon oxide (SiO 2 ) film 640 by wet etching.
[0148] As shown in FIG. 24 , after the resist film 650 remaining in the trenches 140 is removed by wet etching, an NO film 670 about 5 nm thick is formed by LPCVD on the inner surfaces of the trenches 140 , on the surface of the collar oxide film 660 , and on the entire surface of the silicon nitride (SiN) film 120 . In addition, an arsenic-doped polysilicon film 680 about 200 nm thick is formed by depositing arsenic-doped polysilicon on the entire surface of the NO film 670 .
[0149] As shown in FIG. 25 , the arsenic-doped polysilicon film 680 is removed by RIE to a depth of about 30 nm from the surface of the semiconductor substrate 100 , and the NO film 670 formed on the surface of the silicon nitride (SiN) film 120 is removed by wet etching.
[0150] After that, the same steps as in FIGS. 8 to 11 of the first embodiment are executed to fabricate a memory cell of a trench capacitor type DRAM.
[0151] In this embodiment as described above, since the NO film 670 is formed on the entire inner surfaces of the trenches 140 , the capacitor insulating film and impurity diffusion inhibiting film can be formed at the same time. Accordingly, the number of steps can be reduced because it is unnecessary to separately form the capacitor insulating film and impurity diffusion inhibiting film unlike in the first to third embodiments.
[0152] Also, when arsenic-doped polysilicon is divisionally buried in the trenches 140 three times as in the first to third embodiments, native oxide films are formed between the arsenic-doped polysilicon films 160 , 190 , and 210 . However, when the arsenic-doped polysilicon film 680 is formed by burying arsenic-doped polysilicon in the trenches 140 at once as in this embodiment, no native oxide film is formed, and the number of steps can be made smaller than those in the first to third embodiments.
[0153] FIG. 26 shows the structure of a memory cell 700 of the trench capacitor type DRAM according to this embodiment. Note that the same reference numerals as in FIG. 11 denote the same elements as shown in FIG. 11 , and an explanation thereof will be omitted. As shown in FIG. 26 , in the memory cell 700 of the trench capacitor type DRAM, the capacitor insulating film and impurity diffusion inhibiting film are formed by the same NO film 670 .
[0154] In this embodiment as described above, a silicon nitride (SiN) film 200 as an impurity diffusion inhibiting film thinner than a collar oxide film 180 is formed on the inner surface of each trench 140 near the interface between a surface strap 340 and an arsenic-doped polysilicon 210 which forms a conductive layer.
[0155] This makes it possible to inhibit arsenic from diffusing into the semiconductor substrate 100 from the arsenic-doped polysilicon film 210 in each trench 140 , thereby suppressing a short-channel effect caused by a decrease in gate threshold voltage.
[0156] Also, the area of the interface between the surface strap 340 and arsenic-doped polysilicon film 210 can be made larger than that when the collar oxide film 180 thicker than the silicon nitride (SiN) film 200 is formed near the interface between the surface strap 340 and arsenic-doped polysilicon film 210 . Accordingly, a resistance produced in the interface between the surface strap 340 and arsenic-doped polysilicon film 210 can be reduced.
[0157] The above embodiment can suppress the short-channel effect, and reduce the resistance produced in the interface between the surface strap formed on the surface of the semiconductor substrate and the conductive layer formed in the trench.
[0158] Note that the above embodiments are merely examples and do not limit the present invention. For example, as the impurity diffusion inhibiting film, it is also possible to use a silicon nitride (SiN) film, a silicon oxide (SiO 2 ) film, an oxide film mainly containing, e.g., aluminum (Al), tantalum (Ta), titanium (Ti), strontium (Sr), hafnium (Hf), or zirconium (Zr), or a stacked film formed by stacking these materials.
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According to the present invention, there is provided a semiconductor devise comprising: a gate electrode formed via a gate insulating film selectively formed on a predetermined region of a semiconductor substrate; a source region and drain region formed in a surface portion of said semiconductor substrate on two sides of a channel region positioned below said gate electrode; a capacitor insulating film formed in the surface portion of said semiconductor substrate to cover an inner surface near a bottom portion of a trench formed adjacent to one of said source region and drain region; a capacitor electrode formed to be buried in said trench covered with said capacitor insulating film; an insulating film formed to cover an inner surface of said trench, which is not covered with said capacitor insulating film; a conductive layer containing a predetermined impurity and formed in said trench so as to be buried in a portion covered with said insulating film on said capacitor electrode; a surface connecting layer formed on the surface of said semiconductor substrate to electrically connect said conductive layer and one of said source region and drain region; and an impurity diffusion inhibiting film formed to cover the inner surface of said trench to a predetermined depth from an interface between said surface connecting layer and conductive layer, and having a film thickness smaller than that of said insulating film.
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BACKGROUND OF THE INVENTION
The present invention relates generally to building construction and reinforcement, and specifically to a continuity system that resists tension from wind uplift forces or overturning forces from wind or seismic events while compensating for the downward settling of buildings caused by shrinkage of wooden members. Most specifically, the present invention relates to a ratcheting take-up device that reduces slack due to wood shrinkage and building settling in a holdown system of continuous rods, eases installation and compensates for imperfectly aligned rods.
A continuity system is a secondary support system that ties walls or other building elements together and resists lateral overturning forces or uplift forces from events such as earthquakes or strong winds. Earthquake and wind forces produce overturning and uplift loads in the building, which load the building elements in overturning or uplift with respect to the building foundation. A continuity system resists such movements of the building elements. A continuity system generally comprises a plurality of interconnected vertically-oriented elements, typically metal rods and bearing plates, or holdowns, that provide a discrete structural mechanism or load path framework for the transfer of loads through the building from the structural elements that are intended to resist such forces, such as roof or floor diaphragms and shearwalls, to the continuity system, and then to the foundation. For example, the presence of a continuity system enables wall panels to resist overturning and/or moments that might damage or destroy the wall.
A known continuity system is described in U.S. Pat. No. 4,875,314 (“the '314 patent”), the entire disclosure of which is hereby incorporated herein by reference. The '314 patent describes a system in which at least one tie rod is connected to the foundation through a simple threaded coupler and a foundation anchor. Although the tie rod system can be used in a single-story structure, it is particularly suited to multistory structures, as illustrated in the '314 patent. In a multistory structure, a series of anchor elements is used to couple multiple tie rods in a line from the foundation to the top plate of the top story of the structure. The anchor elements of the '314 patent, in addition to coupling tie rods together, are used to secure the tie rods at each level of the structure to eliminate initial slack in the system. The principal shortcoming of the system of the '314 patent is the lack of a means of compensating for slack that builds up in the system as the wood structural members shrink over time. As slack builds up in the system, the system's capacity to resist uplift is correspondingly reduced.
The prior art includes a number of technical solutions to the problem of increasing slack in continuity systems. Simpson Strong-Tie Company's Anchor Tiedown System uses the TUD and ATUD take-up devices, as well as the CTUD coupling take-up device. The CTUD coupling take-up device is the subject of U.S. Pat. No. 7,905,066, granted to Steven E. Pryor et al. All three devices are driven by a torsion spring. The TUD and ATUD are slipped over the tie rod between a horizontally disposed member and a nut threaded onto the tie rod, and they expand to fill the space as it expands enlarges. The CTUD threads onto and couples the vertically-aligned ends of two tie rods, drawing the two together to maintain tight connections between the wood and steel elements as the wood structural members shrink over time.
Similar continuity systems with ratcheting take-up devices are described in U.S. Pat. No. 6,007,284 the entire disclosure of which is hereby incorporated herein by reference, and U.S. Pat. No. 7,744,322, the entire disclosure of which is also hereby incorporated herein by reference. These devices, while similar in both basic form and function to the present invention, lack inventive features of the present invention.
The ratcheting take-up device of the present invention eases installation of continuity systems, compensates for tie rods that are not perfectly perpendicular to the top and bottom plates, and takes up slack in the continuity system after installation.
SUMMARY OF THE INVENTION
The take-up device of the present invention has a plurality of insert segments with concavities that form an inner bore. The insert segments are contained within a housing that has an outer bore. The lower portion of the outer bore in the housing narrows. The lower portions of the insert segments and the lower portion of outer bore contained by the housing have frusto-spherical bearing surfaces. The insert segments are formed and arranged so that they grasp and hold a tie rod received in the housing when a wind uplift or a shear wall overturning force is applied to the wall of which the take-up device is a part. When a wind uplift or a shear wall overturning force is applied to the wall, the tie rod is placed in tension from an anchoring, reactive force pulling on the tension rod from below the housing while the structural member that is part of the wall to which the take-up device is attached pushes upwardly on the housing of the take-up device. The tie rod, the insert segments and the housing are formed such that when the tie rod moves downwardly with respect to the housing, the insert segments will be pulled downwardly in the housing as well. The tension on the tie rod combined with the narrowing in the lower portion of the outer bore of the housing causes a constriction of the insert segments about the tie rod forcing them to grasp and hold the tie rod, preventing any further downward movement of the tie rod with respect to the housing and thus to the building component to which the housing is attached.
An important advantage of the take-up device of the present invention is that its frusto-spherical bearing surfaces allow it to anchor imperfectly aligned tie rods by swinging about a central pivot on the vertical axis of the device in any direction without a reduction in the bearing surfaces or the strength of the anchorage. The lower portions of the insert segments collectively have the geometry of a spherical segment—a spherical cap with the top truncated, or a spherical frustum. The first frusto-spherical bearing surface is the outward-facing, lower surfaces of the insert segments taken together. The second frusto-spherical bearing surface is the inward-facing lower portion of the outer bore of the housing. The insert segments are inserted in the outer bore of the housing. The frusto-spherical sections of each, solid in the segments and hollow in the outer bore, are closely matched. Because the lower bearing surfaces of the insert segments are able to rotate or swing to be in contact with a matching surface in the lower portion of the outer bore of the device housing, there is little or no reduction in the net bearing interface when the rod received by the nut segments is out of alignment with the vertical axis of the housing.
A further advantage of the present invention is that the housing and insert segments are shaped and arranged to allow a tie rod to be quickly inserted through the inner bore formed by the insert segments by pushing the tie rod up through the bore. When a tie rod is first inserted up into the housing, the upward movement of the tie rod forces the insert segments apart from a constricted position—the constriction preferably caused by the downward force of gravity and possibly by a compression member placed above the insert segments, combined with the narrowing in the lower portion of the outer bore of the housing—to the width of the tie rod. The interface between the surfaces of the tie rod and the insert segments creates a ratcheting action as the tie rod is pushed up and the insert segments move up and out laterally, allowing the tie rod to be inserted as far as needed into the housing for installation. When the building shrinks, the relative movement of the tie rod and the housing is similar to movement during installation. The relative upward movement of the rod with respect to the housing pushes the insert segments up and out laterally, and gravity and any relative downward movement of the tension rod as well as the usual tension that is placed on the rod once it is installed pulls the insert segments downwardly and inwardly in combination with the narrowing of the outer bore of the housing and thus against the rod, holding it with respect to the housing.
A further object of the present invention is to provide insert segments that are made with flat tops and bottom edges and in the preferred embodiment are compressed by a member with a flat surface so that it allows tie rods to be inserted with a minimal risk of jamming the take-up device because the insert segments are held in place by a flat, hard washer above, which interface with flat surfaces at the tops of the insert segments to stabilize them as they expand away from and constrict towards the central vertical axis of the device. Another object of the present invention is to provide the housing with a small ledge which interfaces with the bottom edges of the insert segments to stabilize them as they expand away from and constrict towards the central vertical axis of the device.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the take-up device of the present invention.
FIG. 2 is an exploded perspective view of the take-up device of the present invention.
FIG. 3 a perspective view of a connection made with the take-up device of the present invention, showing the take-up device installed on the top plate of a stud wall.
FIG. 4 is a perspective view of a connection made with the take-up device of the present invention, showing two take-up devices of the present invention, each installed on a different level of the same structure.
FIG. 5 is a top plan view of the housing of the take-up device of the present invention.
FIG. 6 is a cross-sectional elevation view of the housing of the take-up device of the present invention taken along view line 6 - 6 in FIG. 5 .
FIG. 7 is a top plan view of the upper and lower hard washers of the compression member of the take-up device of the present invention.
FIG. 8 is a cross-sectional elevation view of the hard washers of the take-up device of the present invention taken along view line 8 - 8 in FIG. 7 .
FIG. 9 is a top plan view of the soft washer of the take-up device of the present invention.
FIG. 10 is a cross-sectional elevation view of the soft washer of the take-up device of the present invention taken along view line 10 - 10 in FIG. 9 .
FIG. 11 is a top plan view of the insert segments of the take-up device of the present invention.
FIG. 12 is a cross-sectional elevation view of the insert segments of the take-up device of the present invention taken along view line 12 - 12 in FIG. 11 .
FIG. 13 is a top plan view of the take-up device of the present invention.
FIG. 14 is a cross-sectional elevation view of the take-up device of the present invention taken along view line 14 - 14 in FIG. 13 .
FIG. 15A is a cutaway elevation view of a connection made with the take-up device of the present invention, showing a threaded rod perfectly centered within and parallel to the inner bore.
FIG. 15B is a cutaway elevation view of a connection made with the take-up device of the present invention, showing a threaded rod imperfectly centered within and not parallel to the inner bore, with the insert segments rotated to accommodate the angle of the threaded rod.
FIG. 16 is a cutaway cross-sectional elevation view of the interface between the insert segments and the outer bore of the take-up device housing of the present invention.
FIG. 17 is a perspective view of an insert segment of the take-up device of the present invention.
FIG. 18 is a perspective view of an insert segment of the take-up device of the present invention; the insert segment shown in FIG. 18 has smaller inner bore than the similar insert segment shown in FIG. 17 .
FIG. 19 is a top plan view of the take-up device of the present invention; the take-up device shown in FIG. 19 has a smaller inner bore than the similar take-up device shown in FIG. 13 .
FIG. 20 is a cross-sectional elevation view of the take-up device of the present invention taken along view line 20 - 20 in FIG. 19 ; the take-up device shown in FIG. 20 has a smaller inner bore than the similar take-up device shown in FIG. 14 .
DETAILED DESCRIPTION
For clarity and convenience, the take-up device 1 of the current invention is described in a single, most common, orientation (except as noted otherwise) in which a top faces up and a bottom faces down. The take-up device 1 can, nevertheless, be installed in essentially any orientation, so that a top can face down or to the side and a bottom can face up or to the side.
As best shown in FIGS. 2 and 11 , the take-up device 1 of the present invention preferably has four insert segments 2 arranged sectionally around an inner bore 16 . Greater or lesser numbers of insert segments 2 are possible, but four is preferred. The insert segments 2 are designed to grasp a preferably vertical tie rod or threaded bolt 24 . Preferably, vertical tie rod 24 is a least threaded where it is grasped by insert segments 2 . Vertical tie rod 24 can be wholly threaded, partially threaded, or unthreaded, although if is unthreaded it is preferable to have a grooved surface that can mate with similar grooves on the insert segments 2 for achieving design load values, although alternate methods of the grasping of the insert segments 2 of the tie rod 24 are encompassed within the invention. The insert segments 2 preferably surround the tie rod or threaded bolt 24 , but with gaps between the insert segments 2 . Preferably, each insert segment 2 has a substantially planar top surface 3 .
The top surface 3 need not be planar, but it is generally advantageous to maximize the area of the top surface 3 because the top surface 3 is where the insert segments 2 are pushed down by compression member 46 which helps to prevent the insert segments 2 from rotating too far out of their upright orientation when the tie rod 24 pushes them upwardly and outwardly during shrinkage of the building or installation of the tie rod 24 , and thus the insert segments 2 are properly positioned to grasp the tie rod 24 as firmly as possible when the tie rod 24 is in tension again. The top surface 3 of each insert segment 2 preferably has a concave inner bore-defining edge 4 that has a first end 5 and a second end 5 . The inner bore-defining edge 4 is preferably an arc 4 . Preferably, a substantially straight first side edge 6 connects the first end 5 of the concave inner bore-defining edge 4 to the first end 8 of a convex outer bore edge 7 . Preferably, a substantially straight second side edge 6 connects the second end 5 of the concave inner bore-defining edge 4 to a second end 8 of the convex outer bore edge 7 . The first and second substantially straight side edges 6 of the top surface 3 are preferably orthogonal to each other. The outer bore edge 7 is preferably a nearly 90-degree arc 7 except where the arc 7 is interrupted by a tab 9 that projects from the convex outer bore edge 7 . Preferably, the tab 9 has a slightly curved outer edge 10 with first and second ends 11 that are connected to the arc 7 by first and second substantially straight side edges 12 , respectively. The tab 9 is preferably formed as an integral part of the insert segment 2 , rather than as a separate part attached to the insert segment 2 .
In the currently preferred embodiments of the invention optimized to grasp a ⅜″ or ½″ diameter threaded rod, in which there are four insert segments 2 , as shown in FIGS. 11 and 14 , the distance between opposite outer edges 10 of the tabs 9 of opposed segments 2 is preferably 1.375 inches.
As best shown in FIGS. 12 , 17 and 18 , each insert segment 2 preferably has first and second substantially planar sides 13 perpendicular to the top surface 3 . Preferably, the first substantially planar sides 13 extend downward from the first and second edges 6 of the top surface 3 . The first and second substantially planar sides 13 are preferably orthogonal to each other. Each insert segment 2 preferably has a rough, threaded, concave inner bore-defining surface 14 that extends downward from the concave inner bore-defining edge 4 and connects the first and second substantially planar sides 13 . Preferably, each bore-defining surface 14 is primarily a section of a rough, threaded, right circular cylindrical surface 15 that defines the inner bore 16 . As shown in FIGS. 12 and 18 , each insert segment 2 preferably has an outer bore-interfacing surface 17 that extends downward from the arc 7 of the outer bore edge 7 . In the currently preferred embodiments of the invention the outer bore-interfacing surface 17 and the inner bore 16 preferably has a surface roughness of 125-250 micro-inches (3.2-6.3 μm).
As best shown in FIGS. 2 and 11 , a portion 103 of the substantially planar top surface 3 of each insert segment 2 preferably extends radially outward away from the inner bore 16 to form the top surface 103 of each tab 9 , bounded by the outer edge 10 and the two sides edges 12 of each tab 9 . Preferably, each tab has a substantially planar outer surface 18 that descends from the outer edge 10 . Each tab 9 preferably has first and second substantially planar side surfaces 19 that descend from the first and second side edges 12 , respectively, of the tab 9 . Preferably, each tab 9 has a substantially planar bottom surface 20 opposite the top surface 103 of the tab 9 . In the currently preferred embodiments of the present invention, each tab 9 is 0.250 inches wide from the first side edge 12 to the second side edge 12 , and each tab 9 is preferably 0.120 inches thick from the top surface 103 to the bottom surface 20 .
As best shown in FIGS. 2 , 12 , 17 and 18 , preferably the general shape of the lower portion of the outer bore-interfacing surfaces 17 of the insert segments 2 is collectively that of a spherical segment—a spherical cap with the top truncated or a spherical frustum. In the currently preferred embodiments of the present invention a radius of 0.5 inches is preferred. The insert segments 2 generally have the form of an inverted dome with the inverted apex cut off parallel to the base. If there are four insert segments 2 , each is approximately one quarter of the spherical frustum and the spherical frustum is vertically quartered, and the quarters preferably spaced slightly apart. Two segments 2 side-by-side have the general shape of an inverted semi-dome. The outer bore-interfacing surfaces 17 preferably taper from the top surfaces 3 of the insert segments 2 to bottom edges 21 of the insert segments 2 , reducing the cross-section of each insert segment 2 from the top surface 3 to the bottom edge 21 . Preferably, the general shape of the upper portion 104 of the outer bore-interfacing surface 17 of the insert segments 2 is collectively that of a cylinder with tabs 9 splayed circumferentially. The lower portion 105 the outer bore-interfacing surface 17 of the insert segments 2 curves inward. In the currently preferred embodiments of the present invention, the substantially planar bottom surface 20 of each tab 9 joins the tapering outer bore-interfacing surface 17 of its insert segment 2 at a tab juncture 25 that has a radius of 0.020 inches. The insert segments 2 together preferably form an inverted dome with a central vertical through-bore.
As best shown in FIGS. 12 , 14 and 20 , the rough, preferably threaded, inner bore-defining surface 14 of each insert segment 2 extends from a top end 22 to a bottom end 23 , where the inner bore 16 flares outward with a substantially annular widening taper surface 36 , or chamfer 36 , on each insert segment 2 that meets the bottom edge 21 of each insert segment. These flared, or beveled, bottom portions 36 of the inner bore 16 are where the tie rod or threaded bolt 24 is inserted; the flared portions 36 ease insertion of the tie rod or threaded bolt 24 . Each substantially planar widening taper surface 36 is preferably oriented at 45 degrees to the top surfaces 3 of the insert segments 4 and at 45 degrees to the central axis 100 of the take-up device 1 , with the acceptable range being up to 15 degrees more or less. Preferably, each taper surface 36 is a surface section of a conical frustum. In the currently preferred embodiments of the present invention, the flared bottom portions 36 widen the inner bore 16 to a maximum width of 0.545 inches across. In the currently preferred embodiments of the present invention, the bottom edge 21 is preferably not a true edge, but is instead a very narrow annular surface 21 , a flat base 21 that helps to stabilize the insert segments 2 . As shown in FIG. 16 , in the currently preferred embodiments of the present invention, the bottom edge 21 of each insert segment is preferably 0.0085 inches across parallel to the top surface 3 : the maximum width across the lowest part of the insert segments 2 collectively is 0.562 inches from edge 21 to edge 21 of opposed segments 2 when the insert segments 2 are resting on the ledge 45 of the outer bore 27 ; the height of the insert segments 2 , measured from the top surface 3 to the bottom edge 21 , is preferably 0.539 inches. The height of the insert segments 2 is sufficient to grasp enough of the tie rod or threaded bolt 24 for a secure connection 110 by connecting to multiple turns of the threaded bolt 24 . In the currently preferred embodiments of the present invention, the insert segments 2 are held apart by the tie rod or threaded bolt 24 , so that adjacent sides 13 of the insert segments 2 do not interface but are instead held 0.062 inches apart.
Currently, the inventors have engineered and developed two preferred sizes of the take-up device 1 of the present invention. The inventors contemplate developing additional sizes for larger sizes of tie rods 24 and will adjust dimensions to maximize the performance of the take-up device with the different tie rods 24 . Currently, the two sizes differ only in the dimension of the right circular cylindrical surfaces 15 that define the inner bore 16 , which in a first embodiment is sized to accept a ⅜-16 UNC threaded rod 24 (best shown in FIG. 20 ) and in a second embodiment is sized to accept a ½-13 UNC threaded rod 24 (best shown in FIG. 14 ). With the preferable spacing of 0.062 inches between the insert segments 2 , the maximum diameter of the rough, threaded, concave inner bore-defining surface 14 (made up of the right circular cylindrical surfaces 15 ) of the inner bore 16 is 0.342 inches when the threaded rod is ⅜-16 UNC. When the threaded rod 24 is ½-13 UNC, the maximum diameter of the rough, threaded, concave inner bore-defining surface 14 (made up of the right circular cylindrical surfaces 15 ) of the inner bore 16 is 0.459 inches.
As best shown in FIGS. 13 , 14 , 19 and 20 , the insert segments 2 fit into an outer bore 27 in a housing 26 that holds the segments 2 in the correct sectional arrangement to form the inner bore 16 . The housing 26 is preferably a seamless, unitary member 26 with a vertical body 28 that is preferably cylindrical and contains the outer bore 27 and a horizontal plate 29 below the vertical body 28 . The horizontal plate 29 has a top face 101 and a bottom face 102 . Preferably, the horizontal plate 29 is shaped generally as an elongated rhombus with two relatively closely spaced corners 30 and two relatively distantly spaced corners 31 . The two relatively closely spaced corners 30 and two relatively distantly spaced corners 31 are preferably rounded. The two closely spaced opposing corners 30 do not extend beyond the cylindrical body 28 and match the curvature of the cylindrical body 28 where the plate 29 and cylindrical body 28 coincide. The two distantly spaced opposing corners 31 are spaced away from the cylindrical body 28 . The plate 29 has a fastener opening 32 between each distantly spaced 31 corner and the cylindrical body 28 . In the currently preferred embodiments of the present invention, each of the fastener openings 32 has a diameter of 0.171 inches. The fastener openings 32 are preferably spaced 1.886 inches apart on center. The center of the outer bore 27 is 0.943 inches from the centers of the fastener openings 32 .
Also, in the currently preferred embodiments of the present invention, the cylindrical vertical body 28 preferably has an outer diameter of 1.283 inches. The vertical body 28 has a top edge 33 . The outer bore 27 within the vertical body 28 has a diameter at the top edge 33 of 1.123 inches. Therefore, the vertical body 28 has a wall 34 that is preferably 0.16 inches thick at the top edge 33 . The cylindrical vertical body 28 is 1.209 inches in diameter from the middle of the wall 34 across to the middle of wall 34 opposite. The top edge 33 is preferably flat except where it is notched with a number of indentations or slots 35 that match the tabs 9 on the insert segments 2 . Each tab 9 preferably fits in an indentation 35 and preferably extends outside the vertical body 28 , and the interlock prevents the insert segments 2 from rotating around the central axis 100 . The interface between the tabs 9 and the indentations 35 also helps to stabilize the insert segments 2 , helping to keep them level especially when a threaded rod 24 is inserted into the inner bore 16 . Rather than being screwed into the inner bore 16 , the threaded rod 24 is preferably pushed in without rotation and the insert segments 2 react by moving apart and together, ratcheting when the threaded inner bore 16 interfaces with a threaded bolt 24 . The compression member 46 allows the insert segments 2 to move up within the housing 26 , and the upwardly-widening outer bore 27 allows the insert segments 2 to move apart. This allows the threaded bolt 24 to be inserted into the inner bore 16 , and as the threaded bolt 24 and the threaded portion of inner surfaces 14 of the insert segments 2 slide against each other, the segments 2 are moved up and outwardly and down and inwardly repeatedly, the inward motion urged by the compression member 46 and the narrowing outer bore 27 in the housing 2 . The threaded bolt 24 can only be inserted in one direction because when it is pulled down, the downwardly-narrowing outer bore 27 forces the insert segments 2 against the threaded rod 24 so that the threaded bolt 24 and the threaded portion of inner surfaces 14 of the insert segments 2 interlock as if the threaded bolt 24 had been screwed into a conventional solid nut.
As shown in FIG. 5 , preferably the housing 26 has a lateral horizontal axis 37 that passes through centers of the two fastener openings 32 and the center of the outer bore 27 , which is preferably also the center of the cylindrical body 28 , the housing 26 and the inner bore 16 . Preferably, the housing 26 also has a medial horizontal axis 38 that also passes through the center of the outer bore 27 and is orthogonal to the lateral horizontal axis 37 . The indentations 35 are preferably centered on first and second diagonal horizontal axes 39 that are 45 degrees off of the lateral horizontal axis 37 and the medial horizontal axis 38 . In the currently preferred embodiments of the present invention, each indentation 35 is preferably 0.281 inches wide along the circumference of the top edge 33 of the cylindrical body 28 . Preferably, each indentation 35 is 0.454 inches deep from the top edge 33 of the cylindrical body 28 .
As best shown in FIGS. 2 , 6 and 16 , in the currently preferred embodiments, the outer bore 27 preferably descends at right angles to the flat surface of the top edge 33 . The outer bore 27 descends 0.045 inches to a groove 40 that runs parallel to the top edge 33 . The groove 40 is 0.062 inches tall and has cross-section that is U-shaped in cross-section, with an internal radius of 0.031 inches. The outer bore 27 preferably descends another 0.324 inches straight down, creating an upper vertical portion 41 that descends a total of 0.431 inches straight down from the top edge 33 ; the groove 40 is within that upper vertical portion 41 . At a depth of 0.431 inches, the outer bore 27 preferably tapers inward at an angle of 65 degrees relative to the bottom face 102 of the horizontal plate 29 , creating a middle inward-angled portion 42 . The middle inward-angled portion 42 transitions to a lower inward-curved portion 43 that preferably has a radius of 0.510 inches in a vertical plane. This closely matches the 0.5-inch radius, also in a vertical plane, of lower portion 105 of the outer bore-interfacing surfaces 17 of the insert segments 2 . The lower inward-curved portion 43 reduces the taper angle from 65 degrees. The middle inward-angled portion 42 and the lower inward-curved portion 43 together reduce the diameter of the outer bore 27 , and their collective depth is preferably 0.419 inches, so that with the upper vertical portion 41 the collective depth is preferably 0.85 inches. Below the lower inward-curved portion 43 the outer bore 27 has a bottom portion 44 that is flared and preferably has a depth of 0.091 inches and that slightly increases the diameter of the outer bore 27 from a minimum of 0.545 inches at the bottom face 102 of the horizontal plate 29 to 0.558 inches. The slight widening of the bottom flared portion 44 eases insertion of the threaded rod 24 . Between the inward-curved portion 43 and the bottom flared portion 44 is a horizontal, or flat, ledge 45 that is 0.0115 inches wide and orthogonal to the central axis 100 of the housing 26 . The diameter of the outer bore 27 is 0.568 inches at the bottom of the lower inward-curved portion 43 and is 0.545 inches at the top of the bottom flared portion 44 . This horizontal ledge 45 helps to keep the insert segments 2 level when a threaded rod 24 is inserted into the ratcheting take-up device 1 to create the basic connection 110 . The preferred total height of the outer bore is 0.941 inches.
As best shown in FIGS. 7-10 , preferably the insert segments 2 are retained within the outer bore 27 by a compression member 46 . The compression member 46 preferably comprises a lower hard washer 47 , a middle soft washer 48 and an upper hard washer 47 . The middle soft washer 48 is preferably made from a resilient material like rubber that, when compressed, stores energy and expands when compression forces are released. Preferably, the middle soft washer 48 is made from soft quick-recovery super-resilient polyurethane foam, which has a firmness at 25 percent deflection, of 4-8 psi, a tensile strength of 40 psi, a stretch limit of 100 percent, and a density of 15 pounds per cubic foot. The middle soft washer 48 functions like a standard metal compression spring and a spring could be used, but the washer 48 is preferred. In the currently preferred embodiments of the present invention, the middle soft washer 48 preferably a 0.235-inch thick ring with an outer diameter of 1 inch and an inner diameter of 0.567 inches. The inner diameters of the compression member 46 limit how far the insert segments 2 can tilt or rotate. The upper and lower hard washers 47 are preferably made from steel. Preferably, each has an inner edge 50 , an outer edge 51 , an upper surface 52 and a lower surface 53 . Preferably, the inner edge 50 and the outer edge 51 are both generally circular. The inner edge preferably has a pair of inclusions 52 , each with a preferred radius of 0.063 inches that evenly divide the remainder into two arcs 53 with a diameter of 0.562 inches. Preferably, the outer edge 51 has four pairs of inclusions 54 , each with a preferred radius of 0.063 inches. Each pair of inclusions 54 preferably is 90 degrees apart around the circumference of the outer edge 51 . Preferably, between the inclusions 54 of each pair is a small arc 55 that is preferably 0.254 inches wide. These four small arcs 55 preferably each have a diameter of 1.187 inches. Preferably, between each pair of inclusions 54 is a large arc 56 with a diameter of 1.108 inches. The preferred total of eight inclusions 54 in the outer edge 51 bound an inner area with a circumference 57 with a diameter of 1.068 inches. The upper and lower hard washers 47 are preferably 0.047 inches thick. Preferably, the small arcs 55 , which project slightly from the rest of the outer edges 51 of the upper and lower hard washers 47 , and are therefore on slight projections 49 that are inserted in the indentations 35 in the wall 34 of the cylindrical body 28 of the housing 26 of the take-up device 1 . The lower hard washer 47 is stabilized by the interfaces between the small arcs 55 and the indentations 35 . The upper hard washer 47 is rotated so small arcs 55 slide into the groove 40 in the wall 34 of the cylindrical body 28 of the housing 26 of the take-up device 1 . This locks the upper hard washer 47 in place. The upper hard washer 47 holds the middle soft washer 48 and the lower hard washer 47 in place, and this whole compression member 46 holds the insert segments 2 down within the outer bore 27 of the take-up device 1 . When the insert segments 2 push up, the middle soft washer 48 compresses and, because it is resilient, the middle soft washer 48 pushes the insert segments 2 down when the upper hard washer 47 is locked in place. The whole compression member 46 functions as a spring tailored for the best performance in this device 1 and connection 110 . The interface between the outer bore-interfacing surfaces 17 of the insert segments 2 and the inward-angled and inward-curved portions 42 and 43 of the outer bore 27 forces the insert segments 2 together. The insert segments 2 clamp together on the tie rod or threaded bolt 24 . The matching curvatures of the bore-interfacing surfaces 17 of the insert segments 2 and the inward-curved portions 43 of the outer bore 27 allow the insert segments 2 to rotate or swing on a horizontal axis generally orthogonal to, and intersecting with, the tie rod or threaded bolt 24 without diminishing the interface area. This allows the take-up device 1 to compensate for imperfect alignment of the tie rod or threaded bolt 24 without diminishing the strength of the connection 110 . The insert segments 2 can tilt, or rotate, in any direction. Generally, the segments 2 need only rotate a maximum of two degrees from the central axis 100 , but the ability to do this without diminishing the interface with the outer bore 27 and the strength of the connection 110 is substantially advantageous since tie rods or threaded bolts 24 are rarely, if ever, aligned perfectly.
As shown in FIG. 3 , an anchor bolt 118 is embedded in a concrete foundation 112 . The anchor bolt 118 passes through the horizontal bottom plate 113 of a wall 111 , in this case the mudsill 113 , and it attached to a coupler 117 that bears down on a holdown 116 that is mounted on one of the vertical wall studs 114 . The coupler 117 joins the anchor bolt 118 to an in-line threaded rod 24 that runs parallel to the wall stud 114 and up through the double top plate 115 , where it is secured to the top plate 115 by a take-up device 1 of the present invention that is fastened to the top plate 115 with a bearing plate 120 sandwiched between the bottom face 102 of the take-up device 1 and the top plate 115 .
As shown in FIG. 4 , take-up devices 1 of the present invention can be placed at every level of a multistory structure. In FIG. 4 , a first take-up device 1 is shown fastened to the bottom plate 113 of an upper floor and a second take-up device 2 is attached to the top plate 115 directly above.
In its simplest form, the present invention is a take-up device 1 that has a housing 26 and a plurality of insert segments 2 . The housing 26 has an outer bore 27 and the outer bore 27 has a lower inward-curved portion 43 that is frusto-spherical. The insert segments 2 each has an outer bore-interfacing surface 17 that interfaces with the inward-curved portion 43 of the outer bore 27 of the housing 26 . The outer bore-interfacing surfaces 17 of the plurality of insert segments 2 are at least in part collectively frusto-spherical. Each insert segment 2 has a concave inner bore-defining surface 14 and the plurality of concave inner bore-defining surfaces 14 define an inner bore 16 . Preferably, the outer bore 27 of the housing 26 has a ledge 45 , the insert segments 2 each have a bottom edge 21 , and the bottoms edges 21 of the insert segments 2 interface with the ledge 45 in the outer bore 27 , stabilizing the insert segments 2 . The take-up device 1 preferably has four insert segments 2 . Each insert segment 2 preferably has a substantially planar top surface 3 . The top surface 3 preferably has a concave inner bore-defining edge 4 with first and second ends 5 , a convex outer bore edge 7 with first and second ends 8 , a first substantially straight side edge 6 that connects the first end 5 of the inner bore-defining edge 4 to the first end 8 of the outer bore edge 7 , and a second substantially straight side edge 6 that connects the second end 5 of the inner bore-defining edge 4 to the second end 8 of the outer bore edge 7 . Each segment 2 preferably also has a tab 9 on the convex outer bore edge 7 , an inner bore-defining surface 14 that descends from the inner bore-defining edge 4 , and an outer bore-interfacing surface 17 that descends from the outer bore-defining edge 7 and tapers a bottom edge 21 . Preferably, the inner bore 12 of the take-up device 1 is threaded.
The housing 26 preferably also has a horizontal plate 29 and a vertical body 28 that surmounts the horizontal plate 29 and the outer bore 27 of the housing 26 is contained within the vertical body 28 . Preferably, the vertical body 28 is cylindrical and has an outer wall 34 with a top edge 33 , a plurality of indentations 35 extend down from the top edge 33 of the wall 34 , and a tab 9 of an insert segment 2 interfaces with each of the indentations 35 in the wall 34 of the cylindrical vertical body 28 . The insert segments 2 are preferably retained within the outer bore 27 by a compression member 46 . Preferably, the compression member 46 has an upper hard washer 47 , and a resilient lower soft washer 48 that pushes the insert segments 2 downward in the outer bore 27 and is restrained from upward movement by the upper hard washer 47 . The compression member 46 preferably also has a lower hard washer 47 that is between the resilient lower soft washer 48 and the insert segments 2 . Preferably, the upper and lower hard washers 47 each have an outer edge 51 with a plurality of projections 49 . The outer bore 27 preferably has a groove 40 connected to the indentations 35 in wall 34 of the cylindrical body 28 . Preferably, the projections 49 of the upper hard washer 47 project into the groove 40 in the outer bore 27 , restraining the compression member 46 . The projections 49 of the lower hard washer 47 preferably project into the indentations 35 in wall 34 of the cylindrical body 28 , stabilizing the compression member 46 .
Preferably, the take-up device 1 is part of a connection 110 that has a first structural member 115 to which the take-up device 1 is fastened, and a tie rod 24 with a top end 124 at least partially held within the inner bore 16 of the take-up device 1 by a plurality of the insert segments 2 . The first structural member 115 preferably is a top plate 115 in an at least partially wood frame wall 111 , and a bearing plate 120 is disposed between the first structural member 115 and the take-up device 1 . Preferably, the tie rod 24 is secured to a foundation 112 below the wood frame wall 111 .
The outer bore 27 of the take-up device 1 preferably has a central vertical axis 100 . Preferably, when the tie rod 24 is not parallel to the central vertical axis 100 of the outer bore 27 , the insert segments 2 that hold the tie rod 24 are canted so the inner bore 16 is parallel to the tie rod 24 where the tie rod 24 is held by the insert segments 2 but the inner bore is not parallel to the central vertical axis 100 of the outer bore 27 .
Preferably, the connection 110 is formed by inserting the top end 124 of the tie rod 24 into the inner bore 16 of the take-up device and fastening the take-up device 1 to the first structural member 115 . The take-up device 1 is preferably fastened to the first structural member 115 with a plurality of screws or nails 119 . Screws provide a stronger connection than nails, but nails are less expensive and can still often provide the necessary strength for the connection.
For purposes of summarizing the invention and the advantages achieved over the prior art, certain objects and advantages of the invention have been described herein above. Of course, it is to be understood that not necessarily all such objects or advantages may be achieved in accordance with any particular embodiment of the invention. Thus, for example, those skilled in the art will recognize that the invention may be embodied or carried out in a manner that achieves or optimizes one advantage or group of advantages as taught herein without necessarily achieving other objects or advantages as may be taught or suggested herein.
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A ratcheting take-up device that compensates for imperfect alignment in a tie rod continuity system in the frame of a building wall. The upper ends of the tie rods are tightly clamped within the take-up device by domed segments inserted in a bowl-shaped housing. The segments are also forced together by a compression member in the housing. The domed shape of the segments and the bowl shape of the housing cooperate so that the segments can rotate in any direction to accommodate tie rods that are not perfectly vertical, without a corresponding loss of strength in the connection.
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[0001] This application claims the benefit of U.S. Provisional Patent Application Ser. No. 60/988,461, filed Nov. 16, 2007, and is a continuation of international application PCT/U.S.08/055,908, the disclosures of which are expressly incorporated herein by reference.
TECHNICAL FIELD
[0002] The present inventions relate generally to providing support for a face of a passage in a geological structure and, more particularly, to a tensionable spiral bolt associated with a resin nut partially occupying a borehole and related methods.
BACKGROUND OF THE INVENTION
[0003] In recent decades, a number of proposals for supporting the face of a passage in a geological structure, such as the roof in an underground mine, have been made. The typical arrangement employs an anchor, such as an elongated roof “bolt,” that extends into a borehole formed in the face. Federal regulations pertaining to underground mine safety require the placement of these bolts at frequent intervals throughout the mine passage. Consequently, ease of manufacture and use are critical factors in terms of reducing the overall installation cost to the mine owner (which directly correlates to the profitability of the mining operation).
[0004] Of course, one of the major areas for lowering the manufacturing cost and installation time for such bolts involves reducing the diversity, complexity, and overall number of the parts required. This includes eliminating the need for specialized expansion shells, external nuts, or other attachments to the bolt required in the past to effect proper tensioning. Extensive processing of the bolt shaft typically necessary for accommodating these types of expansion shells or external nuts should also be eliminated, since this activity not only increases manufacturing time and expense, but also tends to weaken the bolt and the resulting assembly.
[0005] Accordingly, a need exists for an improved bolting apparatus that overcomes the foregoing limitations of the prior art. Specifically, the bolt should be easy and inexpensive to manufacture and install. The bolt would be also be tensionable to compress and provide-secure, reliable support for the adjacent strata once installed.
SUMMARY OF THE INVENTION
[0006] In accordance with one aspect of the invention, an apparatus for installation in a borehole formed in a face of a mine passage is disclosed. The apparatus comprises an elongated bolt including a spiral shaft portion for positioning in the borehole. A stationary, hardened resin nut is formed in a portion of the borehole for surrounding at least part of the spiral shaft portion of the bolt. Rotation of the spiral shaft portion within the resin nut thus serves to move the bolt within the borehole, such as during tensioning.
[0007] In one embodiment, the spiral shaft portion comprises a generally circular cross section, and may include approximately 4-5 threads for about every inch in the longitudinal direction. To facilitate rotation within the resin nut, at least part of the spiral portion may include a lubricity or rust-inhibiting agent. Preferably, a colored agent is also applied along at least part of the spiral shaft portion to allow for identification of the bolt for use with the resin nut.
[0008] The bolt may include a head end and a tail end as well. The tail end for advancing into the borehole may include a taper or point. Preferably, the construction of the bolt is such that it is formed of a single piece of material. A flange may also be provided adjacent the head end, with one side for engaging a plate or like structure adjacent the mine face and the opposite side providing a bearing surface for a device or means for rotating the bolt.
[0009] In accordance with a second aspect of the invention, an apparatus for installation in a borehole formed in a face of a mine passage is disclosed. The apparatus comprises an elongated bolt including a portion, such as for example a spiral portion, for positioning in the borehole. A stationary, hardened resin nut is also provided for receiving a portion of the bolt. The apparatus further includes means for rotating the bolt relative to the hardened resin nut, preferably in the form of a drill head.
[0010] In accordance with a third aspect of the invention, an improvement is proposed for use in a borehole formed in a face of a mine passage for receiving a bolt having an elongated shaft for extending into the borehole. The improvement comprises a resin nut formed in a portion of the borehole and having an internal thread surrounding only a portion of the shaft. Preferably, the shaft of the bolt is spiral, whereby rotating the spiral shaft relative to the internal thread serves to tension the bolt.
[0011] In accordance with a fourth aspect of the invention, a roof bolt is proposed for insertion in a borehole formed in a face of a mine passage. The bolt comprises a shaft having a spiral portion at least partially having a coating selected from the group consisting of a lubricity agent, a rust-inhibiting agent, a colored agent and mixtures thereof. Preferably, the coating is at a distal end of the shaft having a point for insertion in the borehole.
[0012] In accordance with a fifth aspect of the invention, a method of tensioning a bolt including a spiral shaft portion in a borehole formed in a face of a mine passage is disclosed. The method comprises forming a stationary, hardened resin nut adjacent at least the spiral shaft portion of the bolt. The method further comprises rotating the spiral shaft portion relative to the hardened resin nut.
[0013] Preferably, the forming step comprises: (1) providing uncured resin within the borehole adjacent the spiral shaft portion of the bolt; (2) rotating the bolt in a first direction to substantially maintain the resin adjacent the spiral shaft portion; and (3) allowing the resin to substantially cure and form the hardened resin nut. Likewise, the step of rotating the bolt preferably comprises rotating the spiral shaft portion in a second direction opposite the first direction upon the substantial curing of the resin. In any case, the method may further include the step of applying a lubricity or rust-inhibiting agent to at least part of the spiral shaft portion.
[0014] In accordance with a sixth aspect of the invention, a method of installing an elongated bolt having a head end and a threaded or spiral portion in a face of a mine passage having a borehole is disclosed. The method comprises inserting the bolt at least partially within the borehole with the head end spaced from the opening. The bolt is rotated in a first direction and at least partially within an uncured resin within the borehole, and the resin is allowed to substantially cure and form a nut. The bolt is rotated in a second direction opposite the first direction such that the bolt moves through the resin nut with the head end moving closer to the opening of the borehole. Preferably, the head end of the bolt is initially spaced from the open end of the borehole, and the step of rotating the bolt in the second direction advances the head end of the bolt toward the open end of the borehole.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 is an elevational view, not to scale, of one possible embodiment of a roof bolt with a spiral portion;
[0016] FIGS. 1 a and 1 b are cross-sections taken along lines 1 a - 1 a and 1 b - 1 b of FIG. 1 , respectively;
[0017] FIGS. 1 c and 1 d show an alternate spiral bolt;
[0018] FIGS. 2-4 are schematic diagrams showing the manner in which the spiral bolt of FIG. 1 may be tensioned using a resin nut formed in the borehole.
DETAILED DESCRIPTION OF THE INVENTION
[0019] Reference is now made to FIG. 1 , which illustrates one embodiment of a bolt 10 for installation in a face F of a mine passage, such as the roof (see FIG. 2 ) having a borehole H formed vertically therein. Although the bolt 10 and related installation method are described as being used to reinforce and sustain a mine roof, it should be understood that the present invention may be applied to support any one of the other faces of the passage (e.g., a rib) or a different type of geological structure, without limitation.
[0020] As illustrated, the bolt 10 is preferably an elongated, one-piece structure comprising a head end 10 a , an elongated body or shaft 10 b , and a tail end 10 c . As perhaps best understood with combined reference to FIGS. 1 and 1 a , the head end 10 a is adapted for being engaged by a wrench, chuck of a drill head (see FIG. 2 ), or like device or means for rotating the bolt 10 during installation. Despite being shown as having a portion with a generally square cross-section ( FIG. 1 a ), it should be appreciated that the head end 10 a of the bolt 10 may take on other cross-sectional shapes (e.g., hexagonal) without impacting the practice of the present invention in any meaningful way. An annular flange 11 is also provided adjacent the head end 10 a to provide a bearing surface for the means for rotating on one side and the face or intervening structure (such as plate P; see FIG. 2 ) on the other.
[0021] In one embodiment, the shaft 10 b of the bolt 10 is generally square in cross-section (see FIG. 1 b ), but is “twisted” or threaded along its length to form a spiral or helix. In the illustrated embodiment of FIG. 1 , the spiral extends along the entire length of the shaft 10 b , and is left-handed in nature (but could be the opposite as well). Although the number of spirals (twists or threads) per linear unit (inch or foot), or pitch, of the bolt 10 is not essential to practice of the invention, the arrangement is preferably coarse in nature (equal to or greater than about four threads per inch, up to about seven per foot).
[0022] As a specific example, and with reference to FIGS. 1 c and 1 d , the shaft 10 b of the bolt 10 is shown as being generally round in cross-section, and includes a spiral portion formed by threads T. For example, each inch of the spiral shaft 10 b preferably includes between about 4 to 5 complete (e.g., 360°) threads. Most preferably, each complete thread occupies about 0.22 inches of distance in the longitudinal direction, or length, which corresponds to about 4.5 complete twists per linear inch (see reference character d representing pitch in FIG. 1 d ). Of course, a corresponding thread is formed in the resin nut once it is formed in the borehole and the threaded spiral bolt 10 installed in the manner described in the foregoing passage.
[0023] While it is easier in terms of manufacturing to provide a consistent spiral continuously along the entire length of the shaft 10 b (such as by simply twisting square bar stock or cutting threads in round bar stock), it will be understood upon reviewing the description that follows that the spiral may be provided along only a portion of the shaft 10 b . Preferably, in such case, the spiral is along the tail end 10 c , or otherwise away from the head end 10 a.
[0024] Reference is now made to FIG. 2 , which although not drawn to scale, illustrates schematically the manner in which the bolt 10 of FIG. 1 is installed in the borehole H. Specifically, the tail end 10 c of the bolt 10 is inserted through the opening O of the borehole H, which is preferably formed having a diameter close to the width M of the spiral shaft 10 b (e.g., ¾″ for a 1 inch diameter borehole). The borehole H also preferably has a depth D greater than at least the spiral shaft 10 b , and preferably greater than the length of the entire bolt 10 (e.g., dimension B in FIG. 1 ) by at least one inch.
[0025] Using a lift boom associated with a bolting machine or like structure, the bolt 10 is advanced into the borehole H such that the head end 10 a remains spaced from the adjacent face of the roof a distance equal to or slightly less than the excess depth D of the borehole H (e.g., about two inches). As shown in phantom in FIG. 2 , a plate P is typically associated with the head end 10 a of the bolt 10 , and would thus also be spaced from the face F. However, once the bolt 10 is tensioned in the manner described below, this plate P engages the face F and compresses the associated strata (see FIG. 4 ).
[0026] Once the bolt 10 is partially inserted, uncured resin (also sometimes referred to as “grout”) is provided adjacent at least a portion of the spiral shaft 10 b in the associated annulus (which is shown in FIG. 2 as being greatly oversized for purposes of illustration, but is normally only about ⅛″-¼″ on either side). Most preferably, the uncured resin occupies the annulus adjacent the tail end 10 c of the bolt 10 , and in the upper portion of the borehole H. Although the uncured resin may be provided from a remote source, such as by way of injection, it is most preferably supplied in the form of a frangible cartridge (not shown), or resin “sausage” in the vernacular. Typically, this type of cartridge is pre-installed in the borehole H and ruptured during insertion of the bolt 10 , thus causing a quick-curing resin to occupy the surrounding borehole H. This “grout” usually comprises two materials (e.g., polyester resin and a catalyst paste) that make contact and react only upon the rupturing of the cartridge. Upon being thoroughly mixed, such as by the rotation of the bolt 10 within the borehole H, the resin then quickly hardens. The hardened resin or grout thus serves to hold the bolt 10 securely within the borehole H.
[0027] In accordance with another aspect of the invention, the bolt 10 with the spiral shaft 10 b at least partially surrounded by uncured resin is rotated to effect the desired mixing and/or hardening, such as by using any conventional type of bolting machine. In the illustrated embodiment in which the spiral is left-handed in nature, the rotation is in the opposite, or right-handed, direction (see action arrow R in FIG. 2 ). Preferably, this rotation is done without simultaneously advancing the bolt 10 within the borehole H any significant amount, such that it remains spaced from the opening O of the borehole H.
[0028] As should be appreciated, this rotation in combination with the spiral shaft 10 b serves to create a “pumping” action that substantially holds the uncured resin in place, and may possibly advance or “push” this resin deeper within the borehole H. In other words, the spiral shaft 10 b of the bolt 10 may essentially function as an auger or screw with flights that maintain the resin at a particular location within the upper end of the borehole H. In any case, the rotation of the spiral shaft 10 b preferably is such that it prevents the uncured resin from advancing toward the opening O of the borehole H to any significant degree. As a result of this pumping action, once the resin sets or cures (normally, after a period of rest post-mixing), it surrounds only a portion of the spiral shaft 10 b within the borehole H. The amount of resin supplied will of course depend on the relative sizes of the spiral shaft 10 b and the borehole H, but is preferably sufficient to cover about 12-18 inches of the shaft 10 b adjacent the tail end 10 c or otherwise away from the head end 10 a (which, of course, still remains spaced from the opening O of the borehole H).
[0029] Once the resin sets or cures (which normally takes only seconds after mixing), a stationary, hardened resin “nut” 12 is thus formed around at least a portion of the spiral shaft 10 b in the borehole H. As should be appreciated, this resin nut 12 has an internal thread matching the spiral thread of the adjacent shaft 10 b and occupied by it. In the case of the left-handed spiral, the bolt 10 may be rotated in a direction opposite the first direction (note action arrow L) and in the same direction as the spiral. The engagement between the spiral shaft 10 b and the resin nut 12 causes the bolt 10 to advance within the borehole H when so rotated, thus moving the head end 10 a closer to the adjacent opening O. However, the hardened resin nut 12 remains stationary due to the peripheral contact with the sidewall of the borehole H.
[0030] This rotation may be completed until any associated engagement hardware, such as a plate P, is brought into secure engagement with the face F (which normally will take less than one complete turn). The appropriate amount of torque is then applied to ensure that the bolt 10 is fully tensioned and the strata compressed or anchored in the desired manner. As noted above, the depth D of the borehole H is made at least slightly greater than the overall length B of the bolt 10 such that the tail end 10 c can freely advance and does not “bottom out” during the final advance caused by tensioning.
[0031] Numerous advantages may thus arise from the use of the above-described technique. First of all, the bolt 10 in the preferred embodiment may be made of only one piece of material, and need not include any expansion shells or external nuts in order to be effective. Accordingly, no parts require assembly “on-site.” This not only substantially reduces the manufacturing cost, but also facilitates ease of installation and results in a stronger bolt.
[0032] Additionally, only partial grouting of the borehole is required for effectively practicing the present invention. Thus, substantially less grout is required, as compared to arrangements in which the borehole is fully grouted. A concomitant savings in material cost invariably results (possibly as much as 75%), as well as a reduction in the cost of transporting the grout into the mine and maintaining it in a “ready for use” state.
[0033] The completed installation of the bolt 10 also advantageously results in the head end 10 a being positioned extremely close to face F of the mine roof (see FIG. 4 ). Thus, unlike prior arrangements in which an external nut is threaded onto an exposed shank projecting several inches from the face F, there is very little depending structure of the installed bolt 10 to engage a passing machine or person. This is especially important in narrow mine passages resulting from a low seam height. Moreover, since essentially the entire shaft 10 b of the bolt 10 is drawn into the borehole H, the overall appearance of the face F is more regular and aesthetically pleasing.
[0034] Finally, aside from being one piece, the bolt 10 can be manufactured in a relatively easy and inexpensive manner. Square or round bar stock of any suitable width dimension (e.g., 2″, ⅝″, or ¾″ for a 1″ borehole) can simply be worked to the desired pitch (whether considered twists per linear unit, or thread-to-thread spacing) to form the shaft 10 b . The head end 10 a is typically forged. Conveniently, the spiral can also be formed on a relatively long piece of stock, which can then be cut into lengths corresponding to the shaft 10 b of the bolt 10 .
[0035] During manufacturing, the working applied to the bar (which is typically made of steel) may result in the elimination of the exterior surface oxide layer, or “scale,” created during the hot roll process. The absence of the scale allows faster oxidation of the bar, especially when the bolt 10 is stored outdoors and exposed to the elements during the period between manufacturing and ultimate use in the mine. Any deterioration of the surface may inhibit the ability of the shaft 10 b to turn freely within the resin nut 12 during installation.
[0036] To ameliorate any such problem, it is possible to coat at least part of the spiral shaft 10 b (such as the uppermost portion) after manufacture with either a lubricity agent or a rust-inhibiting agent, or both. The partial or full application of such agent(s) is anticipated to ease the installation by allowing the spiral shaft 10 b to rotate more freely relative to the resin nut 12 during tensioning. Providing any coating agent with a coloring (e.g., a yellow pigment) is also contemplated. As a result, the installer may not only ensure that the coating remains present on an appropriate portion of the shaft 10 b , but also can readily differentiate the spiral bolts 10 for use in the present method from others.
[0037] During installation, it may also sometimes result that the resin cures not only along a portion of the spiral shaft 10 b , but also within the portion of the borehole H into which the bolt 10 must advance during tensioning (see dashed line Z in FIG. 4 ). Although this does not preclude installation, it may be helpful to make the tail end of the bolt 10 with a point or taper, as shown. This will help it advance within the resin nut 12 , if such is necessary.
[0038] Although the pitch of the spiral may be varied, it is also desirable to ensure that the spiral bolts 10 for use in a common installation are consistent. This keeps the installation torque required consistent. Likewise, the spiral shaft 10 b should also be consistent to facilitate its movement through the resin nut 12 once formed. The pitch of the spiral is also preferably such that there is noticeable movement of the head end 10 a toward the opening O of the borehole H during installation, thus giving the installer a visual cue that the process is proceeding as expected.
[0039] The use of conventional types of washers, such as those made of, or coated, with TEFLON or other anti-friction types, is also possible between the head end 10 a (or flange 11 ) and any associated structure (such as plate P). However, it is believed that the use of such anti-friction washers is less important with this type of arrangement than with conventionally threaded bolts, since conventionally threaded bolts require many revolutions for installation, resulting in greater friction and heat, and less effective tension/torque ratios.
[0040] The foregoing description 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 form disclosed. Obvious modifications or variations are possible in light of the above teachings. The present embodiments were chosen and described to provide the best illustration of the principles of the invention and its practical application to thereby enable one of ordinary skill in the art to utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. All such modifications and variations are within the scope of the invention.
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In one aspect of the invention, an apparatus and related methods for installation in a borehole formed in a face of a mine passage comprises an elongated bolt including a spiral shaft portion for positioning in the borehole. A hardened, stationary resin nut formed in only part of the borehole, preferably spaced from the distal end thereof, receives the spiral shaft portion of the bolt. Consequently, rotation of the spiral shaft portion within the hardened resin nut serves to move the bolt within the borehole, such as for purposes of tensioning.
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RELATED APPLICATION
[0001] This application claims the benefit under 35 U.S.C. §119 (e) of U.S. Provisional Application No. 61/975,206 filed Apr. 4, 2014 for “Reinforced Tetrahedral Structure”.
BACKGROUND
[0002] The present invention relates to structures that consist of or can be constructed from elongated rigid segments.
SUMMARY
[0003] The present invention is directed to a method for constructing a non-linear structure comprising bending a chain of serially connected hollow metal tetrahedral to form a non-linear segment and reinforcing the connections of the segment to form a rigid non-linear structure.
[0004] The invention is also directed to a tetrahedral structure comprising at least one non-linear segment consisting of a chain of serially connected hollow metal tetrahedra, in which each connection between successive tetrahedra includes external reinforcement
[0005] In one embodiment, the hollow tetrahedra are integrally connected by respective crimped webs of metal, the bending is at least along one web, and the reinforcement is at each web. In another embodiment, each segment is initially formed by tacking a successive series of tetrahedral units at abutting edges, bending the segment into a desired non-linear shape, and then externally reinforcing each connection.
[0006] The invention permits the use of surprisingly thin metal in the formation or fabrication of each segment, thereby minimizing the weight associated with the overall visual impression or aesthetics. However, the strength is much greater than would be suggested by the overall visual impression. Even thin walled hollow tetrahedra are very strong in multi-dimensional tension and compression. In a series of tetrahedra connected at their edges, the relative weakness is in accommodating a bending around an axis defined by the joined edges. This weakness in bending poses an obstacle to using non-linear tetrahedral segments as load-bearing structures.
[0007] According to an aspect of the present invention, the weakness in bending becomes an asset in that initially the segment of connected tetrahedra can be easily bent into any non-linear shape, and thereafter the connections can be externally reinforced.
[0008] This combination of light weight and surprising strength can be utilized on a relatively small sale, such as for making a tripod or room-sized sculpture, but also on a large scale for making structures that rise dozens of feet from a fixed foundation. Examples of the latter include a decorative arch over a roadway or gate, or outdoor sculpture.
[0009] On a smaller scale, several arcuate segments can be joined to form a tripod or other multi-pod which may or may not support a table or decorative top. As an outdoor sculpture, one segment can rise 10, 20, 30 or more feet as a single strand having angulations. Another form of sculpture would evoke images of the Eiffel Tower, with three or four segments rising from a large footprint and converging upwardly to a peak of 40, 50, or more feet in the air.
BRIEF DESCRIPTION OF THE DRAWING
[0010] FIG. 1 shows the first step in one embodiment where a plurality, of individual tetrahedral units oriented such that, in the plane of the paper, vertical edges are aligned and horizontal edges are aligned;
[0011] FIG. 2 shoes the vertically abutting edges of the first and second units tacked together and the abutting horizontal edges of the second and third units are tacked together;
[0012] FIG. 3 shows schematically how the relatively straight segment of FIG. 2 is deliberately bent into a non-linear segment;
[0013] FIG. 4 shows schematically how a plurality of rigid non-linear segments can be joined together to form an arch;
[0014] FIG. 5 shows schematically another example of three curved, rigid segments forming a tripod structure;
[0015] FIG. 6 shows schematically a multi-pod sculpture having a plurality of rigid curvilinear legs that converge at the top and are joined together where they meet;
[0016] FIG. 7 shows schematically another sculpture which has three bends, in three planes;
[0017] FIGS. 8 and 9 show schematically another embodiment, wherein the initial segment is formed as a crimped tube and then reinforced at the crimps; and
[0018] FIG. 10 shows an alternative technique for reinforcing at the crimp.
DETAILED DESCRIPTION
[0019] FIG. 1 shows the first step in one embodiment where a plurality, in this case seven, individual tetrahedral units 1 - 7 are selected and oriented such that, in the plane of the paper, vertical edges 8 and 9 are aligned and horizontal edges (into and out of the paper) 10 and 11 are aligned. Each tetrahedral unit has four faces and six edges which can be pre-formed by bending and welding sheet metal cutouts.
[0020] As shown in FIG. 2 , the vertically abutting edges 8 , 9 of the first and second units 1 , 2 are tacked together as indicated at 12 , and the abutting horizontal edges 10 , 11 of the second and third units 2 , 3 are tacked together as indicated at 13 . Similarly, the vertically abutting edge 14 of the third unit 3 is tacked at 16 to the vertical edge 15 of the adjacent fourth unit 4 , and the sequence is repeated to form a segment 17 of connected units with a center line passing through a multiplicity of vertically oriented tacked edges and a multiplicity of horizontally oriented tacked edges.
[0021] It should be understood that in this context, “vertical” and “horizontal” are proxy terms for mutually perpendicular edges such as 8 and 10 without regard to orientation relative to the horizon, and that the “centerline” of the “straight” unreinforced segment 17 is a nominal centerline which can be substantially straight or follow the gravity-induced, slight continuous curvature of a semi-rigid elongated body.
[0022] A convenient form of tacking 12 , 13 is by tack welding, but it should be understood that any bonding technique that can hold the units together as a segment while accommodating forced bending along an edge is acceptable.
[0023] FIG. 3 shows schematically how the relatively straight segment is deliberately bent into a non-linear segment 17 ′. The segment can be manipulated into the desired final shape and then the tacked abutting edges are reinforced with, for example, a filet weld at each vertical juncture (one shown at 18 ) and at each horizontal juncture (one shown at 19 ) to produce a rigid non-linear segment 17 ′. Generally, the non-linearity will include an overall angular deviation of a segment end-to-end, of at least about 30 degrees relative to a straight line, with constant or changing curvature, or resulting from at least one severe or discontinuous bend.
[0024] FIG. 4 shows an example of how a plurality of such rigid non-linear segments 17 ′, 17 ″ can be joined together with a final weld 20 , to form an arch 21 that is supported by pedestals 22 on ground 23 .
[0025] FIG. 5 shows another example of three curved, rigid segments 25 a , 25 b and 25 c forming a tripod structure 24 , including a decorative headpiece or top 26 .
[0026] FIG. 6 is a schematic representation of a multi-pod sculpture 27 having a plurality of rigid curvilinear legs 28 that converge at the top and are joined together at 29 where they meet. Each segment has first and second longitudinal ends and a plurality of segments are connected together other than at the ends.
[0027] FIG. 7 depicts another sculpture 30 which has three bends, in three planes. These are particularly well suited for large outdoor sculpture that extends vertically for dozens of feet. Especially for a larger structure, the tetrahedra would preferably decrease in size from the units closer to the base or support, toward the units at the top. The lower first end can form a base with the second end extending at least ten feet above the base.
[0028] It should be understood that in forming a segment 17 ′ such as shown in FIG. 3 , it is not necessary that all of the units of the segment be tacked as shown in FIG. 2 , before all of the tacked connections are reinforced. Instead, it is possible to tack several units together, reinforce those, and then orient the edge of another unit relative to an adjacent unit and tack congruent, vertical or horizontal edges such that the horizontal or vertical edge of one unit is not parallel to the horizontal or vertical edge of the adjacent unit, i.e., this begins a deviation of the center lines from a straight line.
[0029] FIG. 8 illustrates another embodiment, wherein the initial segment is formed as a crimped tube, as shown in my U.S. Pat. No. 3,237,362 “Structural Unit for Supporting Loads and Resisting Stress”, the disclosure of which is hereby incorporated by reference. Two successive tetrahedra 32 , 33 are connected by a double-walled crimp 34 , which runs along the longitudinal center line, and the tetrahedron 33 is connected to tetrahedron 35 by a crimp 36 which runs perpendicularly to crimp 34 . Crimps 34 and 36 alternate along the longitudinal extent of the segment 31 . The crimps are relatively weak in resisting a bending force and therefore in the present invention, perform the same function as the tack-weld of the previous embodiment, i.e., they permit selective bending of one unit relative to an adjacent unit.
[0030] Once the final non-linear shape of the segment has been completed in semi-rigid form, the stronger external reinforcement such as spot weld 37 is performed to produce the rigid segment 31 ′ as shown in FIG. 9 .
[0031] FIG. 10 shows an alternative technique 38 for reinforcing the web between a first tetrahedral unit 39 and a second tetrahedral 40 at the crimp 41 . A small diameter steel bar 42 is placed along the crimp and welded to the crimp as shown at 44 and, similarly, on the other side of the crimp another bar 43 is welded 45 to the material of the crimp. The bars 42 , 43 can be portions of a single bar that has been wrapped around the crimp and welded along the crimp and at the outer edges of the crimp. Another alternative shown in FIG. 9 , is for the spot weld 37 to be supplemented with spot welds 46 , 47 at the outer edges or vertices of the tetrahedra.
[0032] A noteworthy advantage is that the fabricator can assemble and inventory various standard lengths of straight, tacked segments, such as 5, 10, 15, and 20 feet. A customer can draw up a bending pattern that specifies the ultimate shape of the sculpture. The customer can observe and/or direct adjustments to the shaping as the workman in the fabrication shop (or at the customer's site) bends the joints. Once the final shape is achieved, the joints are fully welded to produce a very rigid multi-dimensional sculpture piece for the customer.
[0033] It should be understood that, given the wide range of sizes of segments and completed structures that can be fabricated according to the present invention, the natural or nominal bending of a segment that has been formed by tacking or that has been formed by crimping, can differ from one embodiment or end use to another. Generally, the segment would be formed on a rigid surface such as a table, floor, or the ground, so gravity would not produce any bending. For convenience, this condition can be considered as semi-rigid, in that the segment holds its inherent shape but can be manually or mechanically bent at the tack weld or crimps, before reinforcement that produces a much stronger, significantly more rigid segment. As previously described in the embodiment of FIGS. 1-3 , the non-linearity of the semi-rigid segment can be produce not only by bending, but rather by how one edge is oriented relative to an abutting edge before tacking them together. Accordingly, “orienting” should be understood as encompassing bending as well as angled tacking.
[0034] In a completed structure, only about 10-20% of the total weight is attributable to welded connections. It is estimated that to produce a crimped but unwelded segment of equal strength, the sheet metal thickens and thus resulting weight would be two to three times greater than the inventive thin walled tetrahedra with welded connections.
[0035] It should be appreciated that one or more appendages could be attached to a main segment, using the process described above, while the segment is fully or partially reinforced with fillet welds or the like.
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A method for constructing a non-linear structure comprising bending a chain of serially connected hollow metal tetrahedral to form a non-linear segment and reinforcing the connections of the segment to form a rigid non-linear structure, and a tetrahedral structure comprising at least one non-linear segment consisting of a chain of serially connected hollow metal tetrahedra, in which each connection between successive tetrahedra includes external reinforcement. The structure can be a sculpture or a multipod such as legs for a table or the like.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention generally relates to semiconductor devices, and particularly relates to a method of arranging a dummy wire pattern that is prepared for processing needs, and the semiconductor device which has such dummy wire patterns.
2. Description of the Related Art
In recent years, the design ruling of semiconductor device has become finer and finer, causing difficulties in controlling a pattern width. As a parameter which controls the pattern width of wire patterns, a ratio of a resist pattern to a chip area (pattern density) is used. It has been known that a desired pattern can be formed with a satisfactory controllability by keeping the pattern density within a certain predetermined range.
When this pattern density is below the predetermined range, providing dummy wire patterns in addition to a wire pattern actually used (real wire pattern) has been practiced. By providing the dummy patterns, the pattern density is controlled to fall within the predetermined range.
Conventionally, the dummy pattern has been arranged by methods that follow.
The first method arranges dummy patterns to areas on a chip, where there is no wire present, at a certain distance from wires. By this method, the dummy pattern cannot be arranged efficiently.
The second method of solving this problem is to provide imaginary dummy patterns of a basic form (it is also called a unit dummy pattern or a virtual dummy pattern) in a lattice form at a certain interval. This method is described with reference to FIG. 1 .
FIG. 1 is a plan view showing a layout. In FIG. 1, there are two wires 1 and 2 that will be actually formed (real pattern) in addition to which unit dummy patterns 3 are laid at a predetermined interval (it is equal to or larger than the minimum interval standard, which is mentioned later). The squares in dashed line represent the group of the dummy patterns that are laid as described above. At this moment, each dummy pattern 3 is virtual. When processing in a CAD system, the dummy pattern group is treated as a virtual layer.
The dummy pattern group has a single coordinate system with its origin set at the center of the chip concerned on a wafer, for example.
The virtual dummy pattern is chosen as a real dummy pattern if distances in all directions to be measured (e.g., vertically and horizontally in FIG. 1) between each dummy pattern 3 of the virtual layer and the adjacent wires 1 and 2 are determined to be equal to or larger than the predetermined minimum interval standard serving as the wiring condition. The real dummy pattern will be actually formed on a chip with the wires 1 and 2 .
In arrangement of FIG. 1, when the unit dummy pattern 3 is located at the center between the wire 1 and wire 2 , the distance between a dummy pattern and each of the wires 1 and 2 should be equal to or larger than the minimum interval standard. To the contrary, the unit dummy pattern 3 in the center column is not positioned at the center between the wire 1 and the wire 2 , but is offset to the right as shown in FIG. 1 . Due to the offset, the distance D 1 of each dummy pattern 3 from the wire 2 is shorter than the minimum interval. In other words, each dummy pattern 3 in the center column is located in a position interfering with the wire 2 .
Therefore, each dummy pattern 3 in the center column is not chosen as a real pattern. Of course, the dummy patterns 3 of other two columns are not chosen, either. Consequently, there will be no dummy pattern formed at all between the wire 1 and the wire 2 . Therefore, the predetermined pattern density cannot be attained, causing a problem of uneven density.
The third conventional method is shown in FIG. 2 . The dummy pattern group used by the method shown in FIG. 1 was arranged with the dummy patterns aligned in both column and row directions. Here, in the method shown in FIG. 2, dummy patterns are placed in a zigzag format. However, a dummy pattern group has a single coordinate system.
In FIG. 2, R 1 -R 7 indicate each line of dummy patterns. The lines R 1 , R 4 , and R 7 have the same dummy pattern arrangement (column positions of the dummy patterns are the same). The lines R 2 and R 5 have the same dummy pattern arrangement, having different column positions from other lines. The lines R 3 and R 6 have the same dummy pattern arrangement, having different column positions from other lines. That is, the same pattern is repeated every four lines.
In FIG. 2, two dummy patterns (occupying the line R 2 and R 5 , respectively, and on the same column position) indicated by the reference number 4 satisfy the minimum interval standard, and are chosen as the real dummy patterns. Therefore, the probability in which a real dummy pattern is inserted increases.
As described above, by the conventional method shown in FIG. 2, real dummy patterns can be laid out in a curtailed manner (dotted with dummy patterns), causing a problem that the pattern density is not effectively improving.
SUMMARY OF THE INVENTION
It is a general object of the present invention to provide a semiconductor device having a dummy pattern effectively laid out in addition to real patterns for wiring and the like for realizing the desired pattern density and a method thereof, which substantially obviates one or more of the problems caused by the limitations and disadvantages of the related art.
Features and advantages of the present invention will be set forth in the description which follows, and in part will become apparent from the description and the accompanying drawings, or may be learned by practice of the invention according to the teachings provided in the description. Objects as well as other features and advantages of the present invention will be realized and attained by the device particularly pointed out in the specification in such full, clear, concise, and exact terms as to enable a person having ordinary skill in the art to practice the invention.
To achieve these and other advantages and in accordance with the purpose of the invention, as embodied and broadly described herein, the invention provides the semiconductor device having dummy patterns such that the pattern density falls within the desired range, and a method thereof.
The present invention is to provide semiconductor device, which has real patterns such as wires and dummy patterns in different coordinate systems. Using a dummy pattern in a single coordinate system does not allow an effective dummy pattern arrangement. To the contrary, if the dummy patterns in different coordinate systems are used, minimum interval requirements may be satisfied in one coordinate system while such requirements are not met in another coordinate system. Therefore, dummy patterns functioning as a whole can be effectively arranged in addition to the real patterns such as wires.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view of a layout, describing the conventional dummy pattern arrangement method;
FIG. 2 is a plan view of the layout, describing another conventional dummy pattern arrangement method;
FIG. 3 is a plan view of the layout, describing the first embodiment of the present invention;
FIG. 4 is a plan view of the layout, describing the second embodiment of the present invention;
FIG. 5 is a plan view of the layout, describing the third embodiment of the present invention;
FIG. 6 is a plan view of the layout, describing the third embodiment of the present invention;
FIG. 7 is a plan view of the layout, describing the third embodiment of the present invention;
FIG. 8 is a flow chart which shows the dummy pattern arrangement method in the third embodiment of the present invention; and
FIG. 9 is a block diagram showing an example of a CAD system composition for implementing the dummy pattern arrangement method shown in FIG. 8 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the following, embodiments of the present invention will be described with reference to the accompanying drawings. The embodiments of the present invention described below will refer to an arbitrary layer, as an example, out of the wiring layers in multi-layer wires of LSI. FIG. 3 is a layout, describing the first embodiment of the present invention. In the first embodiment of the present invention, three virtual dummy pattern groups are used. Each pattern arrangement of the three virtual dummy pattern groups is the same as the arrangement shown in FIG. 2 . However, the three virtual dummy pattern groups have different coordinate systems.
The first virtual dummy pattern group belongs to the first virtual layer, and has the dummy pattern 5 . The second virtual dummy pattern group belongs to the second virtual layer, and has the dummy pattern 7 . And the coordinates of the second virtual dummy pattern group have shifted to the lower right of the coordinates of the first virtual dummy pattern group so that the second virtual dummy pattern may partially overlap the first virtual dummy pattern group. The third virtual dummy pattern group belongs to the third virtual layer, and has the dummy pattern 9 . And the coordinates of the third virtual dummy pattern group have shifted to the lower right of the coordinates of the second virtual dummy pattern group so that the third virtual dummy pattern may partially overlap the first and second virtual dummy pattern groups.
The first virtual layer is made the base (the origin of the coordinates being at the center of a chip). The second virtual layer and the third virtual layer are defined as the first virtual layer shifted by certain distances. Thus, the first, the second, and third virtual dummy pattern groups are generated. This enables to satisfy the minimum interval standard requirement for the virtual dummy pattern groups that have not satisfied the condition in the single coordinate system wherein the design rule was violated (that is, the minimum interval standard was not satisfied), enabling the coordinate-shifted dummy pattern groups to be placed in areas to which a dummy pattern could not otherwise be arranged.
Within the first to third virtual dummy pattern groups, the distance between adjacent virtual dummy patterns (interval) is equal to or more than the minimum interval standard. On the other hand, the distance of the dummy patterns between different virtual dummy pattern groups may be arbitrary. This is because, in a local area of about one virtual dummy pattern, only one of the first, second, and third virtual dummy pattern groups is chosen, dispensing with the need to satisfy the minimum interval standard of the virtual dummy patterns between different virtual layers. However, it is desirable that the amount of an interval between dummy patterns belonging to mutually different coordinate systems does not satisfy the minimum interval standard. Moreover, it is desirable that the coordinate systems are defined by an amount of the shift interval that makes the dummy patterns of the different coordinate systems partly overlap. Consequently, the amount of gaps of two or more coordinate systems can be set to a minute quantity to increase the probability of dummy pattern presences that satisfy the minimum interval standard between the wire and the dummy pattern for a higher pattern density.
Distances between each dummy pattern of the first through third virtual dummy pattern groups and the wires 1 and 2 are compared with the minimum interval standard for predetermined directions. Dummy patterns that have the distances equal to or larger than the minimum interval standard in all of the directions are chosen to be real dummy pattern. Here, the predetermined directions are, for example, the four directions of above, below, left and right. By considering adjacent wire positions, the comparison in the vertical directions, for example, may be omitted in the case of FIG. 3 . Further, the comparison may be performed in a slanted direction.
By the above comparison processing, the virtual dummy patterns shown by the reference numbers 6 , 8 , and 10 are chosen to be real dummy patterns. The real dummy pattern 6 is a one that satisfies the minimum interval standard to the wire 1 and the wire 2 among the virtual dummy patterns in the first virtual dummy pattern group belonging to the first virtual layer. The real dummy patterns 8 are those that satisfy the minimum interval standard to the wire 1 and the wire 2 among the dummy patterns in the second virtual dummy pattern group belonging to the second virtual layer. The real dummy pattern 10 is a one that satisfies the minimum interval standard to the wire 1 and the wire 2 among the dummy patterns in the third virtual dummy pattern group belonging to the third virtual layer. The real dummy patterns 6 , 8 , and 10 have different coordinate systems, respectively.
As understood by comparing FIG. 3 with FIG. 2, real dummy patterns can be arranged effectively between wire 1 and wire 2 according to the first embodiment of the present invention. That is, real dummy patterns can be surely arranged to positions where the conventional technology could not allow, thereby increasing the pattern density.
By the dummy pattern of a single coordinate system shown in FIG. 2, the arrangement as shown in FIG. 3 cannot be obtained. It is because that each dummy pattern of FIG. 2 should be apart by at least the minimum interval standard. That is, by the single coordinate system, an arrangement wherein each dummy pattern overlaps cannot be taken because of the requirement of the minimum interval standard in a single coordinate system. Therefore, the arrangement of each dummy pattern was decided uniquely, and could not obtain an optimal arrangement by choosing from a plurality of dummy patterns that are slightly shifted in a local domain of about one dummy pattern, causing a thinner pattern density as shown in FIG. 2 .
Further, although a similar arrangement to FIG. 3 may be obtained locally by giving a slight shift among the rows R 1 , R 2 and R 3 of FIG. 2, it will only require a larger number of the rows to complete a row cycle after which dummy patterns come back to occupy the first column position. For example, although a real dummy pattern will be generated in the rows R 1 , R 2 , and R 3 , no real dummy pattern can be generated in the rows R 4 , R 5 , R 6 , and R 7 .
In above, the description was made for the virtual dummy pattern group of FIG. 2 and the virtual dummy pattern group which belongs to the same coordinate system in FIG. 3 that are aligned in one line in the row direction, and shifted in the column direction. The same discussion applies when using a virtual dummy pattern group which has a position shifted to both row and column directions.
An example of the size of each part is shown below. The sizes are set up to 2 μm square for the dummy pattern, 1 μm for the interval between virtual dummy patterns in the same virtual layer, 2 μm for the minimum interval standard between a wire and a dummy pattern, 1 μm for the amount of shift of a virtual dummy pattern in the same virtual layer (the shift amount in the row and column directions shown in FIG. 2 ), and 0.2 μm for the shift amount of the coordinate systems between different virtual layers. These sizes are examples. Optimal values are to be used for every semiconductor device in consideration of various conditions.
In FIG. 3, there is a case wherein two or more virtual dummy patterns belonging to different virtual layers can be adequate as a real dummy pattern, yet overlaying (interfering with) each other. In such a case, any one virtual dummy pattern is chosen as the real dummy pattern. For example, although the virtual dummy pattern 6 ′ can be chosen as a real dummy pattern, it overlaps the real dummy pattern 10 . The real dummy pattern 10 has been chosen in the example of FIG. 3 . Processing in regard to this point will be described later with reference to FIG. 8 .
FIG. 4 is a plan view of a layout showing the second embodiment of the present invention. Same reference number will be used to an item that is same as or similar to a composition element shown in the drawings mentioned above.
A plurality of virtual dummy pattern groups used in FIG. 4 are generated by shifting the coordinate system, as the arrows 20 of FIG. 4 indicate, of the dummy pattern group in the lattice shape as shown in FIG. 1 . The processing for choosing and generating a real dummy pattern from virtual dummy patterns is the same as the first embodiment as described with reference to FIG. 3 . The virtual dummy patterns shown by the reference number 8 are chosen as real dummy patterns. With the conventional technology shown in FIG. 1, no dummy pattern could be arranged between the wires 1 and 2 , however, the second embodiment of the present invention shown in FIG. 4 can increase the pattern density remarkably.
FIGS. 5 through 7 are plan views of layouts of the third embodiment of the present invention. Furhter, FIG. 8 is a flowchart showing arrangement method of the dummy patterns shown in FIGS. 5 through 7. In addition, this flowchart is applicable, as it is, to the first and the second embodiments. Furthermore, FIG. 9 is a block diagram showing an example of a composition of a CAD system which implements the dummy pattern arrangement method shown in FIG. 8 .
As shown in FIGS. 5 through 7, each of wires 11 and 12 includes crank portions 30 . According to the third embodiment of the present invention, a real dummy pattern can be surely arranged between the wires 11 and 12 which include the crank portions 30 , using three virtual dummy pattern groups. The first virtual dummy pattern group includes the virtual dummy pattern 5 drawn in solid lines. The second virtual dummy pattern group includes the virtual dummy pattern 7 drawn in dotted lines. The third virtual dummy pattern group includes the virtual dummy pattern 9 drawn in dashed lines.
Now, a dummy pattern arrangement process will be described. First, the first virtual layer that includes the virtual dummy pattern 5 will be processed the result of which is as shown in FIG. 5 . In a step S 11 shown in FIG. 8, layout data of the wires 11 and 12 and the data of the first virtual dummy pattern group are overlayed.
Here, a CAD system shown in FIG. 9 is described for convenience of describing. The CAD system includes a computer system and possesses as hardware resources a CPU 51 , a memory 52 , an external storage 53 such as a CD-ROM and a hard disk, a keyboard 54 , a display 55 , a mouse 56 , and a bus 57 that connects these items. The process flows as shown in the flowchart in FIG. 8 with necessary data expanded in the memory 52 . The memory 52 includes a RAM used as a working area of the CPU 51 , ROM and the like. The layout data and the data of the first virtual dummy pattern group read in the step S 11 of FIG. 8 are taken into the memory 52 from the external storage 53 .
The CPU 51 overlays the layout data of the wires 11 and 12 , and the data of the first virtual dummy pattern group (data of the first virtual layer) in the step S 11 . FIG. 5 shows all the three virtual dummy pattern groups that include the virtual dummy patterns 5 , 7 and 9 , respectively, to facilitate understanding the relative position of the three virtual dummy pattern groups. The last two virtual dummy pattern groups that include the virtual dummy patterns 7 and 9 are yet to be processed. Only the virtual dummy pattern group that includes the virtual dummy pattern 5 is overlayed to the wires 11 and 12 in the processing the step S 11 . The data expanded to the memory 52 now includes a virtual dummy pattern group that includes the virtual dummy pattern 5 and the layout data of the wires 11 and 12 .
In a step S 12 , the CPU 51 checks whether the distance between each of the wires 11 and 12 and each virtual dummy pattern 5 satisfies the minimum interval standard, having read the data of a rule file into the memory 52 . The rule file is a file that stores the data describing the minimum interval standard. The CPU 51 deletes virtual dummy patterns that do not satisfy the minimum interval standard, uses virtual dummy patterns that satisfy the minimum interval standard as the first real dummy patterns, and fixes positions of the first real dummy pattern group in a step S 13 . In FIG. 5, three first real dummy patterns 6 obtained by the above-mentioned processing are illustrated. This processing is performed by the CPU 51 deleting the data of the virtual dummy patterns that do not satisfy the minimum interval standard and by leaving the first real dummy patterns in the first virtual layer (it is equivalent to a file).
Next, the CPU 51 performs the second step the result of which is shown in FIG. 6 . In a step S 14 , the layout data, the data of the second virtual dummy pattern group (data of the second virtual file), and the data of the first real dummy pattern group are overlayed. Then, the CPU 51 , having read the rule file in a step S 15 , checks whether each virtual dummy pattern 7 satisfies the minimum interval standard in regard to distances to the wires 11 and 12 , and the real dummy pattern 6 fixed in the step S 13 . The CPU 51 leaves the virtual dummy patterns 7 that satisfy the minimum interval standard in regard to all of the wires 11 and 12 and the real dummy patterns in the second virtual layer, deleting virtual dummy patterns that do not satisfy the minimum interval standard in a step S 16 . As the result, the three real dummy patterns 8 in the middle center are obtained.
Next, the CPU 51 performs the third step the result of which is as shown in FIG. 7 . At a step S 17 , the layout data, the data of the third virtual dummy pattern group (data of the third virtual file), and the data of the first and second real dummy pattern groups are overlayed. Then, in a step S 18 , the CPU 51 , having read the rule file, checks whether each virtual dummy pattern 9 in the third virtual dummy pattern group satisfies the minimum interval standard in regard to the wires 11 and 12 , the first real dummy patterns 6 fixed in the step S 13 and the second real dummy patterns 8 fixed in the step S 16 . The CPU 51 leaves each of the virtual dummy pattern 9 which satisfies the minimum interval standard in regard to all of the wires 11 and 12 , the first and the second real dummy patterns 6 and 8 in the third virtual layer, and deletes virtual dummy patterns which do not satisfy the minimum interval standard from the third virtual layer in step S 19 . Consequently, three bottom real dummy patterns 10 are obtained.
Further, in a step S 20 , the CPU 51 overlays the layout data and the first to third virtual layers (the first to third real dummy data), and generates a wire mask data in one layer. A mask pattern is generated using this mask data, an electric conductive pattern layer is formed on a chip surface, and semiconductor device is manufactured.
In the processing of the step S 15 , virtual dummy patterns 7 that satisfy the minimum interval standard in regard to the wires 11 and 12 but do not satisfy in regard to the first real dummy patterns were deleted. Alternatively, the virtual dummy patterns 7 may be left, while deleting the interfering first real dummy patterns.
As mentioned above, although the embodiment using three virtual layers (three virtual dummy pattern groups) has been described, the number of the virtual layers is not limited to 3, but 2, or 4 or more of the virtual layers may be used. Moreover, the present invention includes cases in which a dummy pattern is prepared to patterns other than a wire.
According to the present invention as described above, dummy patterns in different coordinate systems are employed, thereby allowing dummy patterns in a different coordinate system may satisfy the minimum interval standard where dummy patterns in a certain coordinate system infringe the minimum interval standard. Consequently, as a whole, dummy patterns can now be placed effectively to real patterns of the wires and the like.
Further, the present invention is not limited to these embodiments, but various variations and modifications may be made without departing from the scope of the present invention.
The present application is based on Japanese priority application No. 2000-373374 filed on Dec. 7, 2000, with the Japanese Patent Office, the entire contents of which are hereby incorporated by reference.
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A semiconductor device includes a real pattern and dummy patterns in respective different coordinate systems. Using a dummy pattern in a single coordinate system does not allow an effective dummy pattern arrangement. To the contrary, if the dummy patterns in different coordinate systems are used, minimum interval requirements may be satisfied in one coordinate system while such requirements are not met in another coordinate system.
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[0001] This application claims priority to provisional patent application Ser. No. 60/870,685, entitled ICI CANCELLATION FOR OFDMA SYSTEMS filed Dec. 19, 2006.
FIELD OF THE INVENTION
[0002] The present invention relates generally to wireless communications systems and in particular to a system and method for inter-carrier interference cancellation in an OFDMA uplink.
BACKGROUND
[0003] Orthogonal Frequency Division Multiplexing (OFDM) is a digital multi-carrier modulation scheme utilizing multiple closely-spaced, orthogonal sub-carriers. Each sub-carrier is modulated with a conventional modulation scheme (e.g., quadrature amplitude modulation) at a low symbol rate, maintaining data rates similar to conventional single-carrier modulation schemes in the same bandwidth. OFDM modulation provides economical, robust communications under poor channel conditions, such as narrowband interference and frequency-selective fading due to multipath propagation. The low symbol rate allows for the use of a guard interval between symbols, reducing inter-symbol interference. OFDM is deployed or planned for a variety of wireless litigation systems, including IEEE 802.16 (WiMAX), some IEEE 802.11a/g wireless LANs (Wi-Fi), IEEE 802.20 Mobile Broadband Wireless Access (MBWA), and the like.
[0004] One proposal for a new flexible wireless cellular communication system, which can be seen as an evolution of the 3G WCDMA standard, is 3G Long Term Evolution (3G LTE). This system will use OFDM as multiple access technique (called OFDMA) in the downlink and will be able to operate on bandwidths ranging from 1.25 MHz to 20 MHz. Furthermore, data rates up to, and even exceeding, 100 Mb/s will be supported for the largest bandwidth. For the uplink, a kind of pre-coded OFDM is employed, where the primary purpose of the pre-coding is to reduce the large peak-to-average (PAR) ratio commonly known to be one of the drawbacks with OFDM.
[0005] OFDM is uniquely suited for LTE for a number of reasons. Relatively low-complexity receivers, as compared to other access techniques, can be used in case of highly time-dispersive channels. Additionally, at least in theory, OFDM allows for very efficient usage of the available bandwidth. For example, in the case of only one user transmitting, it is possible to exploit the fact that the channel quality typically is very different at different frequencies (that is, the channel is said to be frequency selective). Also, since the information in OFDM is transmitted on a large number of sub-carriers, different modulation and coding can be applied on different sub-carriers, rather than using the same modulation and coding on all sub-carriers.
[0006] One of the main challenges of OFDM is to ensure that the sub-carriers are orthogonal to one another. This implies that, for example, frequency offset and phase noise must be maintained at a sufficiently low level. If the orthogonality is lost, information on one sub-carrier is leaked to other sub-carriers, primarily to the closest ones. This leakage is referred to as inter-carrier interference (ICI).
[0007] OFDMA allows several users to share the available bandwidth by allocating different sub-carriers to the different users, making the users orthogonal to one another. The allocation of sub-carriers may be dynamic, such as allocating a larger number of sub-carriers to users that have a larger amount of data to transmit. Unlike to the situation with a single user in OFDM, loss of orthogonality of the sub-carriers may be significant if the different users' signals are received with very different power, which may occur in the uplink or the downlink.
[0008] Two of the major factors giving rise to ICI are frequency error and Doppler spread. A frequency error is due to a mismatch between the transmitter and the receiver in generating the carrier frequency. A frequency error will also be manifest when the transmitter and the receiver would have identical frequency generators, but where one of the receiver or transmitter is moving relative to the other. For a multi-path channel, different paths will experience different Doppler frequency shifts, giving rise to a spread in the experienced Doppler frequency at the receiver side.
[0009] For OFDM, the ICI caused by a frequency error can be accurately modeled as:
[0000]
I
(
δ
f
)
=
π
2
3
(
δ
f
Δ
f
)
2
,
[0000] where δf is the frequency error and Δf is the carrier spacing between the sub-carriers. Since all the sub-carriers are affected by the same frequency offset, the frequency error may be removed prior to applying the FFT, to eliminate the ICI.
[0010] If instead the ICI is caused by Doppler spread, then if the paths are assumed to arrive from all directions with a uniform distribution (referred to as Jakes' model), the ICI can be accurately modeled as:
[0000]
I
(
f
D
)
=
π
2
3
(
f
D
Δ
f
)
2
,
[0000] where f D is the maximum Doppler frequency and Δf is the carrier spacing between the sub-carriers.
[0011] If the ICI caused by a frequency error or Doppler spread is assumed to have the same effect as additive white Gaussian noise (AWGN), then the total noise experienced by a receiver is simply calculated as N+I, where N is power of the AWGN and I is the ICI power. Consequently, the effective signal-to-noise ratio (SNR) experienced by the system can be expressed as
[0000]
SNR
eff
=
S
N
+
I
.
[0000] Using the effective SNR as defined above, it is easy to determine if ICI is an issue of not. It is also easily seen that the larger effective SNR that is required, the harder requirements there will be on keeping the ICI at a low level.
[0012] From these formulas, it is clear that a straightforward way to reduce the ICI is to increase the carrier spacing Δf. A known feature of OFDM is redundancy in the form of a cyclic prefix (CP) prepended to the useful part of each OFDM symbol of duration T u . The minimum duration of the CP should be at least as long as the (expected) maximum delay spread of the channel where the system is supposed to operate. Since the carrier spacing is the reciprocal of T u , increasing Δf means that T u will be decreased, but the CP duration must be maintained. Accordingly, increasing Δf results in reduced spectrum efficiency.
[0013] Another strategy to reduce ICI is to estimate the ICI and then remove its impact on the received signal. In general, ICI cancellation is a complex operation that adds cost and increases power consumption in an OFDM receiver. There are two major reasons for the complexity of ICI cancellation. First, from a mathematical perspective, removing the impact of ICI involves computing the inverse to a very large matrix, which is a computationally intensive task. Second, to estimate the ICI, both the channel and the channel derivative must be estimated. Since ICI reduces the effective SNR, accurate channel estimation cannot be performed, resulting in poor estimates of the ICI. An iterative approach to ICI cancellation has been suggested in the art, beginning with initial channel estimation and ICI cancellation. Following the initial ICI cancellation, improved channel estimates are obtained from the signals from which the initial ICI estimate has been removed. An improved ICI estimate is then obtained using the improved channel estimates. This iterative procedure may be repeated to obtain the desired performance improvement. Such iterative ICI estimation is computationally complex, and introduces delay.
[0014] One known scheme for ICI cancellation relies on subtracting the ICI from different sub-carriers, rather than attempting to invert a matrix. While this approach yields a significant gain improvement, especially if used together with windowing, it has been shown that the gain remains far from that ideally possible if the ICI could be fully removed, primarily because the channel estimate, and in particular the channel change, are difficult to estimate with sufficient accuracy. ICI cancellation schemes known in the art are complex, and although some yield considerable improvement, in general the improvement is far below what is theoretically possible.
[0015] Prior art OFDM ICI cancellation has only been considered when all the sub-carriers are transmitted by the same user. That is, a signal is sent from one transmitter, over a plurality of sub-carriers, and is received by a single receiver.
SUMMARY
[0016] According to one or more embodiments disclosed and claimed herein, a system and method is presented for ICI cancellation when a total received signal comprises signals transmitted by a plurality of transmitters. This methodology allows for very efficient solutions with low computational complexity, but that achieve ICI cancellation performance much closer to the ideal case than prior art solutions. ICI cancellation is performed by identifying the transmitted signals that cause the largest ICI to received signals from other transmitters, and removing the ICI contribution from these transmissions. This may be accomplished by calculating the ICI terms only based on the received signal and the frequency offset. Alternatively, the transmissions causing the ICI are demodulated, the ICI on other signals is then determined and subtracted, and other signals are then demodulated. Which transmissions cause the largest ICI on others depends on the relative strength of the corresponding signals and how much orthogonality is lost. The latter might be due to frequency error, Doppler spread, or a combination of both.
[0017] One embodiment relates to a method of cancelling ICI in an OFDMA wireless communication system receiver receiving signals from at least a first transmitter on a first set of sub-carriers and second transmitter on a second set of sub-carriers. A frequency offset in the sub-carrier received from the first transmitter is estimated. The ICI in the set of sub-carriers received from the second transmitter caused by the first transmitter is calculated based on the estimated frequency offset in the set of sub-carriers received from the first transmitter. The calculated ICI is subtracted from the set of sub-carriers received from the second transmitter.
[0018] Another embodiment relates to a method of receiving signals from two or more transmitters, each transmitting on one or more unique sub-carriers in an OFDMA wireless communication system. The received power level and the relative frequency offset of each received signal is estimated. The ICI each received sub-carrier causes on other received sub-carriers is estimated in response to its relative received power and frequency offset. The sub-carriers are serially demodulated in response to the ICI they cause other sub-carriers.
[0019] Still another embodiment relates to a receiver in an OFDMA wireless communication system. The receiver includes a receiver operative to receive signals from a plurality of transmitters, the signals carried on a plurality of sub-carriers, and to measure the received signal power levels. The receiver also includes a frequency estimation unit operative to estimate frequency offsets in received signals. The receiver further includes an ICI cancellation unit operative to estimate the ICI in a sub-carrier received from a second transmitter caused by a first transmitter in response to the frequency offset and relative power level of a sub-carrier received from a second transmitter, and further operative to cancel the estimated ICI from the sub-carrier received from the second transmitter.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] FIG. 1 is a functional block diagram of an OFDM receiver.
[0021] FIG. 2 is a graph depicting the received signal power of OFDM sub-carriers transmitted by two users.
[0022] FIGS. 3 and 4 are graphs depicting the simulated effective SNR as a function of frequency error for different power offsets, with and without ICI cancellation.
[0023] FIGS. 5 and 6 are graphs depicting the simulated effective SNR as a function of the power offset between users' signals for different frequency errors, with and without ICI cancellation.
[0024] FIGS. 7 and 8 are graphs depicting the simulated effective SNR as a function of error in the estimation of frequency error, for different frequency errors.
[0025] FIGS. 9 and 10 are graphs depicting the calculated effective SNR as a function of frequency error when ICI is cancelled from increasing number of sub-carriers, for different received signal powers.
DETAILED DESCRIPTION
[0026] FIG. 1 depicts a functional block diagram of the relevant portion of an OFDM receiver 10 . The receiver 10 includes a Fast Fourier Transform (FFT) 12 , ICI Cancellation function 14 , Channel Estimation function 16 providing channel estimates to the ICI Cancellation function 14 , Frequency Estimation function 18 providing frequency estimates to the ICI Cancellation block 14 , Demodulator function 20 , and Further Processing 22 (such as soft value generation, FEC decoding, and the like). In some embodiments, the receiver 10 further includes a Symbol Decision function 24 , which further aids ICI Cancellation 14 by providing decoded symbol information.
[0027] To simplify the description, the present invention is described for the up-link transmission in an OFDM system having 15 kHz sub-carrier spacing. Only two users transmitting to the base station are considered, with each user transmitting on a single resource block of 12 sub-carriers, corresponding to a bandwidth of 180 kHz. Those of skill in the art will readily recognize that the present invention is not limited to this specific configuration, but rather may be advantageously applied to ICI cancellation for any multi-user transmissions in an OFDM wireless communication system.
[0028] FIG. 2 depicts the receipt of transmissions on sub-carriers from two users—user 1 and user 2 . As depicted, the transmissions from user 1 are received at a considerably higher power level than those of user 2 . Due to a relatively large frequency error in the signal transmitted from user 1 , user 1 's signals cause interference in the signals received from user 2 . Since in general the received signal comes from different users, and therefore different sub-carriers of the signal may experience different frequency errors, no attempt is made in the base station to estimate and compensate for the frequency error prior to processing the signal by the FFT.
[0029] One potential source for a large frequency error in user 1 's signal is that user 1 may be traveling at a high speed towards the base station. When user 1 's mobile terminal is receiving, it will experience a positive frequency error due to the Doppler effect. Consequently, the mobile terminal will adjust its frequency so that it matches the true carrier frequency plus the Doppler frequency, and will demodulate received signals properly. Then, when the mobile terminal transmits, it will transmit at a carrier frequency that equals the correct carrier frequency plus the Doppler shift. Since the signal received at the base station (carrier frequency+Doppler) also will experience a positive Doppler shift due to user 1 's relative speed, the frequency error experienced at the base station for user 1 will be twice the Doppler frequency.
[0030] Because the frequency error in the signal received from user 1 is twice the Doppler shift, it might cause a significant leakage in the FFT, wherein information on one sub-carrier leaks over to another sub-carrier. This leakage will degrade the performance for user 1 , and in addition it may completely ruin reception performance for user 2 if the signal from user 1 is received at the base station at much higher power than the signal from user 2 , as depicted in FIG. 2 .
[0031] Numerically, suppose that user 1 is moving at 100 km/h and the carrier frequency is 2.6 GHz. This corresponds to a Doppler frequency shift of 240 Hz. The effective frequency error experienced at the base station will therefore be 480 Hz. Considering how this affects the performance for user 1 , an upper bound on the ICI that user 1 causes to itself can be obtained by assuming an infinite number of sub-carriers being used, rather than just 12. The ICI bound obtained in this way becomes
[0000]
I
(
480
)
=
π
2
3
(
480
15000
)
2
=
0.0034
=
-
25
dB
.
[0000] Thus, if for instance the required SNR for user 1 is 15 dB, there would be a margin of 10 dB to the “noise-floor” caused by ICI, and the effect of ICI can safely be neglected.
[0032] Next, consider the ICI that is caused from user 1 to user 2 . Suppose that the signal from user 1 is received at higher power than the signal from user 2 , as depicted in FIG. 2 . This may occur, for example, if user 1 is much closer to the base station than user 2 , and no power control is applied. FIG. 3 depicts the effective SNR for various frequency errors, where the S/N=30 dB and the signal from user 1 is received with 10 dB higher power. FIG. 4 depicts the effective SNR for various frequency errors, where the S/N=40 dB and the signal from user 1 is received with 20 dB higher power. FIG. 5 depicts the effective SNR for various power offsets between the received signals, where the S/N=30 dB and the signal from user 1 is received with a frequency error of 500 Hz. FIG. 6 depicts the effective SNR for various power offsets between the received signals, where the S/N=30 dB and the signal from user 1 is received with a frequency error of 1000 Hz. As shown, the degradation for user 2 , with no ICI cancellation, is substantial.
[0033] FIGS. 3-6 also depict that ICI cancellation can drastically improve the effective SNR experienced by user 2 , according to the following methodology. Suppose that user 1 is transmitting symbol S K+L on sub-carrier K+L, and let H K+L and H′ K+L , denote the (average) channel transfer function for sub-carrier K+L, and the change of H K+L during the information-carrying part of the OFDM symbol, respectively.
[0034] The corresponding received signal on sub-carrier K+L can be written R K+L =S K+L H K+L , and the ICI that falls into sub-carrier K is approximately given by
[0000]
R
K
,
K
+
L
=
S
K
+
L
H
K
+
L
′
1
j
2
π
L
.
[0035] Thus, to determine the ICI, the transmitted symbol as well as the channel's derivative must be estimated, which usually is very difficult. However, in the case that the experienced channel change is due to a frequency error we note that
[0000] H′ K+L ≈j 2 πδfH K+L /Δf
[0000] where the approximation comes from the fact that the channel change is assumed to be linear in the direction of the tangent, i.e., the approximation that is used is
[0000] exp( j 2 πδf/Δf )≈1 +j 2 πδf/Δf , when δf is small.
[0036] Since R K+L =S K+L H K+L , it follows that
[0000]
R
K
,
K
+
L
=
S
K
+
L
H
K
+
L
′
1
j
2
π
L
≈
R
K
+
L
H
K
+
L
j2π
δ
f
Δ
f
H
K
+
L
1
j2π
L
=
R
K
+
L
δ
f
Δ
fL
.
[0000] Since R K+L is just the received symbol prior to equalization, and δf is the frequency offset, which can be estimated with rather high accuracy, the ICI term can also be accurately estimated. This frequency estimation function is depicted as block 18 in the receiver 10 block diagram of FIG. 1 . Note that the ICI is estimated by an estimate of the frequency error—neither the channel nor the derivative of the channel need to be estimated, as is usually the case in conventional approaches to ICI cancellation.
[0037] In the graphs of FIGS. 3-6 , one ICI cancellation algorithm, denoted “Full non-DD ICI cancellation,” uses the above expression for estimating the ICI component and then subtracts it from a received signal. The other algorithm, denoted “Full DD ICI cancellation,” uses an actually transmitted signal and the actual channel experienced, thus reducing the noise term somewhat. DD stand for Decision Directed, and refers to the fact that in an actual implementation, the transmitted signal is not known, but must be determined. This is depicted by the dashed-line function Symbol Decision 24 in FIG. 2 , which provides the ICI Cancellation 14 with what the receiver determines the transmitted symbol to have been. “Full” ICI cancellation refers to the fact that ICI from all sub-carriers transmitted by user 1 are subtracted from the signal from user 2 .
[0038] The results in FIGS. 3-6 are obtained under the assumption that the frequency error in the signal received from user 1 has been perfectly estimated. Of course, this is not the case in practice. FIGS. 7 and 8 depict the effective SNR of a received signal as function of estimation error for the frequency used to estimate the ICI. FIG. 7 depicts a 250 Hz frequency error; FIG. 8 depicts a 500 Hz error. In both cases, the S/N=30 dB and the signal from user 1 is received with 20 dB higher power. As expected, the effective SNR is degraded when the frequency error is not correctly estimated. The graphs additionally demonstrate that even when the frequency estimation error is relatively large, the gain is still significant compared to the case where no ICI cancellation is performed.
[0039] FIGS. 9 and 10 graph the calculated effective SNR as a function of frequency error for ICI cancellation from different numbers of sub-carriers, and depict how the receiver performance varies depending on the number of sub-carriers transmitted by user 1 for which the corresponding ICI in user 2 's signal is cancelled. Data graphed in the figures was obtained analytically. In FIG. 9 , the signal from user 1 is received with 10 dB higher power than the signal from user 2 ; in FIG. 10 , the user 1 signal is 20 dB higher. S/N=30 dB in both cases. The lower curve corresponds to L=0, meaning that no ICI cancellation is performed. The next curve graphs L=1, wherein only ICI from the user 1 sub-carrier closest (in frequency) to user 2 's signal is cancelled. L=2 means that ICI from the two closest user 1 sub-carriers are cancelled, and so on. For L=12, full cancellation is performed, meaning that the ICI from all user 1 sub-carriers are cancelled from the signal from user 2 . In FIGS. 9 and 10 , this curve is hard to see since it is perfectly horizontal—indicating no SNR degradation due to ICI over 1500 Hz of frequency error in user 1 's received signal.
[0040] As FIGS. 9 and 10 demonstrate, the ICI cancellation methodology of the present invention is scalable. For relatively slight interference, only ICI contributed by the closest interfering sub-carriers from user 1 may be removed from a sub-carrier received from user 2 to achieve an acceptable SNR. For more severe interference, ICI contributed by most or all of the interfering sub-carriers may need to be removed. Additionally, ICI from a variable number of the interfering sub-carriers from user 1 may need to be cancelled from other, further (in frequency) sub-carriers from user 2 . That is, while ICI from most or all user 1 sub-carriers may need to be calculated and removed from adjacent user 2 sub-carriers, user 2 sub-carriers further removed may require ICI cancellation from fewer of user 1 's sub-carriers (e.g., only the closest few).
[0041] Given the teachings herein, those of skill in the art may readily perform the tradeoffs between computational complexity, power consumption for ICI cancellation calculations, receiver delay, and achievable SNR improvement for any given situation. Such determination may, for example, be based on the degree of frequency error in an interfering signal and the relative received power between interfering and interfered signals. In any event, calculating and removing ICI caused by one or more individual sub-carriers transmitted by a first transmitter on a received signal transmitted from a second transmitter may achieve greater ICI cancellation than prior art methods, at reduced computational complexity.
[0042] As those of skill in the art will readily recognize, any or all of the functional blocks depicted in FIG. 1 −including the FFT 12 , ICI Cancellation 14 , Channel Estimation 16 , Demodulator 20 , Further Processing 22 , Frequency Estimation 18 , and Symbol Decision 24 —may, in any receiver 10 , be implemented as hardware circuits, as programmable logic, as firmware or software executing on a microprocessor or Digital Signal Processor (DSP), or any combination thereof. Although the present invention has been explicated herein in terms of two users transmitting via mobile terminals to a base station, the invention is not limited to this system implementation, and may be advantageously applied to any OFDMA receiver that receives signals from two or more transmitters on two or more sub-carriers.
[0043] The present invention may, of course, be carried out in other ways than those specifically set forth herein without departing from essential characteristics of the invention. The present embodiments are to be considered in all respects as illustrative and not restrictive, and all changes coming within the meaning and equivalency range of the appended claims are intended to be embraced therein.
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Inter-carrier interference (ICI) cancellation in an OFDMA receiving signals from two transmitters is performed by identifying the transmitted sub-carriers that cause the largest ICI to sub-carriers received from other transmitters, and removing the ICI contribution from these sub-carriers. This may be accomplished by calculating the ICI terms only based on the interfering sub-carrier and the frequency offset. Alternatively, the transmissions causing the ICI are demodulated, the ICI on other signals is then determined and subtracted, and other signals are then demodulated. Which transmissions cause the largest ICI on others depends on the relative strength of the corresponding sub-carriers and how much orthogonality is lost. The latter might be due to frequency error, Doppler spread, or a combination of both.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application claims priority from Provisional Application Ser. No. 60/069,118, “HID DRIVEN FOCUS-LESS OPTICS SYSTEM,” filed Dec. 9, 1997 and application Ser. No. 09/009,836, “DISTRIBUTED LIGHTING SYSTEM,” filed Jan. 20, 1998, both of which are incorporated by reference.
BACKGROUND
The invention relates to distributed lighting systems.
Distributed lighting systems distribute light from one or more light sources in central locations to one or more remote locations. A distributed lighting system promises several advantages over conventional lighting techniques, including low power consumption, extended life, heat reduction where the light is emitted, and increased design flexibility.
SUMMARY
The invention provides a distributed lighting system (DLS) for use, for example, in an automobile. Issues associated with incorporating a distributed lighting system into an automobile are discussed by Hulse, Lane, and Woodward in “Three Specific Design Issues Associated with Automotive Distributed Lighting Systems: Size, Efficiency and Reliability,” SAE Technical Paper Series, Paper No. 960492, which was presented at the SAE International Congress and Exposition, Detroit, Mich., Feb. 26-29, 1996 and Hulse and Mullican in “Analysis of Waveguide Geometries at Bends and Branches for the Directing of Light,” SAE Technical Paper Series, Paper No. 981189, which are incorporated herein by reference.
A practical distributed lighting system for an automobile must address size, efficiency, and reliability issues. To this end, an implementation of the invention employs focus-less optics components, such as collector elements and waveguides. These components are inexpensive to manufacture, since they can be formed from plastic (acrylic, for example) in an injection molding process. In addition, they have high collecting efficiency and are very compact. For example, a collector element may be smaller than one cubic inch (16.4 cubic centimeters). Components that must handle high heat levels (e.g., components are placed in proximity to the light source) may require a ventilation system or may include portions formed from heat resistant materials, such as glass or Pyrex™.
The DLS may incorporate different types of optical waveguide structures to distribute light throughout the vehicle, including joints, elements with epoxy coatings, pinched end collector portions, integrated installation snaps, integrated input optics and integrated output lenses. The DLS may also include waveguide structures to provide illumination to portions of the vehicle interior, including cup holders, assist grips, and storage pockets.
In one aspect, generally, an optical waveguide for illuminating the interior of a cup holder in a vehicle is formed from a piece of solid material. The solid material has a ring portion that is sized and shaped to be received within a cup holder and that releases light into the cup holder. An input face receives light from a light source. An input portion extends between the input face and the ring portion, confines light through internal reflection, and directs light from the input face to the ring portion.
Embodiments may include one or more of the following features. The ring portion may define an inner circumference and may release light around the inner circumference. The ring portion may have a protruding angled portion around the inner circumference that directs light down toward a bottom portion of the cup holder. The upper surface of the angled portion may be stippled. An upper surface of the angled portion may be covered with an opaque material. The ratio of an inner radius of the ring portion to the width of the ring portion may be greater than or equal to 3:1.
The ring portion may include a first arm and a second arm that define a gap in the inner circumference. The second arm may have a smaller cross-section and a smaller length than the first arm. The ring portion may have a web portion that extends between the first and second arms. The web portion may release light along its edge. The ring portion may include a tab that extends from the inner circumference between the first and second arms. The tab may have a rectangular cross-section and may curve toward the bottom of the cup holder. The tab may have a chamfered leading edge.
The optical waveguide described above may be included in an illuminated cup holder having a bottom surface. A side wall may extend from the bottom surface and define a volume shaped and sized to receive a cup. A rim may be positioned around the upper edge of the side wall.
In another aspect, an optical waveguide illuminates the inside of an assist grip in a vehicle. The waveguide is a piece of solid material having an illumination portion with an inner surface and an outer surface. The illumination portion is sized and shaped to be received within a channel along the length of the assist grip and releases light from the inner surface. An input face at one end of the illumination portion receives light from a light source.
Embodiments may include one or more of the following features. The inner surface may be stippled. The ratio of the inner radius of a bend to the width of the waveguide may be greater than or equal to 3:1. The waveguide may have snaps extending from the outer surface that hold the illumination portion in place within the channel. A lens positioned adjacent to the light source may focus light from the light source to form a courtesy light. An illuminated assist grip for a vehicle including the waveguide described above also may have a handle portion formed of solid material, a channel formed along the length of the handle and a light source receptacle configured to receive a light source.
In another aspect, an optical waveguide for a vehicle door illuminates an area beneath the vehicle. The door has a bottom surface that meets a floor surface of the vehicle when the door is closed. The waveguide includes a door portion positioned inside the door and extending to the bottom surface of the door. A floor portion extends from the floor surface to the underside surface of the vehicle. The door portion and the floor portion meet when the door is closed so that light may pass through the door portion and the floor portion to illuminate the area beneath the vehicle. Embodiments may include a branch that extends from the door portion to an interior surface of the door to illuminate the interior of the vehicle.
In another aspect, an illuminated storage pocket for a vehicle has a surface that defines a storage volume and a rim around an edge of the surface. A waveguide formed from a piece of solid material has an illumination portion that has an inner surface and an outer surface. The illumination portion is received within a channel along the rim of the storage pocket and releases light from the inner surface. An input face at one end of the illumination portion receives light from a light source.
Embodiments may include one or more of the following features. The inner surface of the waveguide may be stippled. The waveguide may include snaps that extend from the outer surface and hold the illumination portion in place within the channel.
In another aspect, an optical waveguide includes a first and a second piece of solid material. The first piece has a transmission portion with a rectangular cross-section. The end of the transmission portion is convex in one dimension. The second piece has a transmission portion with a rectangular cross-section. The end of the transmission portion is concave in one dimension. The end of the first piece and the end of the second piece form an interface between the first and second pieces.
Embodiments may include one or more of the following features. The waveguide may include a third piece of solid material having a transmission portion with a rectangular cross-section. The end of the transmission portion may be concave in one dimension. The end of the third piece and the end of the first piece may form an interface between the first and third pieces. A band may hold the first, second and third pieces together.
The waveguide may include a third piece of solid material having a transmission portion with a rectangular cross-section. The end of the transmission portion may be convex in one dimension. The end of the third piece and the end of the second piece form an interface between the second and third pieces. A band may hold the first, second and third pieces together.
In another aspect, an optical waveguide accepts light from a light source and transmits the light. The waveguide is formed from a piece of solid material having an input face, a transmission portion and an end portion between the input face and the transmission portion. A cross-sectional area of the end portion gradually decreases from the transmission portion to the input portion.
Embodiments may include one or more of the following features. The end portion may have planar sides angled from a longitudinal axis of the transmission portion. The angle formed between the sides and the longitudinal axis may be about 5°. The end portion may increase the acceptance angle of the waveguide. A lens portion may be formed on the input face.
In another aspect, an optical waveguide has integrated installation elements. The waveguide includes first and second sections. The first section has an input face, an output end and a transmission portion extending from the input face to the output end. A key is positioned on the output end and mates with a socket of the second section. The second section has an input face, an output end and a transmission portion extending from the input face to the output end. A socket is positioned on the output end and mates with the key of the first section.
Embodiments may include one or more of the following features. The waveguide may include a snap positioned on the transmission portion of the first or second section. The snap may mate with an installation fitting of a vehicle. The outer surface of the waveguide may be covered with epoxy.
In another aspect, an optical waveguide has integrated installation elements. The waveguide includes first and second sections. The first section has an input face, an output end and a transmission portion extending from the input face to the output end. A claw is positioned on the output end and mates with a detent of the second section. The second section has an input face, an output end and a transmission portion extending from the input face to the output end. A detent is positioned near the output end and mates with the claw of the first section.
Embodiments may include one or more of the following features. A snap may be positioned on the transmission portion and may mate with an installation fitting of a vehicle. An outer surface of the waveguide may be covered with epoxy.
In another aspect, an optical waveguide has an output element for providing illumination in a vehicle. The waveguide includes an input face and a transmission portion extending from the input face. The transmission portion widens at an end to form an output element having a convex lens at the end of the output element. The output element may be formed to leave an air gap between the lens and the end of the transmission portion.
Other features and advantages will be apparent from the following detailed description, including the drawings, and from the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of a vehicle distributed lighting system with hybrid lighting subsystems.
FIG. 2 shows a hybrid headlamp subsystem.
FIG. 3 shows a hybrid headlamp subsystem with a movable lens.
FIGS. 4A-4D show headlamp beam forming structures.
FIG. 5 shows a light source with a diffusion grating.
FIGS. 6A-6F show waveguide outputs modulated with electromechanical or liquid crystal light valves.
FIG. 7 shows a hybrid tail light subsystem.
FIG. 8 shows a compact incandescent cartridge.
FIGS. 9A and 9B show a waveguide output bend for a tail light.
FIGS. 10A and 10B show a combination security/puddle light.
FIGS. 11A-11F show various embodiments of a cup holder illumination component.
FIG. 12A is a rear view of a waveguide installed in a handgrip.
FIG. 12B is a cross-section view of a waveguide and light source installed in a handgrip.
FIG. 12C shows a waveguide with integrated snaps for installation into a handgrip.
FIG. 13 is a cross-section view of an optical waveguide.
FIGS. 14A and 14B are side and bottom views of a waveguide joint.
FIG. 15 is a cross-section view of an epoxy-coated optical waveguide.
FIGS. 16A-16C are cross-section views of non-tapered and tapered waveguide inputs.
FIGS. 17A and 17B are cross-section views of waveguide sections having integrated installation components and an integrated output structure.
FIG. 18 shows a leaky waveguide bend and focusing lens.
FIGS. 19A and 19B show cross-section views of optical manifolds.
DESCRIPTION
Referring to FIG. 1, a vehicle distributed lighting system (DLS) 100 includes hybrid headlamp subsystems 105 , turn signal subsystems 110 and 140 , and hybrid tail light subsystems 130 . The hybrid headlamp subsystems 105 provide primary forward illumination for the vehicle. The headlamp subsystems 105 are also light sources for other exterior lights, such as front turn signals of the subsystems 110 and side markers 115 , as well as interior lights, such as dashboard lights 120 and dome lights 125 . These other lights are connected to the headlamp subsystems by optical waveguides 135 . Similarly, the tail light subsystems 130 provide light for rear turn signals 140 and a center high mounted stop light (CHMSL) 145 . The subsystems of the DLS are interconnected so that the light source of one subsystem serves as a redundant light source for another subsystem.
The DLS incorporates different types of optical waveguide structures to distribute light throughout the vehicle. These include joints, elements with epoxy coatings, pinched end collector portions, integrated installation snaps, integrated input optics and integrated output lenses. The DLS also includes waveguide structures to provide illumination to portions of the vehicle interior, including cup holders, assist grips, and storage pockets.
FIG. 2 illustrates a hybrid headlamp subsystem 105 . The subsystem includes a light source 205 that may be implemented using, for example, a high-intensity discharge (HID) lamp. Light produced by the light source 205 is collected by a reflector 210 and directed through a lens 215 to provide the primary forward illumination for the vehicle. The reflector may be implemented as a parabolic or complex reflector.
The hybrid headlamp subsystem 105 provides both high beam and low beam illumination. To this end, the subsystem may employ a number of different beam forming techniques, as shown in FIGS. 3-5. For example, FIG. 3 shows a simple Fresnel lens 305 that is moved by an actuator 310 between a high beam position and a low beam position. The movement of the lens 305 shifts the position of the “hot spot” (i.e., the area of most concentrated light) of the headlamp beam in the far field between the appropriate positions for the high and low beams. Other portions of the beam also will shift as the lens moves. In addition to lens, other optical elements, such as wedges, may be used to control the beam pattern.
FIGS. 4A-4D show the use of a solid molded plastic form 405 (FIGS. 4A-4C) or a bundle of plastic or glass fibers 410 (FIG. 4D) to generate a desired headlamp beam pattern. Light from light source 205 passes through the form 405 or bundles 410 and then passes through a focusing lens 415 . The shape of the output end 420 of the solid form or bundles, in conjunction with the properties of the focusing lens, determines the beam pattern in the far field. To increase light collection efficiency, the shape of the input end 425 of the solid form may be configured to act as a collector element to receive light from a light source. A reflector 215 may also be used to control the beam pattern, as in FIGS. 2 and 3. FIGS. 4A-4C show dimensions in mm [inches] of a thickness profile that might be used to achieve a desired beam pattern. Similarly, the bundle of fibers can be formed into a desired profile. As with the implementation shown in FIG. 3, the lens 305 may be moved to shift the hot spot of the beam between high beam and low beam positions.
FIG. 5 shows the use of a diffraction grating 500 to control the headlamp beam pattern (the diffraction grating may also be used for other lighting functions, such as stop lights and turn signals). The diffraction grating 500 includes essentially transparent material that has a series of ridges 505 on its surface. The width 510 of the ridges is approximately equal to the wavelength of the light produced by the light source 205 . A portion 515 of the light passing through the diffraction grating 500 is reflected back into the light source, with the size of the portion depending upon the exit angle (θ) of the light ray. Most of the light 520 travelling in a direction close to perpendicular (θ=0°) passes through the grating undisturbed. By limiting the exit angle (θ) of the headlamp illumination, the grating 500 may provide, for example, a more focused headlamp beam in the far field. The grating 500 may be used alone or in conjunction with lenses 305 , solid forms 405 or fiber bundles 410 described above to provide a desired headlamp beam pattern.
In addition to providing the primary forward illumination, the light source 205 acts as a light source for other parts of the system. As shown in FIG. 2, waveguides 135 having collector elements 220 at their ends are positioned close to the light source 205 to receive light and transmit the light to other locations in the vehicle, such as to provide turn signals, interior lighting, fog lights, and side markers. The waveguides 135 may also carry light to other lighting subsystems to provide redundancy, such as the opposite side headlamp or the tail lights. The number of collector elements 220 may be increased as necessary to supply light for other lighting functions. The collector elements 220 may be glass rods (such as Pyrex) with ends that are polished so as to be faceted or pinched. The pinched ends increase the acceptance angle of the collector element.
FIG. 2 . shows a waveguide 225 that carries light from the source to a side marker light 115 . The waveguide 225 may include colored plastic filters 230 to provide a desired output color (e.g., amber) for the side marker 115 . This configuration eliminates the need for an electrical connection and light bulb in the side marker 115 .
Another waveguide provides light to the turn signal subsystem 110 . Alternatively, the turn signal subsystem 110 may include an independent light source and may use the input from the headlamp subsystem 105 for redundancy.
As shown in FIGS. 6A-6D, some implementations of the turn signal subsystem use an electromechanical shutter 605 (FIGS. 6A and 6B) while others use a liquid crystal light valve (LCLV) 610 (FIGS. 6C and 6D) to modulate the light produced by the turn signal. A plastic colored filter provides amber color for the turn signal. The use of a colored filter eliminates the need for light bulbs enclosed in cadmium-doped glass.
The electromechanical modulator 605 , as shown in FIGS. 6A and 6B, includes an opaque shutter 615 that is moved between an ON (FIG. 6A) and OFF (FIG. 6B) position by a solenoid 620 . In the ON position, the shutter 615 is moved away from the illumination path, so that essentially all of the light is transmitted. In the OFF position, the shutter 615 blocks the illumination path so that no light is transmitted. The use of an electromechanical modulator 605 with an amber-colored plastic filter provides a desirable aesthetic effect (i.e., the turn signal appears amber when ON but has no color when OFF).
The LCLV illustrated in FIGS. 6C and 6D has no mechanical components. This increases the reliability of the LCLV relating to systems that include mechanical components. The LCLV 610 has two states. In the OFF state (FIG. 6D) the LCLV 610 reflects or scatters most of incident light. In the ON state (FIG. 6C) the LCLV 610 becomes largely transparent (i.e., greater than 80% of incident light passes through the LCLV). The ratio of the light transmitted in the ON state relative to the light transmitted in the OFF state (i.e., the contrast ratio) is approximately 5:1, which meets SAE requirements for a turn signal. A contrast ratio of 5:1 also meets the SAE requirements for stop lights used as turn signals. An infrared reflecting mirror (not shown) may be used to shield the LCLV from infrared energy from the source, thereby increasing the expected life of the LCLV.
As shown in FIGS. 6E and 6F, LCLV modulators 610 may be combined with diffraction gratings 500 to improve the contrast ratio and achieve a desired beam pattern. As discussed above, light from the light source (waveguide 135 ) is scattered when the LCLV is OFF (FIG. 6 F). The diffraction grating 500 lessens the amount of forward scattered light that is emitted. Focusing optics, such as lenses 630 , may also be used to provide further beam pattern control.
Referring again to FIG. 1, waveguides also may carry light from the headlamp subsystem to other subsystems that have their own light sources, such as the opposite headlamp subsystem (waveguide 137 ) or the corresponding tail light subsystem (waveguide 138 ), to provide light source redundancy. When redundancy is employed and, for example, one of the headlamps fails, light from the operational headlamp will dimly illuminate the failed headlamp. This is safer for the operator of the vehicle than having only one operational headlamp. Redundancy also may be used to reduce the effects of failure of other lighting components. For example, an incandescent PC bulb may be used as a source for trunk lighting and may be connected to provide redundancy to interior reading lights.
The tail light subsystems 130 of FIG. 1 operate similarly to the headlamp subsystems. As shown in FIG. 7, a tail light subsystem 130 has a light source 705 that provides primary rear illumination through a lens 710 . The light source 705 may be a HID lamp or another type of lighting source, such as an incandescent lamp, since the lighting requirement (in lumens) generally is less than the requirement for a headlamp. In general, an incandescent source is significantly less expensive than an HID source.
A compact incandescent cartridge 800 , such as shown in FIG. 8, may be employed as the light source 705 . The cartridge 800 includes a housing 805 having reflective, heat-dissipating interior surfaces 810 . An incandescent bulb 815 is positioned in the center of the housing 805 . Waveguide collector elements 220 are positioned around the light source. The incandescent cartridge 800 has a compact size, stays cool, and reduces lamp placement error, which increases efficiency. In addition, construction of the waveguide collector elements 220 from injection molding is easy and inexpensive. The cartridge 800 or similar incandescent sources may also be used as light sources elsewhere in the DLS, depending on lighting requirements. In addition, networks of cartridges 800 or incandescent sources may be interconnected to provide redundant light sources for interior or exterior lighting functions in the DLS.
Referring again to FIG. 7, waveguide collector elements 220 in the tail light subsystem are positioned close to the source 705 to receive light and transmit the light to other lighting elements, such as the rear turn signals 140 , backup lights 150 , and center high-mounted stop light (CHMSL) 145 . A combination stop/rear turn signal light may be modulated with a LCLV 610 , as discussed above with respect to the forward turn signals. The backup lights 150 and CHMSL 145 , however, are modulated with electromechanical shutters 615 , since they must be completely dark in the OFF mode.
The rear turn signals subsystems 140 also may be implemented in the manner shown in FIGS. 9A and 9B. In particular, a waveguide section 900 may be used to provide a desired beam pattern for the rear turn signal. Light from a collector element 220 or an independent light source is received at the input 910 of the waveguide section 900 and is internally reflected by the surfaces of the waveguide as it propagates. The waveguide 900 includes a bend 920 immediately prior to the output 930 . The outer surface of the bend 920 is s-shaped, which changes the distribution of light across the output surface 930 and hence the far field beam pattern of the turn signal. As an example, FIG. 9B shows dimensions in mm [inches] of a waveguide 900 that might be used to provide a desired beam pattern.
The DLS also may be used to provide other lighting functions. For example, a waveguide 1000 may be installed in the door 1005 , as shown in FIGS. 10A and 10B, to provide a security/puddle light. The waveguide 1000 runs from a light source, such as the hybrid headlamp subsystem 105 (FIG. 1 ), to the bottom edge 1010 of the door 1005 . A waveguide branch 1012 may be used to implement a interior door light. When the door 1005 is closed, as in FIG. 10A, a door waveguide section 1015 connects to a waveguide 1020 that passes through the floor 1025 . The floor waveguide section 1020 provides a security light that illuminates the area 1030 underneath the vehicle. When the door 1005 is open, as in FIG. 10B, the door waveguide 1015 provides a puddle light that illuminates the ground 1035 between the open door and the vehicle. The bend 1040 in the door waveguide section 1015 may have a bend angle (θ B ) of, for example, 20°. The bend 1040 helps to direct the output of the waveguide 1000 to the desired area. Alternatively, the security/puddle light may be implemented as a hybrid subsystem that has an independent light source. The independent light source may directly provide interior lighting for the vehicle in addition to being connected to the waveguide 1000 as a light source for the security/puddle light.
Another waveguide carries light from hybrid headlamp subsystem to the interior of the vehicle to provide, for example, dashboard lighting, dome lights, and reading lights. Waveguides also provide unique, aesthetically pleasing lighting effects for certain interior structures, such as cup holders, map pockets, and assist grips.
For example, as shown in FIGS. 11A and 11B, a ring-shaped waveguide element 1100 may be installed under the lip 1105 of a cup holder 1110 . Although the shape of the waveguide 1100 in FIGS. 11A and 11B is circular, any shape may be used depending upon the shape and size of the cup holder 1110 . The efficiency of the waveguide may be improved by selecting a ratio of the inner radius (r) of the waveguide relative to the width (w) of the waveguide. For example, a waveguide with an inner radius to waveguide width ratio (r/w) of 3:1 will lose less light than a ratio of 1:1 or 0.1:1.
The waveguide 1100 may have a protruding, angled upper region 1115 to reflect and/or transmit light downward toward the bottom 1120 of the cup holder 1110 . The upper surface 1125 of the angled portion 1115 may be stippled and may be covered with a layer of opaque material to prevent leakage of light in the upward direction. A small incandescent bulb 1130 at the input 1135 of the waveguide is used as a source. Light entering the input 1135 is transmitted to the ring-shaped portion 1136 of the waveguide 1100 via an input portion 1137 that is tangentially connected to the ring-shaped portion 1136 . A colored filter 1145 may be placed between the source 1130 and the input 1135 to achieve a desired illumination color. When illuminated, the interior 1140 of the cup holder 1110 glows faintly so as not to interfere with the driver's vision. The glowing illumination allows the occupants of the vehicle to discern the location of the cup holder 1110 . Light for the waveguide 1100 also may be provided by a waveguide 135 connected to one of the lighting subassemblies.
Another embodiment of the cup holder illumination waveguide 1100 is shown in FIGS. 11C-11D. These “wishbone” shaped waveguides 1100 are configured for cup holders having a gap 1150 to accommodate a mug handle. Light for the waveguide 1100 enters the input 1135 and is split essentially equally to the two arms 1155 of the wishbone. The split in the waveguide 1100 may lead to a dark area in the illumination of the cup holder. Therefore, as shown in FIG. 11C, a web portion 1160 is included between the two arms 1155 . The web portion is thinner than the rest of the waveguide 1100 and provides additional illumination to the portion of the interior 1140 of the cup holder directly beneath the split in the wishbone.
Alternatively, as shown in FIG. 11D, a tab 1165 that is thinner than the rest of the waveguide 1100 may extend downward from the split to reflect and/or transmit light toward the bottom of the cup holder. The tab 1165 has a generally rectangular cross-section and curves downward toward the bottom 1120 of the cup holder. As shown in FIG. 11E, the tab 1165 may have a chamfered leading edge 1170 .
Yet another embodiment of the cup holder illumination waveguide 1100 is shown in FIG. 11 F. As in the previous embodiment, the waveguide 1100 is configured for cup holders having a gap 1150 to accommodate a mug handle. Light enters the input 1135 and is split unequally between a primary arm 1175 and a secondary arm 1180 . The secondary arm has a smaller cross-section, (i.e., is thinner and narrower than the primary arm 1175 . Since the secondary arm 1180 is shorter than the primary arm 1175 , there is less loss along its length. The smaller cross-section of the secondary arm 1180 allows less light to enter the secondary arm, which balances the light in the two arms 1175 and 1180 provides uniform illumination around the circumference of the cup holder.
Similar structures may be used in the interior of a map pocket or, as shown in FIGS. 12A-12C, along the interior surface 1205 of a assist grip 1200 . A length of waveguide 1210 is installed along the inner surface 1205 . The waveguide includes bends 1212 at the ends to conform to the shape of the assist grip. A small incandescent bulb 1215 provides a light source. The bulb may be used in conjunction with a lens (not shown) to provide a courtesy light. Alternatively, the assist grip 1200 may be connected by a waveguide to another light source in the DLS. As shown in FIG. 12C, the waveguide 1210 may be formed with snaps 1220 and 1225 to make installation into the assist grip 1200 easier.
Different types of waveguide structures may be used in the DLS to transmit light from the sources to the lighting outputs. A basic waveguide, as shown in FIG. 13, may be formed from optically transparent material such as acrylic or glass. If the waveguide is formed from acrylic or a similar material, it can be manufactured using an injection molding process. The manufacture of waveguide elements using injection molding results in very low manufacturing costs compared to fiber optics. In addition, molded acrylic waveguide elements are more rigid than fiber optics, can be installed by robots, and generally do not require maintenance, waveguide elements can also achieve much smaller bend radii than fiber.
As shown in FIG. 13, a light ray 1305 entering the input face 1310 proceeds through the waveguide 1300 until the light ray 1305 reaches an outer surface 1315 of the waveguide 1300 , i.e. an interface between the material of the waveguide 1300 and air. At the outer surface 1315 , light is reflected in accordance with Snell's law. If the angle of incidence (θ i ) of the light ray 1305 at the outer surface 1315 is less than a threshold referred to as the critical angle (θ c ), then the light ray 1305 is reflected internally, with no light escaping. This phenomenon is known as total internal reflection. The critical angle depends on the index of refraction of the material of which the waveguide is composed relative to that of the material surrounding the waveguide, (e.g., air). For example, if the waveguide were made from acrylic, which has an index of refraction of approximately 1.5, and surrounded by air, the critical angle, θ c , would be:
θ c =arcsin( n a /n b )=arcsin(1/1.5)=41.8
where n a is the index of refraction of air (1.0) and n b is the index of refraction of acrylic (1.5).
Referring to FIGS. 14A and 14B, a waveguide joint 1400 may be used to distribute light in the DLS. For example, the joint may be used to provide light to a door of the vehicle. The waveguide joint 1400 has a trunk section 1405 with a convex curved end 1410 . Branch sections 1415 having convex curved ends 1420 adjoin the trunk section 1405 . The branch sections may be held in place by a plastic band 1425 surrounding the joint region or by epoxy or snaps. Light input to the trunk section 1405 is essentially split among the branches 1415 . The branches 1415 may be positioned to carry light to different sections of the vehicle. It is also possible to reconfigure the branches 1415 in the event of design changes. Epoxy that has an index of refraction approximately equal to that of the waveguide, i.e., that is index-matched, may be used to hold the branches 1415 in place. The joint 1400 may have only a single branch 1415 that is used to change the direction of the trunk 1405 or to provide a hinged connection. A hinged connection using the joint 1400 may be installed, for example, in a car door. Index-matched fluid may be used to lubricate and reduce discontinuity at the interface between the trunk 1405 and the branch 1415 , which will reduce the loss through the joint 1400 .
FIG. 15 shows a waveguide core 1500 encased in a layer of epoxy 1505 . The epoxy coating 1505 may be applied by dipping the waveguide core 1500 (which may be formed, for example, from acrylic) in a reservoir of epoxy and allowing the coating to dry. The epoxy 1505 has a lower index of refraction than the waveguide 1500 , so that most of the light rays 1510 passing through the waveguide core 1500 are internally reflected at the acrylic/epoxy interface 1515 . A portion of the light rays are reflected at the outer epoxy/air interface 1520 . The distribution of light in the waveguide peaks at the center of the waveguide and diminishes toward the edges of the waveguide. Overall, a significant portion of the light is confined within the waveguide core 1500 and only a small portion of the light reaches the outer epoxy/air boundary 1520 .
The epoxy coating 1505 offers several advantages compared to an uncoated waveguide. For example, contaminants on the surface of an uncoated waveguide can cause light at the waveguide/air interface to be scattered and transmitted outside of the waveguide instead of being internally reflected, which increases loss in the uncoated waveguide. The epoxy layer 1505 increases the distance between the contaminants and the waveguide core 1500 , which reduces the amount of light that reaches the waveguide/air interface. In addition, plastic coatings can be applied to the outside surfaces 1520 of the epoxy layer, and clamps and other fixtures can be attached to the outside surfaces 1520 with minimal effect on light transmission through the waveguide 1500 . One also could use a waveguide formed from polycarbonate (which has an index of refraction of 1.58) with an outer coating of epoxy (which has an index of refraction of 1.4). Alternatively, one could use a waveguide having a glass core and an outer coating having a lower index of refraction.
As shown in FIGS. 16A-C, a waveguide 1600 may have a pinched end that acts as a collector element 1605 . The collector element 1605 increases the acceptance angle (α) of the waveguide 1600 and thereby increases light collection efficiency. The end of the waveguide 1600 may be pinched in two dimensions to form an essentially trapezoidally shaped collector element 1605 . The collector element 1605 may be formed on the end of a waveguide 1600 having a rectangular or round cross-section.
For example, FIG. 16A shows a waveguide 1610 without a pinched end. If the critical angle (θ c ) of the waveguide is 45°, the acceptance angle (α) will also be 45°. Light 1615 from a light source 1620 entering the waveguide 1610 at an angle greater than 45° will exit the waveguide 1610 rather than being reflected at the outer surface 1625 . A waveguide 1600 having a pinched end, as shown in FIG. 16B, may have an acceptance angle (α) greater than the critical angle (θ c ). Assuming θ c =45° and the inclined walls 1630 of the waveguide are inclined at an angle of 5° on each side, then the acceptance angle (α) will be 50°. As shown in FIG. 16C, the pinched end of the waveguide 1600 may be formed so that an excess of material at the tip of the waveguide 1600 bulges outward to form a lens 1635 with a desired focal length. The lens 1635 focuses received light, further increasing the acceptance angle of the waveguide 1600 .
The waveguides may be formed as a set of standard components that may be easily interconnected and used as building blocks for different applications. For example, FIG. 17A shows waveguides 1700 and 1705 having integrated installation elements, such as snaps 1710 and detents 1715 . Snaps 1710 can be formed during the injection molding of the waveguide 1700 and provide a convenient means for securing the waveguide 1700 within the vehicle. The snaps are sized and angled to minimize light loss through the snap. For example, the snap may form a 60° angle with the waveguide (toward the direction that light is travelling through the waveguide). The vehicle may have brackets to receive the snaps 1710 or a screw may be inserted into a snap 1710 to secure the waveguide to a mounting surface. The detents 1715 enable the waveguide 1700 to be securely connected to another waveguide 1705 having an integrated claw structure 1720 . Each waveguide may be formed with a detent 1715 at one end and a claw structure 1720 at the other.
FIG. 17B shows waveguides with integrated connection elements. A waveguide 1740 may have a key 1745 formed at one end. The key 1745 is configured to mate with a socket 1750 of another waveguide 1755 . These connection elements may cause a loss of approximately 4% at the interface, however, the connection elements increase the ease with which waveguide components can be installed. Index-matched epoxy or fluid may be used at the interface to secure the connection and reduce losses.
In addition to the installation and connection elements, the waveguide 1700 widens at one end into an output element 1725 having a convex curved surface 1730 . The curved surface 1730 of the output element 1725 essentially acts as a lens to provide a desired light output characteristic. The output element 1725 may form an illumination element for the vehicle, e.g., a courtesy light in the door of a vehicle. A portion of the widened waveguide end may be eliminated, leaving an air gap 1735 , while maintaining desired output characteristics. The air gap 1735 decreases the weight and cost of the waveguide 1700 .
Another configuration for an output element is shown in FIG. 18. A waveguide 1800 has a bend 1805 that is configured to allow a portion of the light travelling in the waveguide to escape at the bend 1805 . A lens 1810 may be used to focus the light to form a desired beam pattern. The amount of light released at the bend 1805 can be controlled by determining the inner radius (r) of curvature of the bend 1805 relative to the width (w) of the waveguide 1800 . For example, a bend with a inner bend radius to waveguide width ratio (r/w) of 3:1 will lose less than 5% of the light in the bend. A bend ratio of 1:1 will result in a loss of approximately 30-35%, and a bend ratio of 0.1:1 will result in a loss of approximately 65-70%. Not all of the light released at the bend enters the lens, however the amount of light entering the lens will be proportional to the amount of light released at the bend.
An optical manifold 1900 , as shown in FIGS. 19A and 19B, is another useful building block for a DLS. Light enters the optical manifold 1900 through one or more inputs 1905 and is split to one or more of the output arms 1910 . Alternatively, light may enter through one or more output arms 1910 and exit through the inputs 1905 . The output arms 1910 may branch off at multiple points from the optical manifold in multiple directions to direct light to other subsystems of the DLS in various locations within the vehicle. The size of the output arms 1910 and their locations determines the proportion of the light input to the manifold that is split to each arm.
As shown in FIG. 19B, the optical manifold 1900 may include integrated output elements 1915 . The output element 1915 may be lens-like structures that provide lighting functions within the vehicle, such as a reading lights or dashboard lights. The manifold 1900 may have multiple input 1905 and output arms 1910 and a portion 1920 where light from the various inputs is combined. Each input and output may use colored filters to achieve desired lighting effects.
Other embodiments are within the scope of the following claims.
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An optical waveguide for illuminating the interior of a cup holder in a vehicle is disclosed. The waveguide includes a piece of solid material having a ring portion sized and shaped to be received within a cup holder and configured to release light into the cup holder. An input face receives light from a light source. An input portion extends between the input face and the ring portion. The input portion confines light through internal reflection to direct light from the input face to the ring portion.
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The present invention relates to amusement devices, and in particular to amusement devices which use circular discs or spherical balls as play objects.
BACKGROUND OF THE INVENTION
Amusement devices wherein a circular disc or ball is projected into a playing field are well known in the art. Pinball machines and the like have spring operated launch mechanisms for injecting a ball into a playing field. A user of such a device can vary the speed of a ball by varying the compression applied to the spring of a launching mechanism. Although such mechanisms permit a player to vary the speed of the ball, they do not permit the player to observe the speed of the ball in motion, and adjust the speed prior to injecting it into the playing field.
SUMMARY OF THE INVENTION
Briefly, the present invention is embodied in an amusement device in which objects, typically circular discs or spherical balls, are projected into a playing field.
In accordance with the present invention, an outer track forming a loop surrounds the playing field, and is adapted to retain one or more play objects in motion around the outer track. The invention further includes a means for adjustably accelerating the play object within the track to a desired speed, and a means for directing a moving play object from the track into the play field.
In a preferred embodiment, the means for accelerating a play object include a motor for which the speed can be adjusted, the output shaft of which is connected to a drive wheel having an elastomeric outer surface. Where the play object is a circular disc of a given diameter or a sphere of a given diameter, the outer surface of the drive wheel is spaced a distance from the outer surface of the track which is not greater than the given diameter of the play object.
The invention also includes a means for deflecting a play object which is moving along the track, into the play field. The player of a game embodying the present invention can, therefore, affect the outcome of the game by adjusting the speed of the play object before it is deflected into the play field.
BRIEF DESCRIPTION OF THE DRAWINGS
A better understanding of the present invention can be had after a reading of the following detailed description taken in conjunction with the drawings wherein:
FIG. 1 is an isometric view of an amusement device embodying the present invention;
FIG. 2 is an enlarged view of the play field and track of the amusement device shown in FIG. 1 with portions thereof shown in phantom lines;
FIG. 3 is a fragmentary cross-sectional view of the amusement device shown in FIG. 1, taken through lines 3--3 of FIG. 2;
FIG. 4 is a rear view of an alternate embodiment for mounting of a motor and drive wheel in an amusement device similar to that shown in FIG. 1;
FIG. 5 is an enlarged cross-sectional view of an alternate embodiment for a mechanism having a deflecting piston to deflect a play object from the track and into the play field of an amusement device similar to that shown in FIG. 1 with the piston shown in the withdrawn position;
FIG. 6 is an enlarged fragmentary cross-sectional view of the mechanism shown in FIG. 5 for deflecting a play object from the track with the piston shown in the extended position;
FIG. 7 is an enlarged fragmentary top view of the mechanism shown in FIG. 5 for deflecting a play object from the track; and
FIG. 8 is a block diagram of the circuit for the device shown in FIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIGS. 1 and 2, an amusement device 10 has a stand 12, a play field 14, a control panel 16, a time and score readout 18, and a coin acceptor 20. The device may also have a dispenser 21 for dispensing redemption tickets or, in the alternative, tokens or capsules or the like. Surrounding the play field 14 is a track 22 which is depicted in FIGS. 1 and 2 as being circular. Those skilled in the art will appreciate that the track 22 can be elliptical or any shape which does not have corners or sharp turns which will slow the movement of a play object along a track 22.
In the preferred embodiment, the amusement device 10 is adapted to utilize a plurality of circular discs as the play objects 24. The circular discs 24 may be quarters or other coins which are received in the acceptor 20, slide along a track 25, and enter through a port 26 positioned inside of the track 22. The play field 14 may be oriented so as to be nearly horizontal, or vertical, or at an intermediate angle as shown in FIG. 1. The play field should not be horizontal because the force of gravity is a factor in causing the play objects to move across the play field to an exit or collector at the lowest elevation thereof as described below. If a coin, such as a quarter, is to be used as the play object 24, the coin acceptor 20 and the track leading to the port 26, and from the port 26 into the track 22, should be oriented such that the force of gravity will draw the coin through the track 25 to the port 26 and into the track 22.
Referring to FIG. 2, the playing field 14 has a substantially planar back panel 28 upon which a plurality of parallel partitions 30--30 are positioned and which are spaced apart a distance which is a little greater than the diameter of the play object 24. The play field also includes a plurality of obstacles 34 and planar surfaces 36 which are perpendicular to the back panel 28 of the play field 14. The planar surfaces 36 and the obstacles 34 are adapted to be stricken by moving play objects 24. It is the intent of a player of the amusement device 10 to direct rapidly moving play objects 24 into the play field 14 from the outer track 22, and to cause the play objects 24 to encounter the obstacles 34 and surfaces 36 and to fall into desired channels formed by the partitions 30--30. The play objects may be collected and retained by solenoid operated retractable stops 38, and the number of play objects 24 which pass between parallel partitions 30--30 may be counted by detection devices 40 positioned within the channel. The retractable stops 38 can be withdrawn by the computer 43 to release all play objects 25 collected in the channels between partitions 30--30 at the conclusion of the game or prior to commencement of a new game. As shown in FIG. 8, covering the play field 14 and the surrounding track 22 is a transparent planar lens 42 which is positioned substantially parallel to the lower panel 28, and sufficiently distant from the lower panel 28 so as to not interfere with the movement of a play object 24 within the track 22, or within the play field 14.
Referring to FIGS. 2 and 8, the obstacles 34 and the surfaces 36 may also incorporate electronic switches 41 which are actuated when a play object 24 has contacted the associated obstacle 34 or surface 36. The signals from the switches 41 on the obstacles 34, and surfaces 36 and from the detection devices 40 are tabulated by a computer 43 and displayed on the readout 18 as a score which reflects the players performance of the amusement device 10.
Referring further to FIGS. 2 and 3, the track 22 has an outer surface 50 against which the play objects 24 can roll, and an inner wall 52. The inner wall 52 is spaced a distance from the outer surface 50 which is greater than the diameter of the play objects 24 such that the play objects 24 may readily roll around the outer surface 50 of the outer track 22 without contact against the inner wall 52.
One channel 46 formed by the partitions 30--30 also having a solenoid operated retractable stop 44 is positioned near an opening in the inner wall 52 of the track 22. Play objects 24 which fall within channels 46 will re-enter the outer track 22 when the retractable stop 44 is withdrawn in response to signal received from a switch 47 on the control panel 16. The play field 14 further includes an exit port 48 positioned at the lowest point on the play field 14 through which play objects 24, which have completed their circuit through the play field 14, may be withdrawn and collected in a coin box or the like, not shown.
To accelerate a play object 24 around the loop of the track 22, a means for accelerating the play object 24 is provided at a low portion of the track 22. The means for accelerating includes a variable speed electric motor 54 the output shaft 56 of which is generally perpendicular to the back panel 28 and extends through a hole 57 in the back panel 28. Attached to the output shaft 56 is a wheel 58 having an elastomeric outer surface 60. The electric motor 54 is attached by any suitable means such as screws, not shown, to a mounting plate 62 which extends rearward of the motor 54, and the rearward end of the mounting plate 62 is attached to a support arm 64 by a transverse hinge 66. The support arm 64 is attached to a substantially planar mounting member 68 which depends perpendicularly below the under surface of the back panel 28, such that the motor 54 and the wheel 58 pivot around the hinge 66. The outer surface 60 of the wheel 58 will move toward or away from the outer surface 50 of the outer track 22. A spring 70 connected between the mounting member 68 and the mounting plate 62 is adapted to draw the mounting plate 62 toward the mounting member 68 and, therefore, urge the wheel 58 toward the outer surface 50 of the track 22. A threaded adjusting screw 72 is fitted into a complementary threaded transverse hole 74 in the mounting member 68 positioned adjacent the motor 54, for adjusting the distance of the surface 60 of the wheel 58 from the outer surface 50 of the track 22. The mounting plate 62 with the motor 54 attached thereto will be drawn by the spring 70 to contact the distal end of the adjusting screw 72. The adjusting screw 72 should be set such that the distance between the outer surface 60 of the wheel 58 and the outer surface 50 of the track 22 is a little less than the diameter of a play object 24.
A play object 24 which enters the track 22 from a port 26 will be drawn by gravity to the lower portion of the track 22 where the motor 54 is positioned. The play object 24 will then move under the rotating wheel 58 driven by the motor 54 and the elastomeric surface 60 of the wheel 58 will apply rotational movement to the play object 24. The play object 24 will be immediately accelerated and caused to move around the track 22 at a speed which is directly proportional to the speed of the motor 54. Typically, the play objects may be caused to move around the track 22 at a relatively slow speed, for example, one revolution around the track per second, to a relatively fast speed whereby a play object may traverse twenty or more revolutions of the track 22 in one second.
Referring to FIG. 8, the motor 54 may be a DC or AC and the speed of the motor controlled by an appropriate speed control circuit 75 as are well known in the art. The speed control circuit 75 includes a control element having a rotatable shaft, not shown, extending through the control panel 16 with a rotatable knob 78 attached at the distal end thereof. Rotation of the knob 78 will adjust the speed of the motor 54, and the speed of play objects 24 which are accelerated by the motor 54 and move around the track 22.
The control panel 16 can have a pair of buttons, not shown, of one of the buttons adapted to cause the speed of the electric motor to increase when it is depressed, and the other of the buttons adapted to cause the speed of the electric motor to decrease when it is depressed.
Referring to FIG. 2, a play object 24, which is rotating around the loop of the track 22, can be deflected into the playing field 14 by a deflecting means such as a deflector arm 80 having an arcuate inner surface 81. The deflector arm 80 is fitted into a gap 82 through the inner wall 52 of the track 22 forming a passage between the track 22 and the play field 14. The deflector arm 80 is pivoted about a transverse pin 83 at one end thereof and moves from a first position wherein the arm 80 does not extend into the track 22 as shown in solid lines in FIG. 2 to a second position wherein the arm 80 extends against the outer wall 50 of the track 22 as shown in phantom lines in FIG. 2. The arm 80 is retained from extending into the track 22 by a spring 86 and drawn into the position shown in phantom lines in FIG. 2 by a solenoid 84, shown in FIG. 8, which is energized by depressing a "snatch" button 85 on the control panel 16.
Upon depressing the "snatch" button 85 on the control panel 16, the solenoid 84 will cause the deflector arm 80 to rotate about the pin 83 to the position shown in phantom lines in FIG. 2 and thereby opening the passage between the track 22 and the play field 14. When the deflector arm 80 is rotated to the position shown in phantom lines in FIG. 2, a play object 24 moving within the track 22 will encounter the arcuate surface 81 of the deflector arm 80 and be deflected and pass through a gap 82 and enter the playing field 14.
Referring to FIGS. 2 and 8, to avoid the deflector arm 80 contacting a moving playing object 24 while the arm 80 is pivoting to its deflecting orientation, the invention also includes a detection means 88 in the track 22 near the deflector arm 80 positioned such that it will be actuated after a moving play object has passed the detection means 88. Where the play object is a metallic coin, the detection means 88 consists of two adjacent electrical contacts 88A, 88B embedded into the lower panel 28. When a metallic coin passes over the contacts of the detection means 88, the resistance between the contacts is reduced, sending a signal to the computer 43 that a coin has passed by the deflector arm 80. When the "snatch" button 85 is depressed, the computer will direct power to the solenoid 84 immediately after the detection device 88 indicates a coin has passed the deflector arm 80, thereby preventing a jamming of the deflector arm 80 against a moving play object. Once the solenoid 84 is activated, power will continue to be applied to the solenoid 84 until the "snatch" button is released by the player enabling the player to cause one or more play objects moving in the track 22 to be deflected into the play field 14.
A clock 89, or the like, may also be incorporated into the amusement device 10 such that a player will forfeit his game or suffer a penalty if he does not cause the play objects to be deflected into the play field 14 within a predetermined period of time.
Referring to FIG. 8, the game is initiated when a play object 24, such as a coin, is deposited in the receptor 20. The receptor 20 also includes a detection device 91 which signals the computer 43 that the game has started and releases all accumulated play objects 24 retained by stops 38. The computer 43 also starts the clock 89 and initiates power to the speed control 75 and motor 54. The play object 24 then passes through port 26 and enters the track 22 where it can be accelerated by the rotating wheel 58 and causing the play object 24 to rotate around the track 22. The player can adjust the speed at which the play object 24 moves around the track 22 by adjusting the control knob 78, and thereby regulating the speed of the motor 54 and the wheel 58. When the player is satisfied that the play object 24 is moving at the desired speed, he may depress and hold down the snatch button 16. After the play object 24 thereafter passes across the detector 88, the solenoid 84 will be actuated and the arm 80 pivoted from the solid line position shown in FIG. 2 to the phantom line position. In the meantime, the play object 24 will continue its movement around the track 22, pass under the wheel 58, and eventually encounter the arcuate surface 81 of the arm 80 and be deflected into the playing field 14.
Within the playing field 14, the play object 24 may hit various detectors 41 and slide between partitions 30--30 so as to actuate switches 40. Signals received from the switches will be tabulated by the computer 43 and the total score shown in the readout 18.
In the event the player fails to depress the snatch button 18 within a certain time, the clock 89 will notify the computer 43 to automatically operate the solenoid 84 and move the arm 80 to the position shown in phantom lines in FIG. 2. The switch 47 which retracts the stop 44 and allows play objects which have accumulated in channel 46 to re-enter the track 22 can be operated by the player. If, however, the player fails to release the stop 44 within a predetermined interval of time, as determined by the clock 89, the computer 43 will then withdraw the stop and release all play objects 24 collected in channel 46, and thereby set a maximum playing time of the game. At the end of the game, the dispenser 21 can be signalled to emit tickets, tokens or other rewards commensurate the the player's skill as determined by the readout 18.
An alternate embodiment of a mounting for a motor is shown in FIG. 4. In this embodiment, a motor 90 is attached to a first end 92 of a pivot arm 94 by a plurality of bolts or the like, not shown. The pivot arm 94 rotates about a pivot pin 96 at a second end 97 thereof and the axis of the pivot pin 96 is parallel to the axis of the drive shaft of the motor 90. The pin extends into a transverse hole, not shown, which passes perpendicularly into the back panel 28. Adjacent the pivot arm 94 and spaced a short distance therefrom is a reference plate 98 which depends from the under surface of the back panel 28. A spring 100 is joined at one end to the reference plate 98 and at the other end to the motor end 92 of the pivot arm 94 and the spring 100 draws the motor end 92 thereof toward the reference plate 98. An adjustable screw 102 extends through a threaded hole, not shown, in the reference plate 98 and the distal end of the adjusting screw 102 abuts against the motor end 92 of the pivot arm 94. As in the prior embodiment, rotation of the screw 102 will result in the wheel 104 attached to the end of the shaft of the motor 90 moving toward or away from the outer surface 50 of the track 22.
Referring to FIGS. 5, 6 and 7 an alternate embodiment of a means for deflecting a playing object is shown. In this embodiment, a wedge shaped pin 110 having a ramp surface 111 is slidably received into sleeve 112 which depends below the under surface of the back panel 28. When the pin 110 extends outward from the sleeve 112, it will project along the outer surface 50 of the track 22, and a playing object 24 moving along the track 22 will be deflected along the ramp surface 111 of the pin 110. A gap 113 in the inner wall 52 separating the track 22 from the play field is sized and positioned to permit play objects 24 deflected by the ramp of the pin 110 to enter the play field 14. A solenoid 114 and a spring 115, or other mechanism known in the art, may be used to control movement of the pin from its retracted position as shown in FIG. 5 or to its extended position as shown in FIG. 6.
In the foregoing embodiments, the play object 24 is depicted as being a circular disc, or a coin, however, spherically shaped paying objects, or egg shaped playing objects may also be used with the present invention. Furthermore, although the play objects 24 are depicted as constructed of rigid material such as metal, it is not necessary that the playing objects be rigid. The playing objects could readily be a plurality of flexible balls. Where the playing objects are flexible balls, the outer surface 60 of the wheel 58 need not be elastomeric, but may be steel without detracting from the effectiveness of the invention.
There is, therefore, disclosed an amusement device 10 in which a player may control the speed at which the play objects 24 move around the outer track 22, and when the player is satisfied that the play objects are moving at a desired speed, the deflecting device can be actuated and one or more play objects deflected into the play field 14.
While the present invention has been described in connection with several embodiments, it will be understood by those skilled in the art that many changes and modifications may be made within the true spirit and scope of the invention. Therefore, it is intended by the appended claims to cover all such changes and modifications which come within the true spirit and scope of the invention.
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An amusement device has an outer track forming a loop surounding a playing field, and is adapted to retain one or more play objects in motion around the outer track. An adjustable motor accelerates the play object within the track to a desired speed, and a lever directs the moving play object from the track to the play field.
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BACKGROUND/SUMMARY
[0001] Direct acting mechanical bucket (DAMB) valve actuators may be produced with no valve lash adjustment. As such, DAMB operated valves may respond quickly, however, temperature changes occurring within the engine having DAMB operated valves may cause expansion or contraction of valves resulting in changes to valve event timing. For example, a change in engine load can cause engine temperatures and pressures to increase. The increased cylinder temperature can cause exhaust valve expansion. Further, the cylinder head may also expand, and the exhaust valve expansion rate may be different from the cylinder head expansion rate because the exhaust valve and the cylinder head may be formed from different materials or because the exhaust valves are cooled differently from the cylinder head. The temperature changes in the cylinder may cause changes in valve stem length and valve diameter. As a result, valve timing changes may occur by way of a valve opening and/or closing at different times as valve temperature and cylinder head temperature change. Consequently, volumetric efficiency of the engine may change during transient engine operating conditions where valve and/or cylinder head temperatures change due to changes in engine operating conditions.
[0002] The inventors herein have recognized the above-mentioned disadvantages and have developed a method of compensating for thermal conditions during transient engine conditions, comprising: adjusting an engine air amount parameter and a cylinder residual gas amount via an engine MAP and cylinder air amount volumetric efficiency relationship in response to a rate of change of cylinder air amount; and adjusting output of an engine actuator in response to the engine air amount parameter.
[0003] By adjusting cylinder air amount and a cylinder residual gas amount via an engine manifold absolute pressure (MAP) and cylinder air amount volumetric efficiency relationship in response to a rate of change of cylinder air amount, it may be possible to account for valve temperatures that can affect engine volumetric efficiency. The change of cylinder air amount may be indicative of a valve temperature change so that cylinder air amount and cylinder residual gas may be compensated until the engine reaches an equilibrium temperature where the MAP and cylinder air amount relationship may be used without compensation.
[0004] The present description may provide several advantages. In particular, the approach can reduce vehicle emissions by providing improved engine air-fuel control. Further, the approach may also reduce engine misfires and/or slow combustion events which also may increase engine emissions. Further still, the approach provides a simple way to compensate cylinder air amount and cylinder exhaust residuals during transient engine operating conditions.
[0005] The above advantages and other advantages, and features of the present description will be readily apparent from the following Detailed Description when taken alone or in connection with the accompanying drawings.
[0006] It should be understood that the summary above is provided to introduce in simplified form a selection of concepts that are further described in the detailed description. It is not meant to identify key or essential features of the claimed subject matter, the scope of which is defined uniquely by the claims that follow the detailed description. Furthermore, the claimed subject matter is not limited to implementations that solve any disadvantages noted above or in any part of this disclosure.
BRIEF DESCRIPTION OF THE FIGURES
[0007] FIG. 1 shows a schematic depiction of an engine;
[0008] FIG. 2 shows a plot of simulated error on cylinder air amount, residual gas, and blow-through air caused by valve temperature related to transient engine operating conditions;
[0009] FIG. 3 shows a high level block diagram of a method for compensating valve temperature;
[0010] FIG. 4 shows a plot illustrating compensation for cylinder volumetric efficiency impacting cylinder air amount and cylinder exhaust gas dilution as determine from MAP;
[0011] FIG. 5 shows a plot illustrating compensation for cylinder volumetric efficiency impacting inferred manifold pressure as determined from MAF; and
[0012] FIG. 6 shows a flowchart of an example method compensating for exhaust valve timing changes during transient conditions.
DETAILED DESCRIPTION
[0013] The present description is directed to adjusting cylinder air amount and cylinder residual gas amount of a cylinder of an engine. FIG. 1 shows one example system for adjusting cylinder air amount of a cylinder. In some examples, the system may include a turbocharger with a spark ignited mixture of air and gasoline, alcohol, or a mixture of gasoline and alcohol. However, in other examples, the engine may be a compression ignition engine, such as a diesel engine. FIG. 2 shows a simulated example plot of curves that are the basis for compensating cylinder air amount and cylinder residual amount.
[0014] FIG. 3 shows an example method for adjusting cylinder air amount. Visual examples of how cylinder air amount, MAP, and cylinder residual amount are adjusting according to the method disclosed herein are shown in FIGS. 4-5 . A flowchart of a method for adjusting cylinder air amount and cylinder residual gas amount is shown in FIG. 6 .
[0015] Referring to FIG. 1 , internal combustion engine 10 , comprising a plurality of cylinders, one cylinder of which is shown in FIG. 1 , is controlled by electronic engine controller 12 . Engine 10 includes combustion chamber 30 and cylinder walls 32 with piston 36 positioned therein and connected to crankshaft 40 . Combustion chamber 30 is shown communicating with intake manifold 44 and exhaust manifold 48 via respective intake valve 52 and exhaust valve 54 . Each intake and exhaust valve may be operated by an intake cam 51 and an exhaust cam 53 . Alternatively, one or more of the intake and exhaust valves may be operated by an electromechanically controlled valve coil and armature assembly. The position of intake cam 51 may be determined by intake cam sensor 55 . The position of exhaust cam 53 may be determined by exhaust cam sensor 57 .
[0016] Fuel injector 66 is shown positioned to inject fuel directly into combustion chamber 30 , which is known to those skilled in the art as direct injection. Alternatively, fuel may be injected to an intake port, which is known to those skilled in the art as port injection. Fuel injector 66 delivers liquid fuel in proportion to the pulse width of signal FPW from controller 12 . Fuel is delivered to fuel injector 66 by a fuel system (not shown) including a fuel tank, fuel pump, and fuel rail (not shown). Fuel injector 66 is supplied operating current from driver 68 which responds to controller 12 . In addition, intake manifold 44 is shown communicating with optional electronic throttle 62 which adjusts a position of throttle plate 64 to control air flow from intake boost chamber 46 .
[0017] Exhaust gases spin turbocharger turbine 164 which is coupled to turbocharger compressor 162 via shaft 161 . Compressor 162 draws air from air intake 42 to supply boost chamber 46 . Thus, air pressure in intake manifold 44 may be elevated to a pressure greater than atmospheric pressure. Consequently, engine 10 may output more power than a normally aspirated engine.
[0018] Distributorless ignition system 88 provides an ignition spark to combustion chamber 30 via spark plug 92 in response to controller 12 . Ignition system 88 may provide a single or multiple sparks to each cylinder during each cylinder cycle. Further, the timing of spark provided via ignition system 88 may be advanced or retarded relative to crankshaft timing in response to engine operating conditions.
[0019] Universal Exhaust Gas Oxygen (UEGO) sensor 126 is shown coupled to exhaust manifold 48 upstream of exhaust gas after treatment device 70 . Alternatively, a two-state exhaust gas oxygen sensor may be substituted for UEGO sensor 126 . In some examples, exhaust gas after treatment device 70 is a particulate filter and/or a three-way catalyst. In other examples, exhaust gas after treatment device 70 is solely a three-way catalyst.
[0020] Exhaust gases may be routed from downstream of turbine 164 to upstream of compressor 162 via exhaust gas recirculation (EGR) valve 80 . In another example, exhaust gases may be routed from upstream of turbine 164 to downstream of compressor 162 . Further, engine combustion chamber 30 may contain residual exhaust from a prior combustion event that remains in combustion chamber during a subsequent cylinder cycle. Thus, combustion chamber 30 may include internal (e.g., exhaust gases that remain in the cylinder from one combustion event to the next) EGR and external EGR via EGR valve 80 .
[0021] Controller 12 is shown in FIG. 1 as a conventional microcomputer including: microprocessor unit 102 , input/output ports 104 , read-only memory 106 , random access memory 108 , keep alive memory 110 , and a conventional data bus. Controller 12 is shown receiving various signals from sensors coupled to engine 10 , in addition to those signals previously discussed, including: engine coolant temperature (ECT) from temperature sensor 112 coupled to cooling sleeve 114 ; a position sensor 134 coupled to an accelerator pedal 130 for sensing accelerator position adjusted by foot 132 ; a knock sensor for determining ignition of end gases (not shown); a measurement of engine manifold pressure (MAP) from pressure sensor 121 coupled to intake manifold 44 ; a measurement of boost pressure from pressure sensor 122 coupled to boost chamber 46 ; an engine position sensor from a Hall effect sensor 118 sensing crankshaft 40 position; a measurement of air mass entering the engine from sensor 120 (e.g., a hot wire air flow meter); and a measurement of throttle position from sensor 58 . Barometric pressure may also be sensed (sensor not shown) for processing by controller 12 . In a preferred aspect of the present description, engine position sensor 118 produces a predetermined number of equally spaced pulses every revolution of the crankshaft from which engine speed (RPM) can be determined.
[0022] In some embodiments, the engine may be coupled to an electric motor/battery system in a hybrid vehicle. The hybrid vehicle may have a parallel configuration, series configuration, or variation or combinations thereof. Further, in some embodiments, other engine configurations may be employed, for example a diesel engine.
[0023] During operation, each cylinder within engine 10 typically undergoes a four stroke cycle: the cycle includes the intake stroke, compression stroke, expansion stroke, and exhaust stroke. During the intake stroke, generally, the exhaust valve 54 closes and intake valve 52 opens. Air is introduced into combustion chamber 30 via intake manifold 44 , and piston 36 moves to the bottom of the cylinder so as to increase the volume within combustion chamber 30 . The position at which piston 36 is near the bottom of the cylinder and at the end of its stroke (e.g. when combustion chamber 30 is at its largest volume) is typically referred to by those of skill in the art as bottom dead center (BDC). During the compression stroke, intake valve 52 and exhaust valve 54 are closed. Piston 36 moves toward the cylinder head so as to compress the air within combustion chamber 30 . The point at which piston 36 is at the end of its stroke and closest to the cylinder head (e.g. when combustion chamber 30 is at its smallest volume) is typically referred to by those of skill in the art as top dead center (TDC). In a process hereinafter referred to as injection, fuel is introduced into the combustion chamber. In a process hereinafter referred to as ignition, the injected fuel is ignited by known ignition means such as spark plug 92 , resulting in combustion. During the expansion stroke, the expanding gases push piston 36 back to BDC. Crankshaft 40 converts piston movement into a rotational torque of the rotary shaft. Finally, during the exhaust stroke, the exhaust valve 54 opens to release the combusted air-fuel mixture to exhaust manifold 48 and the piston returns to TDC. Note that the above is described merely as an example, and that intake and exhaust valve opening and/or closing timings may vary, such as to provide positive or negative valve overlap, late intake valve closing, or various other examples.
[0024] Turbocharged and supercharged engines pressurize air entering an engine so that engine power may be increased. The pressurized air provides for an increased cylinder air charge during a cycle of the engine as compared to a naturally aspirated engine. Further, the cylinder fuel charge can be increased as the cylinder air charge is increased to increase the amount of energy produced when the fuel is combusted with the air during a cycle of the cylinder. However, during periods of valve overlap where both intake and exhaust valves of a cylinder are simultaneously open, it is possible for air to pass directly from the engine intake manifold to the engine exhaust manifold without participating in combustion within a cylinder. Air passing directly from the intake manifold to the exhaust manifold without participating in combustion may be referred to as blow-through.
[0025] Thus, the system of FIG. 1 provides for an engine system, comprising: an engine; a turbocharger coupled to the engine; and a controller including instructions for adjusting an engine air amount parameter and a cylinder residual gas amount in response to a rate of change of cylinder air amount flow during blow-through and non-blow-through engine operating conditions, the controller including further instructions for adjusting an actuator in response to the engine air amount parameter. Thus, the system provides compensation for both blow-through and non-blow-through conditions.
[0026] The engine system further comprises adjusting a residual gas amount based on the adjusted engine air amount parameter. The engine system also includes where the rate of change of cylinder air amount flow is determined from a difference between engine air flow and filtered engine air flow. The engine system further comprises additional instructions for adjusting the engine air amount parameter in response to cam timing. The engine system further comprises additional instructions for adjusting the engine air amount parameter in response to engine speed and engine load. In another example, the engine system further comprises additional instructions to determine blow-through during cylinder air flow conditions where cylinder air flow is greater than a cylinder air flow at an intersection of a maximum volumetric efficiency curve and a non-blow-through curve.
[0027] Referring now to FIG. 2 , a plot of simulated error on cylinder air amount, residual gas, and blow-through air caused by transient thermal engine operating conditions is shown. The X axis of plot 200 represents air mass amount of a cylinder per cylinder intake event or cylinder cycle. Air mass amount increases from the left side of the plot to the right side of the plot. The Y axis of plot 200 represents engine intake manifold absolute pressure (MAP) and MAP increase from the bottom of the origin of the plot in a direction of the Y axis. Vertical marker 250 represents a cylinder air amount where air blow-through occurs if cylinder air amount increases to the right of vertical marker 250 , and where air blow-through does not occur to the left of vertical marker 250 . Vertical marker 250 passes through the intersection of curves 202 and 206 which may be used to identify blow-through conditions via comparing cylinder air flow to the air flow at the intersection of curves 202 and 206
[0028] Curve 202 represents the theoretical maximum air amount (e.g., 100% volumetric efficiency) that the cylinder can hold at a given pressure at intake valve closing (IVC). Thus, the cylinder mass amount increases linearly as the cylinder pressure increases. In one example, the maximum air amount that the cylinder can hold may be characterized as a slope of a line where the slope is described as:
[0000]
Slope
=
1
(
1
-
r
pb
)
c
norm
[0000] where variable c norm accounts for physical properties of air, intake manifold temperature, and cylinder displacement. Variable r pb is an effective pushback ratio characterizing a portion of a cylinder mixture that may be pushed into the engine intake manifold from the cylinder as the piston moves in a direction toward the cylinder head while the intake valve is open. The pushback ratio may be determined as the greater of a constant multiplied by the physical ratio of cylinder volume displaced by the piston moving from bottom dead center (BDC) to the intake valve closing (IVC) point, to the total cylinder displacement volume of the cylinder and the pushback ratio computed from engine mapping as:
[0000]
1
-
1
c
norm
*
air_slope
[0000] where air_slope is the least-squares linear fit of the manifold pressure vs. trapped air amount data excluding blow-through data points.
[0029] Curve 204 represents a cylinder air amount vs. MAP volumetric efficiency relationship during cold engine operating conditions where engine and/or cylinder valve temperature are less than at nominal (e.g. steady-state) engine operating conditions. During cool conditions, cylinder valves may expand less than during conditions where the engine is operating at nominal engine temperature (e.g., 90° C.). As a result, exhaust gas residuals held in a cylinder after a compression stroke of the cylinder and into a subsequent compression stroke of the cylinder may decrease as compared to nominal engine operating conditions.
[0030] Curve 206 represents a cylinder air amount vs. MAP volumetric efficiency relationship during nominal mapped engine operating conditions that are stored in controller memory where engine temperature and cylinder valve temperature have time to stabilize. In particular, curve 206 represents steady state engine speed and load conditions.
[0031] Curve 208 represents a cylinder air amount vs MAP volumetric efficiency relationship during warm engine operating conditions where engine and/or cylinder valve temperature are greater than at nominal engine operating conditions. During warm conditions, cylinder valves may expand more than during conditions where the engine is operating at nominal engine temperature. Consequently, exhaust gas residuals held in a cylinder after an intake stroke of the cylinder and into a subsequent compression stroke of the cylinder may increase as compared to nominal engine operating conditions.
[0032] It can be seen that curve 206 exhibits a lower cylinder air amount for an equivalent MAP as compared to curve 202 for cylinder air amounts less than or to the left of vertical marker 250 . The lower cylinder air amount may be attributed to residual exhaust gases remaining in the cylinder from a previous combustion event.
[0033] The engine controller includes a function or table containing values that represent curves 206 and 202 . The engine controller may also contain curves 208 and 204 as well as curves for other engine temperatures; however, storing and retrieving additional curves can complicate, slow down, and increase the cost of the controller. In addition, relationship between the cylinder air amount and MAP represented by the curves 204 and 208 can only be observed during large transients, which makes their characterization more difficult compared to the nominal relationship described by curve 206 . Therefore, it can be beneficial to compensate curve 206 for the conditions that provide curves 204 and 208 according to the methods of FIGS. 3 and 6 . Thus, cylinder air amount and cylinder residual gas amount can be determined by interpreting curve 206 and adjusting for the engine operating conditions so as to follow curves 204 and 208 .
[0034] Two examples are provided to illustrate how valve and engine temperature affect cylinder air amount and cylinder exhaust gas residual amount. Similar relationships occur to the right of vertical marker 250 between curves 202 and 208 ; however, the distance between curve 202 and curves 204 - 208 represent different amounts of blow-through air (e.g., air that blows through a cylinder when intake manifold pressure is greater than exhaust pressure while intake and exhaust valves of a cylinder are simultaneously open).
[0035] Horizontal marker 260 represents a first constant intake manifold pressure. Horizontal marker 260 intersects curve 202 at 261 . If a vertical line is extended from 261 to the X axis, a cylinder air amount may be determined at the intersection of the vertical line and the X axis. Cylinder air amount at 261 represents a condition of 100% cylinder volumetric efficiency (e.g., the theoretical amount of air a cylinder can hold) when the engine is operated at a MAP of horizontal marker 260 and at the nominal air temperature. Cylinder air amount at 262 represents cylinder air amount at nominal engine operating conditions where the relationship between MAP and cylinder air amount is mapped. If a vertical line is extended from 262 to the X axis, cylinder air amount for nominal mapped conditions may be determined at the intersection of the vertical line and the X axis. Cylinder air amount at 263 represents cylinder air amount at warm engine operating conditions where the relationship between MAP and cylinder air amount is compensated by the methods of FIGS. 3 and 6 . If a vertical line is extended from 263 to the X axis, cylinder air amount for warm conditions may be determined at the intersection of the vertical line and the X axis.
[0036] The distance between arrows 264 represents a difference in cylinder air amount between nominal engine mapping conditions and warm engine operating conditions at MAP level 260 . In particular, when the engine is operated warm at low load conditions (warmer than steady-state operating temperatures for this condition), cylinder air amount is over estimated because cylinder air amount at nominal engine operating conditions (e.g., 262 ) is greater cylinder air amount at warm operating conditions (e.g., 263 ). Thus, cylinder air amount will be overestimated via mapped curve 206 unless compensation is provided to adjust cylinder air amount to 263 during warm engine operating conditions.
[0037] Distance 266 represents an amount of exhaust gas residuals in a cylinder during a cycle of the cylinder for warm engine operating conditions when MAP is at the level of horizontal marker 260 . The amount of exhaust gas residuals in a cylinder for warm engine operating conditions can be determined at the MAP level of 260 via subtracting the cylinder air mass at 263 of warm volumetric efficiency curve 208 of from the cylinder air mass at 261 of maximum volumetric efficiency curve 202 . Distance 268 represents an amount of exhaust gas residuals in a cylinder during a cycle of the cylinder for nominal engine operating conditions. The amount of exhaust gas residuals in a cylinder for nominal operating conditions at MAP level 260 can be determined via subtracting the cylinder air mass at 262 of nominal volumetric efficiency curve 206 from the cylinder air mass at 261 of maximum volumetric efficiency curve 202 .
[0038] Horizontal marker 280 represents a second constant MAP. Horizontal marker 280 intersects maximum volumetric efficiency curve 202 at 281 . If a vertical line is extended from 281 to the X axis, a cylinder air amount may be determined at the intersection of the vertical line and the X axis. Cylinder air amount at 281 represents a condition of 100% cylinder volumetric efficiency when the engine is operated at a MAP of horizontal marker 280 . Cylinder air amount at 282 represents cylinder air amount at cold engine operating conditions where the relationship between MAP and cylinder air amount is compensated by the methods of FIGS. 3 and 6 . If a vertical line is extended from 282 to the X axis, cylinder air amount for cold conditions may be determined at the intersection of the vertical line and the X axis. Cylinder air amount at 283 represents cylinder air amount at nominal engine operating conditions where the relationship between MAP and cylinder air amount is mapped. If a vertical line is extended from 283 to the X axis, cylinder air amount for nominal mapped conditions may be determined at the intersection of the vertical line and the X axis.
[0039] The distance between arrows 284 represents a difference in cylinder air amount between nominal engine mapping conditions and cold engine operating conditions when MAP is at 280 . In particular, when the engine is operated cold at medium load conditions, cylinder air amount is under estimated because cylinder air amount at nominal engine operating conditions (e.g., 283 ) is less than cylinder air amount at cold operating conditions (e.g., 282 ). Thus, cylinder air amount will be underestimated via curve 206 unless compensation is provided to adjust cylinder air amount to 283 during cold engine operating conditions.
[0040] Distance 286 represents an amount of exhaust gas residuals in a cylinder during a cycle of the cylinder for nominal engine operating conditions when MAP is at the level of horizontal marker 280 . The amount of exhaust gas residuals in a cylinder for nominal engine operating conditions can be determined via subtracting the cylinder air mass at 283 of nominal volumetric efficiency curve 206 from the cylinder air mass at 281 of maximum volumetric efficiency curve 202 . Distance 288 represents an amount of exhaust gas residuals in a cylinder during a cycle of the cylinder for cold engine operating conditions. The amount of exhaust gas residuals in a cylinder for cold operating conditions can be determined via subtracting the cylinder air mass at 282 of cold volumetric efficiency curve 204 from the cylinder air mass at 281 of nominal volumetric efficiency curve 202 .
[0041] Thus, it can be observed from FIG. 2 that when cylinder air amount is estimated according to curve 202 , cylinder air amount will be underestimated when the engine and valves are cold if compensation is not provided. Further, it can be observed that the exhaust gas residual amount estimated in a cylinder will be overestimated when the engine and valves are cold if compensation is not provided. Similarly, cylinder air amount will be overestimated when the engine and valves are warmer than nominal conditions if compensation is not provided. Additionally, the exhaust gas residual amount estimated in a cylinder will be underestimated when the engine and valves are warmer than nominal conditions if compensation is not provided.
[0042] Referring now to FIG. 3 , a high level block diagram of a method for compensating valve temperature is shown. The method of FIG. 3 may be implemented via instructions in a controller of a system as shown in FIG. 1 .
[0043] At 302 , method 300 judges whether or not a condition of blow-through exits. In one example, method 300 may judge that blow-through exists when air flow into a cylinder exceeds a cylinder air amount described by a maximum cylinder volumetric efficiency curve (e.g., to the right of vertical marker 250 of FIG. 2 ). If a blow-through estimate is determined to be less than or equal to zero (e.g., a non-blow-through condition), a value of one is output at 302 . Otherwise, if the blow-through estimate is determined to be greater than zero, a value of zero is output at 302 .
[0044] At 304 , a base non-blow-through gain is determined. The base gain amount may be empirically determined and stored in a table that is indexed by engine speed, engine load, and engine temperature. The output of 304 and 302 are multiplied at junction 306 .
[0045] At 308 , engine air flow and engine speed are used to determine air flow rate. In one example, air flow rate is determined by integrating engine air flow during a selected engine rotation interval (e.g., one cylinder cycle) and multiplying the result by an engine speed factor (e.g., conversion from engine speed to cylinder strokes) to determine cylinder air amount per cylinder stroke. In other examples, an air flow rate in other units may be provided. An air flow rate is directed from 308 to 310 .
[0046] At 310 , method 300 filters the air flow rate output of 308 . In one example, a low pass filter with a higher cut-off frequency may be applied to the air flow rate. The filtered air flow rate is directed to summing junction 314 and low pass filter 312 . Low pass filter 312 may be a first-order or higher order filter. Low pass filter 312 may include an adjustable time constant that is based on engine operating conditions. For example, low pass filter 312 may have a first time constant at lower engine temperatures and a second time constant for higher engine temperatures.
[0047] At 314 , method 300 subtracts the low pass filtered air flow rate from the non-low pass filtered air flow rate. Subtracting the low pass filtered air flow rate from the air flow rate provides a rate of change of air flow rate. The rate of change in the air flow rate is directed to 316 .
[0048] At 318 , engine speed indexes a function of empirically determined gain that accounts for an engine speed dependency in the air amount adjustment for changes in engine temperature. The output of 318 is directed to 316 .
[0049] At 320 , engine speed indexes a function of empirically determined gain that accounts for engine valve overlap relative to top-dead-center exhaust stroke. The output of 320 is directed to 316 .
[0050] At 322 , engine speed indexes a function of empirically determined gain that accounts for engine valve overlap duration. The output of 322 is directed to 316 .
[0051] At 324 , engine speed indexes a function of empirically determined gain that accounts for an engine load dependency in the air amount adjustment for changes in engine temperature. The output of 324 is directed to 316 .
[0052] At 316 , the outputs of 306 , 314 , 318 , 320 , 322 , and 324 are multiplied together to provide a non-blow-through volumetric efficiency correction. Thus, if the output of 302 is a value of one, a value other than zero may be output from 316 . If the output of 302 is zero, non-blow-though compensation is not provided. In this way, the non-blow-through volumetric efficiency can be zeroed when blow-through occurs.
[0053] For the blow-through volumetric efficiency correction, the blow-through air estimate is passed directly to 334 . The blow-though air may be determined as described above.
[0054] At 326 , engine air flow and engine speed are used to determine air flow rate as described at 308 . An air flow rate is directed from 326 to 328 . At 328 , method 300 filters the air flow rate output of 326 as described at 310 . However, a different filter and/or filter time constant may be provided at 328 . The filtered air flow rate is directed to summing junction 332 and low pass filter 330 . Low pass filter 330 may be a first-order or higher order filter as described at 312 . However, low pass filter 330 may have a time constant that is different from the time constant of low pass filter 312 .
[0055] At 332 , method 300 subtracts the low pass filtered air flow rate from the non-low pass filtered air flow rate. Subtracting the low pass filtered air flow rate from the air flow rate provides a rate of change of air flow rate. The rate of change in the air flow rate is directed to 334 .
[0056] At 336 , engine speed indexes a function of empirically determined gain that accounts for an engine speed dependency in the air amount adjustment for changes in engine temperature. The values at 336 may be different than the values at 318 . The output of 336 is directed to 334 .
[0057] At 338 , engine speed indexes a function of empirically determined gain that accounts for engine valve overlap. The values at 338 may be different than the values at 320 . The output of 338 is directed to 334 .
[0058] At 340 , engine speed indexes a function of empirically determined gain that accounts for engine valve overlap duration. The values at 340 may be different than the values at 322 . The output of 340 is directed to 334 .
[0059] At 342 , engine load indexes a function of empirically determined gain that accounts for an engine load dependency in the air amount adjustment for changes in engine temperature. The values at 342 may be different than the values at 324 . The output of 342 is directed to 334 .
[0060] At 334 , the blow-through air estimate and the outputs of 332 , 336 , 338 , 340 , and 342 are multiplied together to provide a blow-through volumetric efficiency correction. Thus, if the blow-through amount is non-zero, a value other than zero may be output from 334 . If the blow-through amount is zero, blow-though compensation is not provided. In this way, the blow-through volumetric efficiency correction can be output when blow-through occurs.
[0061] At 350 , the blow-through volumetric efficiency correction and the non-blow-through volumetric efficiency correction amounts are summed. However, because of the way method 300 is structured, either the blow-through compensation or the non-blow-through compensation will be zeroed out so that only blow-through or non-blow-through compensation is provided. The output of 350 is directed to an engine air amount parameter compensation method where an engine air amount parameter (e.g., cylinder air amount or blow-through air amount) and cylinder residual exhaust gases are determined via curves similar to curves 202 and 206 of FIG. 2 . In particular, if MAP is known, cylinder air amount is determined by indexing a function similar to that of FIG. 2 with MAP and the cylinder air amount value output is then added with the compensation output of 350 . The exhaust gas residual is determined by subtracting the cylinder air amount from the maximum cylinder air amount at a MAP value as described with regard to FIG. 2 via curve 202 . In this way, the cylinder air amount and residual exhaust amount may be determined. Further, the cylinder air amount reduction or increase is phased out as time increases from the transient condition. The phase out of cylinder air amount change emulates conditions of a valve thermal transient.
[0062] In other examples, where cylinder air mass is measured, MAP may be determined via indexing a table or function similar to FIG. 2 which outputs MAP for the determined cylinder air amount. The residual gas amount may be determined as previously described.
[0063] Referring now to FIG. 4 , a plot illustrating thermal compensation for cylinder volumetric efficiency impacting cylinder air amount and cylinder exhaust gas dilution is shown. The method described herein is executable via instructions of a controller in a system such as in FIG. 1 and useful for systems that measure mass air flow and is included in the method of FIG. 6 .
[0064] The X axis represents cylinder air amount and cylinder air amount increases from the left side of the plot to the right side of the plot. The Y axis represents MAP and MAP increases from the X axis in the direction of the Y axis arrow. Vertical marker 450 indicates where air blow-through can occur. Specifically, blow-through can occur when cylinder air flow is greater than or to the right of the level indicated by vertical marker 450 . Blow-thorough is not present during cylinder air flows that are to the left of vertical marker 450 .
[0065] In the example of FIG. 4 , volumetric efficiency compensation for valve temperature changes during a load change from a lower load to a higher load where valve temperature increases is shown. In this example, the cylinder air amount increases due to compensation for increasing valve temperature.
[0066] Further in this example, cylinder air amount increases from a low level to the level shown by vertical marker 404 . Vertical marker 404 represents a mapped base cylinder air amount that is uncompensated and determined via a MAP sensor, for example. Cylinder air amount may be estimated at a level shown by vertical marker 404 by indexing a table or function via MAP at the level of 402 to output cylinder air amount at the level 404 according to curve 430 (e.g. a mapped non-blow-through curve describing cylinder volumetric efficiency based on MAP and cylinder air amount). The base estimated cylinder exhaust gas dilution is determined as the difference between the value of curve 430 at 404 and the value of curve 431 at 408 , where curve 431 represents the maximum level or theoretical cylinder volumetric efficiency. The base estimated cylinder exhaust gas dilution is indicated by arrow 422 .
[0067] The volumetric efficiency compensation described in FIGS. 3 and 6 is added to the cylinder air amount represented by vertical marker 404 to provide compensated cylinder air amount as indicated by vertical marker 406 . The amount of cylinder air amount compensation is represented by arrow 420 . The compensated estimated cylinder exhaust gas dilution is determined as the difference between the value of curve 430 at the intersection with vertical marker 406 and the value of curve 431 at the intersection with vertical marker 408 . The compensated estimated cylinder exhaust gas dilution is indicated by arrow 424 .
[0068] The cylinder air amount compensation shown in FIG. 4 impacts estimated MAP by providing an increased cylinder air amount for a lower MAP. Thus, the compensated cylinder air amount is determined from a base cylinder air amount as determined from MAP added to an amount of cylinder air amount compensation.
[0069] Referring now to FIG. 5 , a plot illustrating thermal compensation for cylinder volumetric efficiency impacting MAP is shown. The method described herein is executable via instructions of a controller in a system such as in FIG. 1 and useful for systems that measure MAP and is included in the method of FIG. 6 .
[0070] The X axis represents cylinder air amount and cylinder air amount increases from the left side of the plot to the right side of the plot. The Y axis represents MAP and MAP increases from the X axis in the direction of the Y axis arrow. Vertical marker 550 indicates where air blow-through can occur. Specifically, blow-through can occur when cylinder air flow is greater than or to the right of the level indicated by vertical marker 550 . Blow-thorough is not present during cylinder air flows that are to the left of vertical marker 550 .
[0071] In the example of FIG. 5 , volumetric efficiency compensation for valve temperature changes during a load change from a lower load to a higher load where valve temperature increases is shown. In this example, the cylinder air amount increases due to compensation for increasing valve temperature.
[0072] Further in this example, cylinder air amount increases from a low level to the level shown by vertical marker 508 . Vertical marker 508 represents a mapped base cylinder air amount that is uncompensated and determined via a mass air flow meter, for example. MAP may be estimated at a level shown by horizontal marker 502 by indexing a table or function to output MAP at the level of 502 based on cylinder air amount at 508 according to curve 530 (e.g. a mapped non-blow-through curve describing cylinder volumetric efficiency based on MAP and cylinder air amount). The base estimated cylinder exhaust gas dilution is determined as the difference between the value of curve 530 at 508 and the value of curve 531 at 510 , where curve 531 represents the maximum level or theoretical cylinder volumetric efficiency. The base estimated cylinder exhaust gas dilution is indicated by arrow 522 .
[0073] The volumetric efficiency compensation described in FIGS. 3 and 6 is added to the cylinder air amount represented by vertical marker 508 to compute a temporary cylinder air amount that is the basis for revising MAP. The temporary cylinder air amount is indicated by vertical marker 506 and is not a basis for adjusting the cylinder fuel amount. The amount of cylinder air amount compensation is represented by arrow 520 . MAP at the level of 504 is determined via indexing curve 530 using the temporary cylinder air amount. The compensated estimated cylinder exhaust gas dilution is determined as the difference between the value of curve 530 at the intersection with vertical marker 506 and the value of curve 531 at the intersection with vertical marker 511 . The compensated estimated cylinder exhaust gas dilution is indicated by arrow 524 .
[0074] Referring now to FIG. 6 , a method for compensating for exhaust valve timing changes during transient conditions due to thermal conditions is shown. The method of FIG. 6 is executable via instructions of a controller in a system as shown in FIG. 1 .
[0075] At 602 , method 600 determines engine operating conditions. Engine operating conditions may include but are not limited to engine speed, engine load, engine intake manifold pressure, engine air flow rate, engine temperature, and cam position. Method 600 proceeds to 604 after engine operating conditions are determined.
[0076] At 604 , method 600 judges whether cylinder air amount is based on MAP or MAF sensor inputs. If cylinder air amount is based on MAP YES is answered at 604 and method 600 proceeds to 606 . Otherwise, NO is answered at 604 and method 600 proceeds to 608 .
[0077] At 608 , method 600 determines a base cylinder air amount from a mass air flow (MAF) sensor, and MAP is determined via indexing a table or function that includes a cylinder volumetric efficiency relationship curve according to a MAP cylinder air amount relationship (e.g., curve 530 of FIG. 5 ) using cylinder air amount as determined from the MAF sensor. The table outputs a base MAP. Further, a base cylinder exhaust gas residual may be determined via subtracting a cylinder air amount determined from the cylinder volumetric efficiency relationship curve (e.g., curve 530 of FIG. 5 ) from a maximum cylinder air amount determined from a theoretical cylinder air amount curve (e.g., 531 and residual amount 524 of FIG. 5 ) at the MAP level determined from cylinder air amount. Method 600 proceeds to 610 after based values of cylinder air amount, MAP, and cylinder exhaust gas residual are determined.
[0078] At 606 , method 600 determines a base cylinder air amount from a MAP sensor via indexing a table or function that includes a cylinder volumetric efficiency relationship curve according to a MAP cylinder air amount relationship (e.g., curve 430 of FIG. 4 ) using MAP. The table outputs a base cylinder air amount. Further, a base cylinder exhaust gas residual may be determined via subtracting a cylinder air amount determined from the cylinder volumetric efficiency relationship curve from a maximum cylinder air amount determined from a theoretical cylinder air amount curve (e.g., curve 431 of FIG. 4 and residual amount 422 ) from the MAP determined from the MAP sensor. Method 600 proceeds to 610 after based values of cylinder air amount, MAP, and cylinder exhaust gas residual are determined.
[0079] At 610 , method 600 judges whether or not blow-through is present at the current engine operating conditions. In one example, blow-through may be determined when air flow into a cylinder exceeds a cylinder air amount described by a maximum cylinder volumetric efficiency curve (e.g., to the right of vertical marker 550 of FIG. 5 ). For example, if the cylinder air amount from curve 530 at a MAP level is subtracted from the maximum cylinder volumetric efficiency curve 531 for cylinder air flow at a level to the right of vertical marker 550 of FIG. 5 and the result is negative, blow-thorough may be determined. Method 300 proceeds to 614 if blow-through is not determined and the blow-through amount is set to zero. Otherwise, if the answer at 610 is yes, method 600 proceeds to 612 .
[0080] At 612 , method 600 determines the amount of blow-through. A blow-through amount may be determined via subtracting a maximum cylinder air amount at a MAP level from a cylinder air amount at the same MAP level when the cylinder air amount is greater than a cylinder air amount at an intersection of a maximum cylinder air amount curve and a volumetric efficiency curve that represents a cylinder air amount MAP relationship during mapped engine operating conditions where engine temperature and cylinder valve temperature have time to stabilize. For example, at a constant level of MAP greater than MAP at the location where vertical marker 550 intersects curve 531 in FIG. 5 , subtracting a cylinder air amount as determined from a maximum cylinder air amount curve 531 of FIG. 5 from cylinder air amount determined from curve 530 of FIG. 5 . Method 600 proceeds to 616 after the blow-through amount is determined.
[0081] At 614 , method 600 determines a base gain amount for adjusting cylinder air amount. The base gain amount may be empirically determined and stored in memory that is indexed according to engine speed and load, for example. Method 600 proceeds to 616 after the base gain amount is determined.
[0082] At 616 , method 600 determines a rate of change of engine or cylinder air flow rate. In one example, the rate of change of engine or cylinder air flow rate may be determined via subtracting a filtered value of engine or cylinder air flow rate from the engine or cylinder air flow rate. In other example, other approaches such as taking a derivative of cylinder air flow rate may also be used to determine the rate of change of engine or cylinder air flow rate. Method 600 proceeds to 618 after the rate of change of engine or cylinder air flow rate is determined.
[0083] At 618 , method 600 looks up empirically determined gain adjustments for intake and exhaust valve overlap duration, intake and exhaust valve overlap position relative to crankshaft position, engine speed, and engine load. The gain adjustments may be empirically determined and stored in table and/or functions that are indexed via intake and exhaust valve overlap duration, intake and exhaust overlap position relative to crankshaft position, engine speed and engine load. Method 600 proceeds to 620 after gain adjustments are determined at 618 .
[0084] At 620 , method 600 multiplies the base gain, blow-through amount, rate of change of engine or cylinder air flow rate, and gain adjustments from 618 to determine the volumetric efficiency correction that is to be added to the cylinder air amount. During conditions where blow-through is zero, the base gain from 614 is multiplied by the rate of change of engine or cylinder air flow rate and the gain adjustments from 618 . When blow-through is present, the blow-through amount is multiplied by the rate of change of engine or cylinder air flow rate, and the gain adjustments from 618 without using the base gain amount of 614 . Method 600 proceeds to 622 after the volumetric efficiency correction is determined.
[0085] At 622 , method 600 adjusts MAP, cylinder air amount, and cylinder residual gas amount. The cylinder air amount is adjusted via adding the volumetric efficiency correction from 620 to the cylinder air amount as determined at 606 or 608 .
[0086] MAP is adjusted for systems that sense engine air flow rate and infer MAP. In one example, MAP is adjusted as is described in the description of FIG. 5 . In particular, the cylinder air amount is first measured and then compensation is added to the cylinder air amount to account for thermal conditions. The adjusted cylinder air amount is then used to index a curve in a table or function that represents MAP versus cylinder air amount during mapped engine conditions (e.g., curve 530 of FIG. 5 ). The table or function outputs the adjusted MAP value.
[0087] Cylinder air amount is adjusted for systems that sense MAP and infer cylinder air amount. In one example, cylinder air amount is adjusted as is described in the description of FIG. 4 . In particular, MAP is measured and cylinder air amount is determined via index a curve in a table or function that represents MAP versus cylinder air amount during mapped engine conditions (e.g., curve 430 of FIG. 4 ). The table or function outputs a base cylinder air amount. The cylinder air amount compensation is determined and added to the base cylinder air amount to provide a compensated cylinder air amount.
[0088] Cylinder exhaust residual amounts may be determined as described in the description of FIGS. 4 and 5 . For example, at a MAP sensed or determined from cylinder air amount, base cylinder exhaust gas residual amount may be determined by taking a difference between a maximum cylinder air amount and a mapped cylinder air amount as determined from taking a difference between a curve representing a theoretical maximum air amount that the cylinder can hold at a given pressure at intake valve closing (IVC) (e.g., curve 431 of FIG. 4 ) and a curve representing a cylinder air amount MAP relationship during nominal mapped engine operating conditions where engine temperature and cylinder valve temperature have time to stabilize (e.g., curve 430 of FIG. 4 ).
[0089] Compensated cylinder exhaust residual amounts may be determined as described in the description of FIGS. 4 and 5 . For example, at an adjusted MAP, compensated cylinder exhaust gas residual amount may be determined by taking a difference between a maximum cylinder air amount (e.g., curve 431 of FIG. 4 ) and a mapped cylinder air amount (e.g., curve 430 of FIG. 4 ) plus cylinder air amount compensation as determined from taking a difference between a curve representing a theoretical maximum air amount that the cylinder can hold at a given pressure at intake valve closing (IVC) and a curve representing a cylinder air amount MAP relationship during nominal mapped engine operating conditions where engine temperature and cylinder valve temperature have time to stabilize. Method 600 proceeds to 624 after MAP, cylinder air amount, and cylinder residual gas amount are adjusted via the volumetric efficiency correction.
[0090] During conditions where blow-through is determined at a given MAP level, the amount of blow-through can be revised by adding the volumetric efficiency compensation (e.g, 350 of FIG. 3 ) to the air flow through the engine at the given MAP level and then subtracting the cylinder air amount described by the maximum cylinder volumetric efficiency curve at the given MAP level.
[0091] At 624 , method 600 adjusts engine actuators in response to MAP, compensated cylinder air amount, and compensated cylinder exhaust residual amount. In one example, where cylinder air amount is increased, the engine throttle position may be reduced so that a desired engine torque may be provided. For example, throttle position can be adjusted based on an empirically determined throttle map that provides a throttle position for a desired air flow rate. If the engine air flow rate increases due to thermal conditions, the throttle may be closed to reduce cylinder air amount and to provide a desired air flow rate based on the compensated cylinder air amount.
[0092] In another example, where the cylinder residual amount increases due to thermal conditions, an opening amount of an EGR valve may be decreased to compensate for the additional amount of cylinder exhaust residual. Specifically, if thermal conditions increase cylinder residuals, the EGR valve opening amount may be decreased according to the pressure across the EGR valve and the amount of increase in cylinder residuals. EGR valve flow is commonly mapped based on pressure drop across the EGR valve and position of the EGR valve so the EGR flow can be reduced proportionally to the increase in EGR flow into the cylinder. Of course, the EGR valve may be opened further when EGR flow into the cylinder decreases so as to better match actual cylinder EGR with desired cylinder EGR. Additionally, position of the EGR valve can be adjusted based on compensated MAP so that EGR flow rate more closely matches desired EGR flow rate. In other words, the flow rate through the EGR valve may be based on adjusted MAP. Additionally, intake and exhaust cam overlap can be adjusted to increase or decrease cylinder exhaust gas residual based on the compensated cylinder exhaust residual amount.
[0093] Spark timing may also be adjusted via an ignition system for compensated cylinder air amount and cylinder exhaust residuals. In particular, the spark is provided at a crankshaft angle that is based on compensated cylinder air amount and engine speed. Further, spark may be further adjusted according to a table that accounts for cylinder exhaust gas residual amount, and the table is indexed via the compensated cylinder exhaust gas residual amount so that spark is adjusted according to compensated cylinder exhaust gas residual amount.
[0094] Fuel injector injection amount may also be adjusted according to the compensated cylinder air amount. For example, if the compensated cylinder air amount increases, fuel injection amount may be increased to provide a desired engine air-fuel ratio Likewise, if the compensated cylinder air amount decreases, fuel injection amount may be decreased to provide a desired engine air-fuel ratio.
[0095] During conditions where the blow-through amount increases or decreases, blow-through may be adjusted. In one example, if a change in engine thermal conditions increases an amount of engine blow-through (e.g., when air flow into a cylinder exceeds a cylinder air amount described by a maximum cylinder volumetric efficiency curve) blow-through may be reduce via partially closing the throttle or reducing boost pressure. Method 600 proceeds to exit after engine actuators are adjusted.
[0096] Thus, the methods of FIGS. 3 and 6 provide for compensating for thermal conditions during transient engine conditions, comprising: adjusting an engine air amount parameter and a cylinder residual gas amount via an engine MAP and cylinder air amount volumetric efficiency relationship in response to a rate of change of cylinder air amount; and adjusting output of an engine actuator in response to the engine air amount parameter. The method may be particularly useful for providing compensating due to valve timing changes resulting from temperature change.
[0097] The method also includes where the engine actuator is a fuel injector, and where the engine air amount parameter is based on a curve empirically determined from a plurality of engine MAP and cylinder air amount readings. The method further includes where the engine air amount parameter is adjusted in response to a curve representing engine volumetric efficiency in a MAP versus cylinder air amount space, and where the curve accounts for residual exhaust gas. In some examples, the method includes where the engine actuator is an air inlet throttle, and further comprising adjusting a position of an EGR valve in response to the cylinder residual gas amount. The method also includes where the rate of change of cylinder air amount is determined via a difference between an air flow rate and a filtered air flow rate. The method further comprises adjusting the engine air amount parameter in response to engine cam timing. The method also includes where the engine air amount parameter is a cylinder air amount estimate and where the cylinder air amount estimate is reduced when an engine temperature transitions from a higher temperature to a lower temperature, and where the engine temperature is a temperature of a valve of a cylinder.
[0098] In another example, the methods of FIGS. 3 and 6 provide for a method compensating for thermal conditions during transient engine conditions, comprising: adjusting an engine air amount parameter and a cylinder residual gas amount during a condition of blow-through in response to a rate of change of cylinder air amount; and adjusting an output of an engine actuator in response to the engine air amount parameter. The method also includes where the condition of blow-though is estimated from to a difference between a total cylinder air mass flow curve and a maximum volumetric efficiency curve. The method also includes where the engine air amount parameter is adjusted based on a blow-through air estimate.
[0099] In one example, the method includes where the engine air amount parameter is a cylinder air amount estimate and where the cylinder air amount estimate is increased when an engine temperature transitions from a lower temperature to a higher temperature, and where the engine temperature is a temperature of a valve of a cylinder. In this way, changes due to valve temperature may be compensated. The method also includes where the engine actuator is an ignition coil, and where the output of the ignition coil is a spark timing. The method also includes where the engine actuator is a throttle, and where the output of the throttle is a position of a throttle plate. The method further comprises adjusting a blow-through amount in response to a rate of change of cylinder air amount.
[0100] As will be appreciated by one of ordinary skill in the art, the method described in FIGS. 3 and 6 may represent one or more of any number of processing strategies such as event-driven, interrupt-driven, multi-tasking, multi-threading, and the like. As such, various steps or functions illustrated may be performed in the sequence illustrated, in parallel, or in some cases omitted. Likewise, the order of processing is not necessarily required to achieve the objects, features, and advantages described herein, but is provided for ease of illustration and description. Although not explicitly illustrated, one of ordinary skill in the art will recognize that one or more of the illustrated steps or functions may be repeatedly performed depending on the particular strategy being used.
[0101] This concludes the description. The reading of it by those skilled in the art would bring to mind many alterations and modifications without departing from the spirit and the scope of the description. For example, single cylinder, I2, I3, I4, I5, V6, V8, V10, V12 and V16 engines operating in natural gas, gasoline, diesel, or alternative fuel configurations could use the present description to advantage.
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A method for compensating for thermal transient conditions of an engine that can cause valve growth or contraction is disclosed. In one example, the method provides cylinder air amount compensation during non-blow-through and blow-through conditions. The approach may improve cylinder air amount estimates, thereby improving engine emissions.
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FIELD OF THE INVENTION
The present invention relates to a heating device for simultaneous heating of water for heating radiators and hot consumption water, comprising a heat pump and a water receptacle heated by the heat pump.
BACKGROUND OF THE INVENTION
It is well known to use a heat pump in order to utilize the heat energy stored in a heat reservoir, for instance in the earth surface. Due to the fact that it is very difficult to regulate the capacity of a compressor, the known device has the drawback that the compressor rather quickly after the start is adjusted to a certain temperature of condensation and compression independent of the demand for heating, such that the efficiency factor, i.e. the relation between the total heating effect and the consumed effect for the operation of the compressor does not become optimal.
SUMMARY OF THE INVENTION
The object of the present invention is the provision of a heating device with a heat pump for simultaneous heating of water for heating radiators and hot consumption water, which device is so arranged that the highest possible efficiency factor is obtained.
A further object of the invention is to make use of the accumulating property of the hot water receptacle so that the operation time of the compressor will be equalized and the temperature of the cooling medium of the heat pump will not be able to rise substantially over the temperature of the hot water.
Another object of the invention is to utilize the inherent heat of the cooling medium condensate before the condensate vaporizes at the expansion valve.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be further described with reference to the following description of one embodiment and with reference to the drawings, where
FIG. 1 shows a vertical section through one embodiment of the heat pump device according to the invention, while
FIG. 2 shows a horizontal section through the device shown in FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The heat pump device according to the invention is mounted inside a heat insulating housing 1 and comprises a hot water receptacle 2 which has a cover 3 filled with water, in which there is disposed a helical copper pipe 5 which forms the predominant part of the condenser of the heat pump. The heat pump comprises a compressor 10, a vaporizer disposed in a heat exchanger 7, a thermostatic expansion valve 16 and a drying filter 17. The part of the condenser which is not disposed inside the water holding cover 3 is disposed in a heat exchanger 6, the function of which will be described below.
By means of the heat exchanger 7 the vaporizer of the heat pump is in heat transferring connection with a a brine device, i.e. a device comprising a circulating fluid, the freezing point of which is below 0° C. The fluid in the brine device receives heat energy for instance from the earth surface or from the surrounding air (as diagrammatically shown), which heat energy is delivered in the heat exchanger 7, when the cooling medium in the heat pump vaporizes. The brine device comprises a circulation pump 14, which is mounted so that the brine fluid flows from the circulation pump 14 through tubes 37 and 37' to the heat exchanger 7, and therefrom through tubes 38 and 38'. Then the heat generated by the circulation pump is utilized, and for further increasing the temperature of the brine fluid a helical copper tube 11 is wound about the lower part of the compressor 10. In accordance with the invention the ends of this tube are disposed in the brine fluid between the circulation pump 14 and the heat exchanger 7 so that the open ends of the tube are directed in the flow direction of the brine and in the reverse direction, respectively.
As mentioned above, the water receptacle 2 which holds the hot water is in heat transferring connection with a hollow cover 3 which encloses the water receptacle and in which the predominant part of the condenser of the heat pump is arranged. At the condensation of the cooling medium heat energy is delivered to the fluid flowing through the cover 3 and heat energy is also delivered to the water in the receptacle 2. The receptacle 2 has a volume of at least 300 liters and in this way it forms a heat accumulating means for equalizing the operational time of the compressor.
By means of a circulation pump 13 the fluid in the cover 3 is circulated through a heating radiator system, a system for floor heating or the like. Since the temperature of the circulating return fluid, for instance from the heating radiators is lower, in the order of 10° C, than the temperature of the supply water, the return fluid is directed through the heat exchanger 6 for further cooling of the cooling medium condensate, the temperature of which is substantially the same as the temperature at the bottom of the cover 3. In this way a smaller medium pressure of the cooling medium through the condenser is obtained and in this way the efficiency factor is increased. The fluid flow is supplied to the heat exchanger 6 and to the cover 3 in such a way that the fluid rotates, whereby the transmission factor is increased.
The radiator water from the heating radiator system is supplied to an inlet 21 and passes through the conduit 22 to the circulation pump 13. From this pump the radiator water is transferred to the three-way valve 12, which is controlled by the motor 23. One output conduit 24 from the valve 12 brings the radiator water to the heat exchanger 6 and after it has been warmed up therein, it passes through the conduit 25 to the interior of the cover 3. From this cover the heated radiator water is transferred through the conduit 26 to an outlet 27 and then from there to the heating radiator system. Finally a by-pass conduit 28 directly connects a second output from the valve 12 with the outlet 27. The heat pump medium is conducted from the compressor 10 through the conduit 29 to the helical copper tube 5 and then from there through the conduit 30 to a helical tube 31 in the heat exchanger 6. Then the heat pump medium is conducted to the drying filter 17, the expansion valve 16 and from there to the heat exchanger 7 to pass in heat exchange relationship with the brine. Finally, the heat pump medium is returned to the compressor 10 through the conduit 32.
The water to be heated in the water receptacle passes from a connection 33 through a conduit 34 to the bottom of the water receptacle 2. The heated water is obtained at the top of the water receptacle 2 and reaches an outlet 36 for hot water through a conduit 35.
The heat medium (brine) from the heat reservoir is supplied through the conduit 37 and tube 37' to the heat exchanger 7 by means of the circulation pump. From the heat exchanger 7 the heat medium is returned to the heat reservoir through the tube 38' and conduit 38. The helical copper tube 11 is connected with two tubes 39 and 40 which extend into the conduit 37, whereby, as described above, the open ends of the helical tube 11 are directed in the same and in the opposite direction as the current in the conduit 37, respectively.
In accordance with the invention the temperature of the device is controlled in a manner which is very advantageous for heat pumps. The temperature of the supply water for the heating radiators for instance should be as low as possible in order to meet the heat requirements of the house. This is achieved by means of a motor-controlled three-way valve 12, by means of which a certain amount of the return fluid can be directed in a path parallel to the cover 3 and directly to the supply conduit. The motor of the three-way valve is controlled according to the invention by means of a thermostat mounted in a room or outside the house, while the operational periods of the compressor 10 are governed by means of a thermostat mounted inside the cover 3. When the device is controlled in this manner, the heat accumulating properties of the hot water receptacle 2 are utilized in the best possible way.
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A heat pump for simultaneous heating of hot water for consumption and water for heating radiators comprising besides the heat pump in itself a water reservoir heated by the condenser of the heat pump. The water reservoir is enclosed by a fluid holding cover which forms a part of the heating radiator system. Means are provided for regulating the part of the water of the heating system that passes through the cover and the part of the water that passes through a by-pass branch around said cover. The relation between said two parts may be thermostatically regulated.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority of U.S. provisional patent application Ser. No. 61/871,906 filed Aug. 30, 2013, incorporated by reference herein.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention generally relates to a method of and an apparatus for detecting atrial fibrillation.
[0004] 2. Discussion of the Related Art
[0005] The heart is the major muscle that functions as the primary pump for blood flow throughout the body. The heart contains two upper chambers called atria and two lower chambers called ventricles. The right atrium receives oxygen-depleted blood while the left atrium receives blood enriched with oxygen from the lungs. When the atria are full, the outlet valves within the heart open and the atria squeeze blood into the ventricles. The right ventricle then pumps oxygen-depleted blood to the lungs while the left ventricle pumps oxygen-enriched blood to all parts of the body. In this fashion, the heart functions primarily as a double sided pump.
[0006] The heart's internal pacemaker, known as the sinus node, signals the start of each heart beat. This signal originates in the right atrium in the sinoatrial node and travels simultaneously to the left atrium and down to the interatrial septum to the atrioventricular node. This electrical impulse results in a “p” wave on the electrocardiogram. This cycle of electrical stimulation that occurs normally is referred to as normal sinus rhythm. The contraction of the ventricles is preceded by QRS waves on the electrocardiogram (ECG), which is the electrical activity that begins ventricular contraction. This electrical activity is also often referred to as the “R” wave. The contraction of the heart occurs after the R wave. The impulse caused by cardiac contractility is transmitted through the arteries and is detected as a pulse. This pulse beat usually occurs from about 200 msec to about 700 msec after the R wave.
[0007] Many rhythm abnormalities may cause an irregular heart rhythm. Atrial fibrillation is a rhythm abnormality in which the atria do not contract normally. Instead, there is a continuously varying pattern of electrical activation of the atria resulting in a rapid highly irregular pattern of impulses reaching the atrioventricular node. The atrioventricular node acts as a filter and allows a reduced number of these impulses to reach the ventricles which results in a highly irregular heartbeat pattern. Since there is no organized electrical activity in the atrium, atrial fibrillation does not produce a p wave on the ECG.
[0008] Atrial fibrillation is one of the most common arrhythmias requiring medical attention. Atrial fibrillation may be caused by a number of heart conditions, such as coronary artery disease, myocardial infarction, heart valve abnormalities, and high blood pressure. These conditions may stretch or scar the atria, thereby causing irregularities in the heart system. Atrial fibrillation may also accompany lung problems or thyroid gland disorders and is also associated with significant morbidity and possible mortality. All persons, young and old, female or male, including the visually and/or sight impaired, may experience atrial fibrillation.
[0009] The most serious complication of atrial fibrillation is formation of a blood clot in the left atrium which may result in a stroke. The standard therapy used to prevent strokes in patients with risk factors for a stroke and atrial fibrillation is an anticoagulant, or blood thinner. Many people who develop atrial fibrillation, however, are unaware of their abnormal rhythm.
[0010] Recommendations have been made for people at risk of developing atrial fibrillation, to check their pulse periodically. Checking the pulse manually by palpation is often difficult for some people, especially the elderly, to do reliably. Therefore, use of a device that periodically automatically assess the heart rhythm and alerts the patient to the presence of atrial fibrillation would be helpful in getting patients with atrial fibrillation to be treated earlier. This may help prevent strokes in patients who are unaware that they have atrial fibrillation.
[0011] There are devices available that can be used by patients to screen for atrial fibrillation. The electrocardiogram (ECG) is the gold standard for determining if a person has atrial fibrillation. However, checking the ECG is cumbersome because it requires the person to place at least two electrodes on different body locations, such as both arms, an arm and a leg or an arm and the chest, or two locations on the chest. Also ECG monitoring at home often requires a technician and then a physician to read the ECG. The cost of this approach is prohibitive for the general population at risk of atrial fibrillation.
[0012] There are devices that can read the ECG automatically. However, they are easily compromised by a noisy signal, which is very common with ECG's. A noisy ECG signal can result in what is described as artifacts on the ECG signal. These artifacts can appear to be multiple R waves in an irregular pattern. These artifactual R waves will not have p waves preceding them and will, thus, result in the ECG meeting the criteria for diagnosing atrial fibrillation even though the true rhythm may be regular.
[0013] The use of blood pressure monitors and smartphones which can determine the time interval between pulse beats have been described. The blood pressure monitors rely on plethysmographic signals to detect the pulse, while smartphones can use the light transmittance through the skin to detect the pulse. The blood pressure devices, in particular, are able to detect the pulse reliably with artifacts rarely affecting the pulse signal. These modalities rely on assessing the regularity of the pulse rhythm which is irregular in atrial fibrillation. However, other rhythm abnormalities, such as extra heart beats may cause an irregular heart rhythm. These extra beats often follow normal beats that have both p and R waves on the ECG. Differentiating the rhythms due to extra heartbeats from atrial fibrillation can be performed most accurately by using the ECG.
[0014] Combining both the ECG recording and the pulse recording can improve the accuracy of detecting the true pulse beats. As mentioned previously, noise in either the ECG or pulse rhythm recording can result in artifacts that look like extra beats. Heart beats that occur with an adequate time interval following the previous beat to generate a pulse will always generate an R wave on the ECG and a pulse beat. Therefore, it is possible to use the pulse rhythm recording to help determine if what looks like an R wave on the ECG is due to a very premature R wave or an artifact since that electrical activity will not have a pulse beat. By deleting that electrical activity from the ECG, it is possible to generate a modified ECG that will have less electrical noise and very premature beats. This new modified ECG recording can then be analyzed for regularity. If it is regular, then the rhythm is not atrial fibrillation. If it is irregular, then the R waves on the modified ECG can be identified, and an attempt can be made to detect the preceding p waves. If the p waves are present, then the rhythm is not atrial fibrillation. If the p waves are absent, then the rhythm is atrial fibrillation.
[0015] The ECG recording and the pulse rhythm recording can be most easily compared by shifting the time of the ECG by from about 200 msec to about 700 msec so that the R waves occur at a later time. When the ECG time is shifted enough to account for the delay in generating the pulse rhythm, then the ECG and pulse recordings should have R waves and pulse beats occurring simultaneously. That is the time shift that can be used to generate the new modified ECG recording.
[0016] What is needed is a device that can be worn on a daily basis and can periodically take automatic pulse readings when the person is not moving so as to accurately determine if the heart rhythm is irregular.
[0017] What is further needed is for that device to inform the person when the automatic pulse reading showed an irregular rhythm and a combined ECG and pulse rhythm recording needs to be taken.
[0018] What is further needed is for the combined pulse and ECG recording to be analyzed to determine if atrial fibrillation is present and to inform the person of that result.
[0019] Methods for determining if an ECG waveform is noisy has been described in U.S. Pat. No. 8,639,316. However, in this patent publication, the presence of noise is determined by analyzing the properties of the ECG signal such as the morphology, amplitude or frequency content of the signal. This can also be applied to other physiological signals such as blood pressure waveforms. However, there is no mention of using a combination of physiological signals to determine if the ECG signal is noisy. There is also no mention of generating a new ECG recording by using a physiological signal to modify the ECG signal and then using that modified ECG to determine if atrial fibrillation is present.
[0020] U.S. Pat. Appln. Publ. No. 20130060154 describes a watch-like device that is worn on the wrist and can detect pulse signals which can be used to determine if atrial fibrillation is present. However, it does not describe obtaining recordings periodically and automatically when the person is not moving.
BRIEF SUMMARY OF THE INVENTION
[0021] The present invention provides a method and apparatus that can screen for atrial fibrillation periodically by automatically checking for a pulse irregularity when the appendage, on which the apparatus is worn or secured, is motionless. It then adds an additional step to determine if atrial fibrillation is present when the pulse rhythm is found to be irregular, by taking a combined ECG and pulse reading. In this combined reading, the presence of atrial fibrillation may be determined by (i) detecting the pulse beat intervals and the ECG signal simultaneously when at least one appendage is motionless, (ii) generating a new modified ECG recording that includes only heartbeats that are present on both the ECG and pulse rhythm recording, (iii) analyzing the modified ECG recording for regularity or irregularity, (iv) if an irregularity is found, then determining if “p” waves are present preceding the R waves on the modified ECG, (v) determining if atrial fibrillation is present by the lack of p waves, and (vi) communicating this information to the user so that a medical practitioner may be consulted by the user for further testing and/or treatment.
[0022] The present invention also provides a method of and an apparatus for detecting irregular pulses and ECG rhythms during a time period and storing this information for comparison with the pulse rhythm at later time periods. The present invention may also detect patterns over multiple time periods and compare the patterns over various time periods.
[0023] Pulse beats may be obtained by plethysmography such as the use of an inflatable cuff wrapped around a person's appendage, such as a wrist, which detects the pulse beats by either oscillometric or auscultatory means. The time intervals between pulse beats can be determined during cuff deflation or while the cuff is inflated at a fixed pressure. This cuff device can be incorporated into a wrist watch that can be worn on a daily basis and automatic recordings obtained periodically, such as once a day or once a week. The device would inflate the cuff only when the wrist has been stationary and motionless for a specified time period before the inflation as determined by an accelerometer within the device. The waveform generated by the device would only be analyzed if the accelerometer confirmed that no movement occurred during the measurement period.
[0024] Pulse beats may also be monitored through changes in light transmitted through various body appendages. Each pulse beat changes the light transmission through a location on the appendage. The change in the light transmission corresponds to a pulse beat and the time intervals between pulse beats may be determined. This can be done with a wrist watch device that includes a light source and a light sensor on the part of the wrist watch that makes contact with the skin at the wrist. This wrist watch that can be worn on a daily basis and automatic recordings can be obtained periodically, such as once a day or once a week. The device measures light transmittance only when the wrist has been stationary and motionless for a specified time period before the measurement as determined by an accelerometer within the device. The waveform generated by the device would only be analyzed if the accelerometer confirmed that no movement occurred during the measurement period.
[0025] Pulse beats may also be monitored using other plethysmographic devices, ultrasound devices that measure arterial motion with each pulse beat, ultrasound doppler devices that detect blood flow within an artery or devices that rely on localized compression of the artery to detect the presence of a pulse beat. Using any of these techniques the time intervals between pulse beats can be determined.
[0026] ECG signals may be obtained by placing electrical conducting leads on the limbs, other appendages or the chest. It may also be obtained by obtaining electrical signals from conducting leads in the heart or in other locations in the chest such as in pacemakers.
[0027] A monitoring method of the present invention includes communicating this information to a user such as via a screen display, a paper printout, a tone, or auditory, vibratory or other sensory communication.
[0028] The invention may utilize algorithmic or heuristic techniques to determine whether the ECG and pulse beats signal the possible presence of atrial fibrillation.
[0029] Other features and advantages of the present invention will become apparent from the following detailed description of the invention with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] For a better understanding of the present invention, reference is made to the following description and accompanying drawings, while the scope of the invention is set forth in the appended claims:
[0031] FIG. 1 is shows an exemplifying, non-limiting embodiment of a wrist watch in accordance with the invention;
[0032] FIG. 2 is a schematic showing the components in the housing of the wrist watch in accordance with the invention;
[0033] FIG. 3 is an example of an ECG signal with noise and a simultaneous pulse beat waveform obtained from a pulse oxymeter;
[0034] FIG. 4 shows the ECG time shifted so that the R waves coincide with the pulse beats and location of the R waves that would not be deleted from the new modified ECG; and
[0035] FIG. 5 is a schematic similar to FIG. 2 but including a wireless ECG device.
DETAILED DESCRIPTION OF THE INVENTION
[0036] Referring to the accompanying drawings wherein like reference numbers refer to the same or similar elements, one embodiment of the apparatus in accordance with the invention and that may be used in a method in accordance with the invention uses pulse beats and an ECG that are detected using a wristwatch 10 which has a conductive watch band or strap 12 as shown in FIG. 1 . The watch band or strap 12 is an example of a securing mechanism for securing a housing 40 including the electrical and mechanical components of the invention to the wrist of the patient. Other securing mechanisms may be used in the invention.
[0037] The wrist watch 10 also includes a light source 14 and sensor 16 on the bottom side of watch 10 , preferably directly on or against the skin surface 18 . The light source 14 and light sensor 16 are controlled to transmit light to the skin of the wearer and receive reflected light which can be converted into a pulse in a manner known to those skilled in the art to which this invention pertains. Other pulse detector mechanisms may also be used in the invention and included in the housing of the watch 10 that is secured to the wrist of the wearer, or another appendage of the wearer.
[0038] An accelerometer 20 is preferably built into the housing 40 of the watch 10 . The ECG is obtained from electrically conductive portions in wrist straps 12 , 22 on and in skin contact with both wrists of the same person with a limb lead 24 from strap 22 connected to the housing 40 of the watch 10 . Data from the accelerometer 20 is used to determine whether the wrist to which the watch 10 is secured is sufficiently motionless or moving. In this context, motionless means that the position of the wrist is not changing. A totally still state of the appendage is desirable but practically difficult to achieve. Therefore, a threshold may be set as to the degree of permissible motion of the appendage and an indication of motion below the threshold may be considered a motionless state.
[0039] Since the light source 14 and sensor 16 are operative on the underside of the watch 10 , and hence in dotted lines in FIG. 1 , the wrist watch 10 would be able to keep track of time via a conventional time keeping and displaying mechanism 26 visible to the wearer and determine when the next automated pulse reading should be obtained. A timing mechanism to achieve this timed determination is readily configured to one skilled in the art in view of the disclosure herein. For example, pulse readings may be obtained once a day to detect if the patient has an episode of atrial fibrillation. The wrist watch 10 would automatically begin to determine if the wrist is moving when the time for the next pulse reading occurs. This movement detection is preferably performed using the accelerometer 20 , but as an alternative, another movement detection means or mechanism may be used in the invention.
[0040] If the accelerometer 20 determines that the wrist is moving at that time, it will not attempt to take a pulse reading. The accelerometer 20 may be used to check for movement again a set period of time later, e.g., five minutes later, and continue to enable such movement checking until it is found that the wrist is motionless. At that time, a 30 second pulse rhythm will be obtained. If data from the accelerometer 20 confirms that no movement occurred during that 30 second reading, then the pulse rhythm obtained during the 30 second period will be analyzed to determine if the pulse rhythm is regular or irregular. If it is regular, then atrial fibrillation is not present and the watch 10 will obtain the next reading according to its programmed schedule, e.g., the following day at the same set time.
[0041] If the pulse rhythm is irregular, the watch 10 will signal the person wearing the watch 10 by voice, beeping, vibration, a text, a light or on the watch screen display 26 , that an abnormal rhythm was found and an ECG needs to be taken. The mechanism that provides this is referred to as a signaling mechanism 28 and may be incorporated into the housing 40 of the watch 10 . The signaling mechanism 28 may be configured to perform one or more of these actions or responses to the determination of the irregularity of the pulse rhythm by the processor 32 in the housing 40 of the watch 10 (see FIG. 2 ).
[0042] Once notified that an ECG needs to be taken, the person should then take a conductive wrist strap 22 that is incorporated in the wristwatch band 12 and pull it off the watch band 12 and place it on the other wrist (as shown in FIG. 1 ). The wrist strap 22 will have a wire or lead 24 that is in place connecting it to the housing of the watch 10 , i.e., to the electronic componentry in the housing of the watch 10 (schematically shown in FIG. 2 ). A connector 42 , e.g., an elastic cord, is optionally provided to connect the wrist strap 40 to the housing 40 . Once the second wrist strap 22 is in place, the conductive wristwatch band 12 and the other wrist strap 22 become two leads for the ECG. The wristwatch band 12 is positioned to have continuous contact with the skin surface 20 on the wrist and the watch 10 , i.e., processor 32 therein, can detect that the second wrist strap 22 has made contact with the skin surface 30 since an ECG signal will then be generated.
[0043] At that point, data from the accelerometer 20 will be used to determine if the wrist watch 10 is motionless. If it is not, then the wrist watch 10 will signal to the person to stop moving both arms and to relax. If data from the accelerometer 20 provides a determination that there is no movement, then the ECG and the pulse rhythm will be recorded simultaneously for 30 seconds. This recording may be stored in a memory 34 of the housing of the watch 10 (see FIG. 2 ).
[0044] Once the ECG and pulse signals are obtained, the processor 32 in the wristwatch 10 will analyze the two signals (see FIG. 2 ). The pulse rhythm recording will be used to help the processor 32 determine if what looks like an R wave on the ECG is due to a very premature R wave or an artifact. Electrical activity on the ECG that does not have a pulse beat associated with it will be deleted (through processing performed by the processor 32 upon execution of appropriate software being executed by the processor 32 ). By deleting that electrical activity from the ECG, the processor 32 is configured to generate a modified ECG that will have less electrical noise and very premature beats.
[0045] This new modified ECG recording can then be analyzed by the processor 32 for regularity using algorithms or other processing techniques. If it is regular, then the rhythm is not atrial fibrillation and the person will be informed by voice, by a green light or by the watch screen that the rhythm is normal, via the signaling mechanism 28 , and the next automatic reading will be performed as scheduled. If it is irregular, then the R waves on the modified ECG can be identified by the processor 32 , and an attempt can be made to detect the preceding p waves. If the p waves are present, then the rhythm is not atrial fibrillation and the person will be informed that the rhythm is normal, again by means of the signaling mechanism 28 . If the p waves are absent, then the rhythm is atrial fibrillation and the person will be informed that he has atrial fibrillation via the signaling mechanism 28 and should seek the advice of a physician. After the person acknowledges that he has received this message by pressing a button 38 on the watch 10 , then the watch 10 will take the next reading as scheduled. If no acknowledgement is made, then the watch 10 will continue to show that atrial fibrillation was detected.
[0046] The processor 32 can store the time of each pulse beat, the intervals between pulse beats and other information in the memory 34 (see FIG. 2 ). The memory 34 may include RAM or other device memory or include a hard disc, a floppy disk or other memory devices. The processor 32 may comprise a microprocessor, and applications specific integrated circuit (ASIC), a programmable logic array (FLA) or reduced instruction set chip (RISC).
[0047] Instead of incorporating the ECG determination and analysis unit in the processor 32 , the ECG device may be a separate ECG recorder with a signal output that can be connected to the wrist watch processor 32 (see ECG device 36 in dotted lines in FIG. 2 ). The wrist watch 10 may also have one lead incorporated into other accessories on the device such that it can be strapped onto the limbs or chest of the patient. The ECG device 36 may thus be a wearable electrocardiogram device configured to be attached to the limbs or the chest of the patient and provides an electrocardiogram signal to the processor 32 via an electrical lead (in dotted lines in FIG. 2 ).
[0048] Referring now to FIG. 5 , the wrist watch 10 may also communicate wirelessly with a separate ECG device 46 that may have leads 50 , 52 placed upon the person's limbs or chest or is worn by the person. The wireless communication may be with radio waves using Bluetooth, near field communication technology or other data communication technologies. One embodiment using wireless technology would include the ECG device 46 that is separate and apart from the housing 40 of the wrist watch 10 , and which would incorporate a wireless signal transmission and/or reception unit 48 , and two or more electrically conductive leads 50 , 52 that are adapted to be secured or otherwise attached at a respective location to the person for which the ECG is to be taken, specifically in contact with skin of the person. The ECG device 46 may thus be configured as a wearable electrocardiogram device attachable to the limbs or chest of the patient with the leads 50 , 52 extending therefrom to be positioned in contact with skin of the patient. The housing 40 of the wrist watch 10 is then also provided with a wireless signal transmission and/or reception unit 44 and configured to issue commands to be wirelessly transmitted to the ECG device 46 to cause the ECG device 46 to obtain an electrocardiogram signal via the leads 50 , 52 and output an ECG which is then transmitted to the wrist watch 10 via the wireless signal transmission and/or reception units 44 , 48 . An example of a wearable electrocardiogram device 36 that may be used in the invention is a T-shirt manufactured by HealthWatch of Tel Aviv, Israel.
[0049] In either case, the processor 32 determines from the pulse beats and ECG if the results suggest atrial fibrillation or not. Programming of the processor 32 to perform this determination is readily ascertainable by those skilled in the art in view of the disclosure herein. The processor 32 can then deliver the results to a printer, a display, a vibration generator, and/or an auditory generator, etc. (signaling mechanism 28 ) which may include an indication that the pulse beat pattern is regular, irregular, in possible atrial fibrillation, or that a physician should be contacted. Other information, such as the pulse rate, may also be displayed.
[0050] FIG. 3 shows an exemplifying ECG signal, the top signal, simultaneous with a pulse waveform, the bottom signal. The diagonal lines extending between the ECG signal and the pulse waveform show the R wave with the resulting pulse beat generated by the cardiac contraction caused by the R wave. ECG waveforms that do not have a resulting pulse beat are due to electrical noise. The noise stops after the third R wave. In this example of a recording, the ECG signal shows noise artifact that cannot easily be differentiated from the real R waves.
[0051] FIG. 4 shows an exemplifying ECG signal, the top signal, time shifted so that pulse beats, the middle signal, coincide with R waves. The noise artifact on the ECG signal can then be ignored since they do not coincide with the pulse beats. Combined heart rhythm recording, the lower signal, shows which wave would not be deleted from the new modified ECG generated by the processor 32 in the manner described above, i.e., the new ECG recording can be generated at each time point where both R wave and pulse beats occur simultaneously. If this heart rhythm recording were regular, then the rhythm would be determined not to be atrial fibrillation. However, since this heart rhythm recording is irregular, further analysis of the modified ECG is needed to determine the presence or absence of p waves. The R waves are analyzed by the processor 32 to determine if there are p waves that preceded them. Since p waves are noted before the R waves on this tracing, the rhythm would be called not atrial fibrillation.
[0052] Advantageously, the invention provides a method and apparatus that easily detect the presence of atrial fibrillation, and differentiates atrial fibrillation from non-atrial fibrillation rhythms including normal and other abnormal rhythms.
[0053] A still further advantage is that the invention provides relatively simple, non-invasive monitoring for long term at home or other location outside of a physician's office. Nevertheless, the use of the invention may occur at a physician's office or hospital or at any location where long term heart monitoring is desired.
[0054] Additional information about heart monitoring and processing of heart signals is disclosed in U.S. Pat. Nos. 6,519,490, 7,020,514, 7,680,532 and 7,706,868, to the same inventor. The disclosures of all of these patents are incorporated by reference herein. Also, the techniques disclosed in these patents may be used in combination with or as modifications to the techniques disclosed herein, and such are also considered to be inventions
[0055] Although the present invention has been described in relation to particular embodiments thereof, many other variations and modifications and other uses may become apparent to those skilled in the art. It is preferred, therefore, that the present invention be limited not by this specific disclosure herein, but only by the appended claims.
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Method of determining atrial fibrillation including determining if a patient's pulse beats form an irregular pattern and only if so, indicating the presence of an irregular pulse to the patient and obtaining an electrocardiogram for determining atrial fibrillation. Initially, a pulse is detected at regular time intervals of a first appendage of the patient when motionless using a pulse detector secured to the first appendage and pulse rhythms from a succession of time intervals are detected each corresponding to a respective interval of time between successive pulse beats of a sequence of the pulse beats. Then, an electrically conductive unit is attached to a second appendage of the patient, or a wearable electrocardiogram is attached to the patient, and electrocardiograms signals are detected simultaneously with pulse rhythms while the first appendage is motionless and analyzed to determine whether, in combination, they are indicative of atrial fibrillation. If so, an indication of atrial fibrillation is provided at least to the patient.
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This application is a divisional of application Ser. No. 09/098,585 entitled AIR PRESS FOR DEWATERING A WET WEB and filed in the U.S. Patent and Trademark Office on Jun. 17, 1998 which is a continuation of Ser. No. 08/961,915, filed Oct. 31, 1997, abandoned, which is a continuation in part of Ser. No. 08/647,508, filed May 14, 1996 now abandoned. The entirety of application Ser. No. 09/098,585 is hereby incorporated by reference.
BACKGROUND OF THE INVENTION
There are many characteristics of tissue products such as bath and facial tissue that must be considered in producing a final product having desirable attributes that make it suitable and preferred for the product'intended purpose. Improved softness of the product has long been one major objective, and this has been a particularly significant factor for the success of premium products. In general, the major components of softness include stiffness and bulk (density), with lower stiffness and higher bulk (lower density) generally improving perceived softness.
While enhanced softness is a desire for all types of tissue products, it has been especially challenging to achieve softness improvements in uncreped throughdried sheets. Throughdrying provides a relatively noncompressive method of removing water from a web by passing hot air through the web until it is dry. More specifically, a wet-laid web is transferred from the forming fabric to a coarse, highly permeable throughdrying fabric and retained on the throughdrying fabric until dry. The resulting dried web is softer and bulkier than a conventionally-dried uncreped sheet because fewer bonds are formed and because the web is less compressed. Thus, there are benefits to eliminating the Yankee dryer and making an uncreped throughdried product. Uncreped throughdried sheets are typically quite harsh and rough to the touch, however, compared to their creped counterparts. This is partially due to the inherently high stiffness and strength of an uncreped sheet, but is also due in part to the coarseness of the throughdrying fabric onto which the wet web is conformed and dried.
Therefore, what is lacking and needed in the art is a method for manufacturing tissue products having improved softness, and in particular uncreped throughdried tissue products having improved softness, as well as an apparatus that permits the manufacture of such tissue products.
SUMMARY OF THE INVENTION
It has now been discovered that an improved uncreped throughdried web can be made by dewatering the web to greater than about 30 percent consistency prior to transferring the wet web from a forming fabric to one or more slower speed intermediate transfer fabrics before further transferring the web to a throughdrying fabric for final drying of the web. In particular, increasing the consistency of the uncreped throughdried web before the point of differential speed transfer has surprisingly been found to result in: (1) both higher machine direction and cross direction tensile properties, contributing to improved runnability of the web; and (2) reduced modulus, that is increased softness, when the tensile strength is adjusted to the normal value. This discovery allows for the manufacture of tissue products with lower modulus at given tensile strengths as compared even to tissue products produced by undergoing differential speed transfer at lower consistencies.
One aspect of the present invention concerns an air press for noncompressively dewatering the wet web. The air press is a particularly desirable apparatus for dewatering the uncreped throughdried web to about 30 percent consistency or greater prior to the differential speed transfer. While pressurized fluid jets in combination with a vacuum device have previously been discussed in the patent literature, such devices have not been widely used in tissue manufacturing. Principally, this appears to be due to the fact that it had not been previously recognized that dewatering the web to greater than about 30 percent consistency in advance of the differential speed transfer would result in the improved product properties identified herein. Moreover, the disincentive to using such equipment is also believed to be attributable to the difficulties of actual implementation, including disintegration of the tissue web, pressurized fluid leaks, seal and/or fabric wear, and the like. The air press disclosed herein overcomes these difficulties and provides a practical apparatus for dewatering a wet web to consistency levels not previously thought possible at industrially useful speeds without thermal dewatering.
Hence, in one embodiment, an air press for dewatering a wet web according to the present invention comprises: support fabrics adapted to sandwich the wet web therebetween and transport the wet web through the air press; a first dewatering device comprising a pair of cross-machine direction sealing members including sealing blades; a second dewatering device comprising a cross-machine direction sealing member formed of a deformable material, the first and second dewatering devices moveable relative to one another and adapted to assume an operating position in which the first and second dewatering devices are operatively associated with one another and at least one sealing blade impinges upon the support fabrics and is opposed on the other side of the support fabrics by the sealing member formed of deformable material; and wherein one of the first and second dewatering devices comprises an air plenum operatively connected to a source of pressurized fluid and the other comprises a collection device operatively connected to a vacuum source.
In another embodiment, an air press for dewatering a wet web according to the present invention comprises: support fabrics adapted to sandwich the wet web therebetween and transport the wet web through the air press; an air plenum positioned on one side of the wet web and operatively connected to a source of pressurized fluid, the air plenum comprising a sealing assembly that is adapted to move between an operating position and a retracted position, the sealing assembly comprising a pair of machine direction sealing members and a pair of cross-machine direction sealing members that form an integral seal with the wet web when the sealing assembly is in the operating position; a collection device positioned on the opposite side of the wet web and operatively associated with the air plenum, the collection device defining therein a pair of sealing slots that extend across the width of the wet web and also defining therein a central passageway disposed between the sealing slots and adapted to receive pressurized fluid from the air plenum and water from the wet web, the collection device comprising deformable sealing members disposed within the sealing slots; means for moving the machine direction sealing members into and out of contact with one of the support fabrics, the machine direction sealing members positioned opposite and forming a seal against the deformable sealing members when the sealing assembly is in the operating position; and means for moving the cross-machine direction sealing members into and out of contact with one of the support fabrics.
The air press is able to dewater the wet web to very high consistencies due in large part to the high pressure differential established across the web and the resulting air flow through the web. In particular embodiments, for example, the air press can increase the consistency of the wet web by about 3 percent or greater, particularly about 5 percent or greater, such as from about 5 to about 20 percent, more particularly about 7 percent or greater, and more particularly still about 7 percent or greater, such as from about 7 to 20 percent. Thus, the consistency of the wet web upon exiting the air press may be about 25 percent or greater, about 26 percent or greater, about 27 percent or greater, about 28 percent or greater, about 29 percent or greater, and is desirably about 30 percent or greater, particularly about 31 percent or greater, more particularly about 32 percent or greater, such as from about 32 to about 42 percent, more particularly about 33 percent or greater, even more particularly about 34 percent or greater, such as from about 34 to about 42 percent, and still more particularly about 35 percent or greater.
The air press is able to achieve these consistency levels while the machine is operating at industrially useful speeds. As used herein, "high-speed operation" or "industrially useful speed" for a tissue machine refers to a machine speed at least as great as any one of the following values or ranges, in feet per minute: 1,000; 1,500; 2,000; 2,500; 3,000; 3,500; 4,000; 4,500; 5,000, 5,500; 6,000; 6,500; 7,000; 8,000; 9,000; 10,000, and a range having an upper and a lower limit of any of the above listed values. Optional steam showers or the like may be employed before the air press to increase the post air press consistency and/or to modify the cross-machine direction moisture profile of the web. Furthermore, higher consistencies may be achieved when machine speeds are relatively low and the dwell time in the air press in higher.
The pressure differential across the wet web provided by the air press may be about 25 inches of mercury or greater, such as from about 25 to about 120 inches of mercury, particularly about 35 inches of mercury or greater, such as from about 35 to about 60 inches of mercury, and more particularly from about 40 to about 50 inches of mercury. This may be achieved in part by an air plenum of the air press maintaining a fluid pressure on one side of the wet web of greater than 0 to about 60 pounds per square inch gauge (psig), particularly greater than 0 to about 30 psig, more particularly about 5 psig or greater, such as about 5 to about 30 psig, and more particularly still from about 5 to about 20 psig. The collection device of the air press desirably functions as a vacuum box operating at 0 to about 29 inches of mercury vacuum, particularly 0 to about 25 inches of mercury vacuum, particularly greater than 0 to about 25 inches of mercury vacuum, and more particularly from about 10 to about 20 inches of mercury vacuum, such as about 15 inches of mercury vacuum. Both pressure levels within both the air plenum and the collection device are desirably monitored and controlled to predetermined levels.
The collection device desirably but not necessarily forms an integral seal with the air plenum and draws a vacuum to facilitate its function as a collection device for air and liquid. The terms "integral seal" and "integrally sealed" are used herein to refer to: the relationship between the air plenum and the wet web where the air plenum is operatively associated and in indirect contact with the web such that about 70 percent or greater of the air fed to the air plenum flows through the web when the air plenum is operated at a pressure differential across the web of about 30 inches of mercury or greater; and the relationship between the air plenum and the collection device where the air plenum is operatively associated and in indirect contact with the web and the collection device such that about 70 percent or greater of the air fed to the air plenum flows through the web into the collection device when the air plenum and collection device are operated at a pressure differential across the web of about 30 inches of mercury or greater.
Significantly, the pressurized fluid used in the air press is sealed from ambient air to create a substantial air flow through the web, which results in the tremendous dewatering capability of the air press. The flow of pressurized fluid through the air press is suitably from about 5 to about 500 standard cubic feet per minute (SCFM) per square inch of open area, particularly about 10 SCFM per square inch of open area or greater, such as from about 10 to about 200 SCFM per square inch of open area, and more particularly about 40 SCFM per square inch of open area or greater, such as from about 40 to about 120 SCFM per square inch of open area. Desirably, 70 percent or greater, particularly 80 percent or greater, and more particularly 90 percent or greater, of the pressurized fluid supplied to the air plenum is drawn through the wet web into the vacuum box. For purposes of the present invention, the term "standard cubic feet per minute" means cubic feet per minute measured at 14.7 pounds per square inch absolute and 60 degrees Fahrenheit (° F.).
The terms "air" and "pressurized fluid" are used interchangeably herein to refer to any gaseous substance used in the air press to dewater the web. The gaseous substance suitably comprises air, steam or the like. Desirably, the pressurized fluid comprises air at ambient temperature, or air heated only by the process of pressurization to a temperature of about 300° F. or less, more particularly about 150° F. or less.
In an alternative embodiment, a device for dewatering a wet web traveling in a machine direction, comprises: a frame structure; support fabrics adapted to sandwich the wet web therebetween; an air press comprising an air plenum and a collection device positioned on opposite sides of the wet web and support fabrics, the air plenum and collection device operatively associated with one another and adapted to establish a flow of pressurized fluid through the wet web, the air plenum comprising: stationary components mounted on the frame structure; a sealing assembly that is adapted to move relative to the stationary components between an operating position and a retracted position, the sealing assembly comprising a pair of machine direction sealing members and a pair of cross-machine direction sealing members that together form an integral seal with the wet web when the sealing assembly is in the operating position; means for moving the cross-machine direction sealing members generally perpendicular to a plane containing the wet web and into and out of contact with one of the support fabrics; means for moving the machine direction sealing members generally perpendicular to the plane containing the wet web and into and out of contact with one of the support fabrics; and means for moving the machine direction sealing members generally parallel to the plane containing the wet web and generally perpendicular to the machine direction.
In another alternative embodiment, a device for dewatering a wet web traveling in a machine direction, comprises: a frame structure; support fabrics adapted to sandwich the wet web therebetween; an air press comprising an air plenum and a collection device positioned on opposite sides of the wet web and support fabrics, the air plenum and collection device operatively associated with one another and adapted to establish a flow of pressurized fluid through the wet web, the air plenum comprising: stationary components mounted on the frame structure and defining a loading surface generally parallel to a plane containing the wet web; a sealing assembly that is adapted to move relative to the stationary components between an operating position in which the sealing assembly forms an integral seal with the wet web and a retracted position, the sealing assembly defining a control surface generally parallel to the plane containing the wet web and adapted to contact the loading surface; and means for moving the sealing assembly generally perpendicular to the plane containing the wet web, wherein contact between the control surface and the loading surface interrupts movement of the sealing assembly toward the wet web when the sealing assembly reaches the operating position.
In a further embodiment, a device for dewatering a wet web traveling in a machine direction, comprises: a frame structure; support fabrics adapted to sandwich the wet web therebetween; an air press comprising an air plenum and a collection device positioned on opposite sides of the wet web and support fabrics, the air plenum and collection device operatively associated with one another and adapted to establish a flow of pressurized fluid through the wet web, the air plenum comprising: stationary components mounted on the frame structure; a sealing assembly that is adapted to move relative to the stationary components between an operating position in which the sealing assembly forms an integral seal with the wet web and a retracted position, inward facing surfaces of the sealing assembly and inward facing surfaces of the stationary components together defining a chamber for the pressurized fluid, the inward facing surfaces of the sealing assembly that partially define the chamber being generally perpendicular to the plane containing the wet web; means for moving the sealing assembly generally perpendicular to the plane containing the wet web and into and out of contact with one of the support fabrics; and means for applying a loading force to the sealing assembly to maintain the sealing assembly in the operating position, the loading force being independent of the pressure of the pressurized fluid.
This design of the air press uses internal surfaces that are normal to the loading direction to completely isolate the loading force from the air plenum pressure. Thus, the loading force can be maintained at a constant value to provide a proper seal despite the air plenum pressure varying from zero to maximum pressure. Accordingly, the loading force does not have to be adjusted in response to pressure changes within the air press.
With the embodiments of the air press disclosed herein, the competing goals of minimizing leakage and minimizing fabric wear can both be accomplished. In particular embodiments, the air press establishes a seal across the width of the wet web without having to align the CD sealing members of the air plenum with hard surfaces on the vacuum box. Rather, the CD sealing member are offset from the hard surfaces of the vacuum box cover and are positioned in vacuum passages. This design relies upon a flow of ambient air into the vacuum box to create a seal rather than having to rely on the careful alignment and machining of mating arcuate surfaces on the air plenum and vacuum box.
In another embodiment, an air press for dewatering a wet web includes an air plenum comprising a plenum cover having a bottom surface and a vacuum box comprising a vacuum box cover having a top surface positioned in close proximity to the bottom surface of the plenum cover. The air press also includes means for supplying pressurized fluid to the air plenum and means for applying vacuum to the vacuum box. Side seal members of the air press are adapted to reside in contact with the air plenum and the vacuum box for minimizing the escape of the pressurized fluid. The side seal members are attached to one of the air plenum and the vacuum box, and are positioned in close proximity to side seal contact surfaces defined by the other of the air plenum and the vacuum box. The side seal members are adapted to flex into sealing contact with the side seal contact surface upon exposure to the pressurized fluid to enhance the seal effectiveness.
Optionally, the air press may include a position control mechanism that functions to maintain the air plenum in close proximity to the vacuum box. In particular, the position control mechanism desirably includes a rotatably mounted lever attached to the air plenum, and a counterbalance cylinder attached to the lever. The position control mechanism is adapted to rotate the lever to counteract pressure changes within the air plenum. In this way, the air plenum resides in close proximity to or in contact with the fabrics passing between the air plenum and the vacuum box, without clamping the fabrics therebetween.
In another embodiment, the air press includes an air plenum comprising a plenum cover having a bottom surface, and means for supplying pressurized fluid to the air plenum. The air press also includes a vacuum box comprising a vacuum box cover having a top surface positioned in close proximity to the bottom surface of the plenum cover, and means for applying vacuum to the vacuum box. An arm that is pivotally mounted on the air plenum comprises first and second portions, with the first portion of the arm being disposed at least partially inside the air plenum. A sealing bar is formed from or mounted on the first portion of the arm. The air press also includes means for pivoting the arm in response to fluid pressure within the air plenum.
In this embodiment, the sealing bar portion of the pivotable arm acts as an end seal to prevent the escape of pressurized fluid from between the air plenum and the vacuum box. The sealing bar may conform to fabric irregularities or misalignment of the supporting structure. The end seals, which are also referred to as cross direction or CD seals, improve containment of the pressurized fluid and thus result in more efficient operation of the air press. The loading of the end seals is controlled to maintain the sealing bar in contact with the underlying moving fabric, without causing undue wear of the fabric.
The air press is useful in a variety of machine configurations to dewater wet webs, including paper, tissue, corrugate, liner board, newsprint, or the like. In particular, the air press can be employed on a tissue machine to mold the wet web onto a three-dimensional fabric and thereby increase the bulk of the web, The air press can be used in a variety of positions on the machine, particularly where the web is sandwiched between two fabrics, and where the web is transferred onto a three-imensional fabric. Because the pressure differential generated by the air press is significantly greater than has been possible using conventional vacuum boxes, suction boxes, blow boxes, and the like, tissue webs with relatively high bulks can be created in a molding stage operation utilizing the air press. Various wet-pressed machine configurations that lend themselves to dewatering using the air press are disclosed in U.S. patent application Ser. No. unknown filed on the same day as the present application by M. Hermans et al. and titled "Method For Making Tissue Sheets On A Modified Conventional Wet-Pressed Machine"; U.S. patent application Ser. No. unknown filed on the same day as the present application by M. Hermans et al. and titled "Method For Making Low-Density Tissue With Reduced Energy Input"; U.S. patent application Ser. No. unknown filed on the same day as the present application by F. Druecke al. titled "Method Of Producing Low Density Resilient Webs"; and U.S. patent application Ser. No. unknown filed on the same day as the present application by S. Chen et al. and titled "Low Density Resilient Webs And Methods Of Making Such Webs"; which are incorporated herein by reference.
One aspect of the invention pertains to a method for dewatering a cellulosic web using pressurized fluid, comprising the steps of: depositing an aqueous suspension of papermaking fibers onto an endless forming fabric to form a wet web; sandwiching the wet web between a pair of fluid permeable fabrics; passing the sandwiched wet web structure through an air press comprising an air plenum and a collection device, the air plenum and collection device being operatively associated and integrally sealed such that about 70 percent or greater of the pressurized fluid supplied to the air plenum passes through the wet web; supplying the pressurized fluid to the air plenum to create a pressure differential across the wet web of about 25 inches of mercury or greater; transporting the wet web through the air press at industrially useful speeds to provide a dwell time of about 10 milliseconds or less; and drying the web to a final dryness.
Various embodiments of the air press are described herein in relation to a throughdrying tissue making process. Thus, in one embodiment, a method for making soft tissue includes the steps of: depositing an aqueous suspension of papermaking fibers onto an endless forming fabric to form a wet web; dewatering the wet web to a consistency of from about 20 to about 30 percent; supplementally dewatering the wet web using noncompressive dewatering means to a consistency of greater than about 30 percent; transferring the supplementally dewatered web to a transfer fabric traveling at a speed of from about 10 to about 80 percent slower than the forming fabric; transferring the web to a throughdrying fabric; and throughdrying the web to a final dryness.
The intermediate transfer fabric or fabrics are traveling at a slower speed than the forming fabric during the transfer in order to impart stretch into the sheet. As the speed differential between the forming fabric and the slower transfer fabric is increased (sometimes referred to as "negative draw" or "rush transfer"), the stretch imparted to the web during transfer is also increased. The transfer fabric can be relatively smooth and dense compared to the coarse weave of a typical throughdrying fabric. Preferably the transfer fabric is as fine as can be run from a practical standpoint. Gripping of the web is accomplished by the presence of knuckles on the surface of the transfer fabric. In addition, it can be advantageous if one or more of the wet web transfers, with or without the presence of a transfer fabric, are achieved using a "fixed gap" or "kiss" transfer in which the fabrics simultaneously converge and diverge, which will be hereinafter described in detail. Such transfers not only avoid any significant compaction of the web while it is in a wet bond-forming state, but when used in combination with a differential speed transfer and/or a smooth transfer fabric, are observed to smoothen the surface of the web and final dry sheet.
The speed difference between the forming fabric and the transfer fabric can be from about 10 to about 80 percent or greater, preferably from about 10 to about 35 percent, and more preferably from about 15 to about 25 percent, with the transfer fabric being the slower fabric. The optimum speed differential will depend on a variety of factors, including the particular type of product being made. As previously mentioned, the increase in stretch imparted to the web is proportional to the speed differential. For an uncreped throughdried three-ply wiper having a basis weight of about 20 grams per square meter per ply, for example, a speed differential in the production of each ply of from about 20 to about 25 percent between the forming fabric and a sole transfer fabric produces a stretch in the final product of from about 15 to about 20 percent.
The stretch can be imparted to the web using a single differential speed transfer or two or more differential speed transfers of the wet web prior to drying. Hence there can be one or more transfer fabrics. The amount of stretch imparted to the web can hence be divided among one, two, three or more differential speed transfers.
The transfer is desirably carried out such that the resulting "sandwich" (consisting of the forming fabric/web/transfer fabric) exists for as short a duration as possible. In particular, it exists only at the leading edge of the vacuum shoe or transfer shoe slot being used to effect the transfer. In effect, the forming fabric and the transfer fabric converge and diverge at the leading edge of the vacuum slot. The intent is to minimize the distance over which the web is in simultaneous contact with both fabrics. It has been found that simultaneous convergence/divergence is the key to eliminating macrofolds and thereby enhances the smoothness of the resulting tissue or other product.
In practice, the simultaneous convergence and divergence of the two fabrics will only occur at the leading edge of the vacuum slot if a sufficient angle of convergence is maintained between the two fabrics as they approach the leading edge of the vacuum slot and if a sufficient angle of divergence is maintained between the two fabrics on the downstream side of the vacuum slot. The minimum angles of convergence and divergence are about 0.5 degree or greater, more specifically about 1 degree or greater, more specifically about 2 degrees or greater, and still more specifically about 5 degrees or greater. The angles of convergence and divergence can be the same or different. Greater angles provide a greater margin of error during operation. A suitable range is from about 1 degree to about 10 degrees. Simultaneous convergence and divergence is achieved when the vacuum shoe is designed with the trailing edge of the vacuum slot being sufficiently recessed relative to the leading edge to permit the fabrics to immediately diverge as they pass over the leading edge of the vacuum slot. This will be more clearly described in connection with the Figures.
In setting up the machine with the fabrics initially having a fixed gap to further minimize compression of the web during the transfer, the distance between the fabrics should be equal to or greater than the thickness or caliper of the web so that the web is not significantly compressed when transferred at the leading edge of the vacuum slot.
Increased smoothness is achieved by use of the air press upstream of the differential speed transfer. This is most preferably used in combination with a fixed gap carrier fabric section following drying. Calendering of the web is not necessary to obtain desirable levels of smoothness, but further processing of the sheet, such as by calendering, embossing or creping, may be beneficial to further enhance the sheet properties.
As used herein, "transfer fabric" is a fabric which is positioned between the forming section and the drying section of the web manufacturing process. Suitable transfer fabrics are those papermaking fabrics which provide a high fiber support index and provide a good vacuum seal to maximize fabric/sheet contact during transfer from the forming fabric. The fabric can have a relatively smooth surface contour to impart smoothness to the web, yet must have enough texture to grab the web and maintain contact during a rush transfer. Finer fabrics can produce a higher degree of stretch in the web, which is desirable for some product applications.
Transfer fabrics include single-layer, multi-layer, or composite permeable structures. Preferred fabrics have at least some of the following characteristics: (1) On the side of the transfer fabric that is in contact with the wet web (the top side), the number of machine direction (MD) strands per inch (mesh) is from 10 to 200 and the number of cross-machine direction (CD) strands per inch (count) is also from 10 to 200. The strand diameter is typically smaller than 0.050 inch; (2) On the top side, the distance between the highest point of the MD knuckle and the highest point of the CD knuckle is from about 0.001 to about 0.02 or 0.03 inch. In between these two levels, there can be knuckles formed either by MD or CD strands that give the topography a 3-dimensional characteristic; (3) On the top side, the length of the MD knuckles is equal to or longer than the length of the CD knuckles; (4) If the fabric is made in a multi-layer construction, it is preferred that the bottom layer is of a finer mesh than the top layer so as to control the depth of web penetration and to maximize fiber retention; and (5) The fabric may be made to show certain geometric patterns that are pleasing to the eye, which typically repeat between every 2 to 50 warp yarns.
Specific suitable transfer fabrics include, by way of example, those made by Asten Forming Fabrics, Inc., Appleton, Wis. and designated as numbers 934, 937, 939 and 959. Particular transfer fabrics that may be used also include the fabrics disclosed in U.S. Pat. No. 5,429,686 issued Jul. 4, 1995, to Chiu et al., which is incorporated herein by reference. Suitable fabrics may comprise woven fabrics, nonwoven fabrics, or nonwoven-woven composites. The void volume of the transfer fabric can be equal to or less than the fabric from which the web is transferred.
The forming process and tackle can be conventional as is well known in the papermaking industry. Such formation processes include Fourdrinier, roof formers (such as suction breast roll), gap formers (such as twin wire formers, crescent formers), or the like. Forming wires or fabrics can also be conventional, with the finer weaves with greater fiber support being preferred to produce a more smooth sheet or web. Headboxes used to deposit the fibers onto the forming fabric can be layered or nonlayered.
The method disclosed herein can be applied to any tissue web, which includes webs for making facial tissue, bath tissue, paper towels, wipes, napkins, or the like. Such tissue webs can be single-ply products or multi-ply products, such as two-ply, three-ply, four-ply or greater. One-ply products are advantageous because of their lower cost of manufacture, while multi-ply products are preferred by many consumers. For multi-ply products it is not necessary that all plies of the product be the same, provided at least one ply is in accordance with this invention. The webs can be layered or unlayered (blended), and the fibers making up the web can be any fibers suitable for papermaking.
Suitable basis weights for these tissue webs can be from about 5 to about 70 grams per square meter (gsm), preferably from about 10 to about 40 gsm, and more preferably from about 20 to about 30 gsm. For a single-ply bath tissue, a basis weight of about 25 gsm is preferred. For a two-ply tissue, a basis weight of about 20 gsm per ply is preferred. For a three-ply tissue, a basis weight of about 15 gsm per ply is preferred. In general, higher basis weight webs will require lower air flow to maintain the same operating pressure in the air plenum. The width of the slots of the air press are desirably adjusted to match the system to the available air capacity, with wider slots used for heavier basis weight webs.
The drying process can be any noncompressive drying method which tends to preserve the bulk or thickness of the wet web including, without limitation, throughdrying, infra-red irradiation, microwave drying, or the like. Because of its commercial availability and practicality, throughdrying is a well-known and preferred means for noncompressively drying the web. Suitable throughdrying fabrics include, without limitation, Asten 920A and 937A, and Velostar P800 and 103A. The throughdrying fabrics may also include those disclosed in U.S. Pat. No 5,429,686 issued Jul. 4, 1995, to Chiu et al. The web is preferably dried to final dryness without creping, since creping tends to lower the web strength and bulk.
While the mechanics are not completely understood, it is clear that the transfer fabric and throughdrying fabric can make separate and independent contributions to final sheet properties. For example, sheet surface smoothness as determined by a sensory panel can be manipulated over a broad range by changing transfer fabrics with the same throughdrying fabric. Webs produced by the present method and apparatus tend to be very two-sided unless calendered. Uncalendered webs may, however, be plied together with smooth/rough sides out as required by specific product forms.
Numerous features and advantages of the present invention will appear from the following description. In the description, reference is made to the accompanying drawings which illustrate preferred embodiments of the invention. Such embodiments do not represent the full scope of the invention. Reference should therefore be made to the claims herein for interpreting the full scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 representatively shows a schematic process flow diagram illustrating a method and apparatus according to the present invention for making uncreped throughdried sheets.
FIG. 2 representatively shows an enlarged top plan view of an air press from the process flow diagram of FIG. 1.
FIG. 3 representatively shows a side view of the air press shown in FIG. 2, with portions broken away and shown in section for purposes of illustration.
FIG. 4 representatively shows an enlarged section view taken generally from the plane of the line 4--4 in FIG. 3.
FIG. 5 representatively shows an enlarged section view similar to FIG. 4 but taken generally from the plane of the line 5--5 in FIG. 3.
FIG. 6 representatively shows a side view of an alternative sealing system for the air press shown in FIGS. 2 and 3, with portions broken away and shown in section for purposes of illustration.
FIG. 7 representatively shows an enlarged side view of a vacuum transfer shoe shown in FIG. 2.
FIG. 8 representatively shows an enlarged side view similar to FIG. 7 but illustrating the simultaneous convergence and divergence of fabrics at a leading edge of a vacuum slot.
FIG. 9 is a generalized plot of load/elongation curve for tissue, illustrating the determination of the MD Slope.
FIG. 10 representatively shows an enlarged end view of an alternative air press according to the present invention, with an air plenum sealing assembly of the air press in a raised position relative to the wet web and vacuum box.
FIG. 11 representatively shows a side view of the air press of FIG. 10.
FIG. 12 representatively shows an enlarged section view taken generally from the plane of the line 12--12 in FIG. 10, but with the sealing assembly loaded against the fabrics.
FIG. 13 representatively shows an enlarged section view similar to FIG. 12 but taken generally from the plane of the line 13--13 in FIG. 10.
FIG. 14 representatively shows a perspective view of several components of the air plenum sealing assembly positioned against the fabrics, with portions broken away and shown in section for purposes of illustration.
FIG. 15 representatively shows an enlarged section view of an alternative sealing configuration for the air press of FIG. 10.
FIG. 16 representatively shows an enlarged schematic diagram of a sealing section of the air press of FIG. 10.
DETAILED DESCRIPTION OF THE INVENTION
The invention will now be described in greater detail with reference to the Figures. Similar elements in different Figures have been given the same reference numeral for purposes of consistency and simplicity. In all of the embodiments, illustrated, conventional papermaking apparatus and operations can be used with respect to the headbox, forming fabrics, web transfers, drying and creping, all of which will be readily understood by those skilled in the papermaking art. Nevertheless, various conventional components are illustrated for purposes of providing the context in which the various embodiments of the invention can be used.
One embodiment of a method and apparatus for manufacturing a tissue is representatively shown in FIG. 1. For simplicity, the various tensioning rolls schematically used to define the several fabric runs are shown but not numbered. A papermaking headbox 20 injects or deposits an aqueous suspension of papermaking fibers 21 onto an endless forming fabric 22 traveling about a forming roll 23. The forming fabric 22 allows partial dewatering of the newly-formed wet web 24 to a consistency of about 10 percent.
After formation, the forming fabric 22 carries the wet web 24 to one or more vacuum or suction boxes 28, which may be employed to provide additional dewatering of the wet web 24 while it is supported on the forming fabric 22. In particular, a plurality of vacuum boxes 28 may be used to dewater the web 24 to a consistency of from about 20 to about 30 percent. The Fourdrinier former illustrated is particularly useful for making the heavier basis weight sheets useful as wipers and towels, although other forming devices such as twin wire formers, crescent formers or the like can be used instead. Hydroneedling, for example as disclosed in U.S. Pat. No. 5,137,600 issued Aug. 11, 1992 to Barnes et al., can optionally be employed to increase the bulk of the web.
Enhanced dewatering of the wet web 24 is thereafter provided by suitable supplemental noncompressive dewatering means, for example selected from the group consisting of the air press described herein, infra-red drying, microwave drying, sonic drying, throughdrying, superheated or saturated steam dewatering, supercritical fluid dewatering, and displacement dewatering. In the illustrated embodiment, the supplemental noncompressive dewatering means comprises an air press 30, described in greater detail hereinafter. The air press 30 desirably raises the consistency of the wet web 24 to greater than about 30 percent, such that in particular embodiments the wet web has a consistency upon exiting the air press and prior to subsequent transfer of from about 31 to about 36 percent. In particular embodiments, the air press 30 increases the consistency of the wet web 24 by about 5 percent or greater, such as about 10 percent.
Desirably, a support fabric 32 is brought in contact with the wet web 24 in advance of the air press 30. The wet web 24 is sandwiched between the support fabric 32 and the forming fabric 22, and thus supported during the pressure drop created by the air press 30. Fabrics suitable for use as a support fabric 32 include almost any fabric including forming fabrics such as Albany International 94M.
The wet web 24 is then transferred from the forming fabric 22 to a transfer fabric 36 traveling at a slower speed than the forming fabric in order to impart increased stretch into the web. Transfer is preferably carried out with the assistance of a vacuum transfer shoe 37 as described hereinafter with reference to FIGS. 7 and 8. The surface of the transfer fabric 36 is desirably relatively smooth in order to provide smoothness to the wet web 24. The openness of the transfer fabric 36, as measured by its void volume, is desirably relatively low and can be about the same as that of the forming fabric 22 or even lower. The step of rush transfer can be performed with many of the methods known in the art, particularly for example as disclosed in U.S. patent application Ser. No. 08/790,980 filed Jan. 29, 1997 by Lindsay et al. and titled "Method For Improved Rush Transfer To Produce High Bulk Without Macrofolds"; U.S. patent application Ser. No. 08/709,427 filed Sep. 6, 1996 by Lindsay et al. and titled "Process For Producing High-Bulk Tissue Webs Using Nonwoven Substrates"; U.S. Pat. No. 5,667,636 issued Sep. 16, 1997 to S. A. Engel et al.; and U.S. Pat. No. 5,607,551 issued Mar. 4, 1997 to T. E. Farrington, Jr. et al.; which are incorporated herein by reference.
The transfer fabric 36 passes over rolls 38 and 39 before the wet web 24 is transferred to a throughdrying fabric 40 traveling at about the same speed, or a different speed if desired. Transfer is effected by vacuum transfer shoe 42, which can be of the same design as that used for the previous transfer. The web 24 is dried to final dryness as the web is carried over a throughdryer 44.
Prior to being wound onto a reel 48 for subsequent conversion into the final product form, the dred web 50 can be carried through one or more optional fixed gap fabric nips formed between carrier fabrics 52 and 53. The bulk or caliper of the web 50 can be controlled by fabric embossing nips formed between rolls 54 and 55, 56 and 57, and 58 and 59. Suitable carrier fabrics for this purpose are Albany International 84M or 94M and Asten 959 or 937, all of which are relatively smooth fabrics having a fine pattern. Nip gaps between the various roll pairs can be from about 0.001 inch to about 0.02 inch (0.025-0.51 mm). As shown, the carrier fabric section of the machine is designed and operated with a series of fixed gap nips which serve to control the caliper of the web and can replace or compliment off-line calendering. Alternatively, a reel calender can be employed to achieve final caliper or complement off-line calendering.
The air press 30 is shown in greater detail by the top view of FIG. 2 and the side view of FIG. 3, the latter having portions broken away for purposes of illustration. The air press 30 generally comprises an upper air plenum 60 in combination with a lower collection device in the form of a vacuum or suction box 62. The terms "upper" and "lower" are used herein to facilitate reference to and understanding of the drawings and are not meant to restrict the manner in which the components are oriented. The sandwich of the wet tissue web 24 between the forming fabric 22 and the support fabric 32 passes between the air plenum 60 and the vacuum box 62.
The illustrated air plenum 60 is adapted to receive a supply of pressurized fluid through air manifolds 64 operatively connected to a pressurized fluid source such as a compressor or blower (not shown). The air plenum 60 is fitted with a plenum cover 66 which has a bottom surface 67 that resides during use in close proximity to the vacuum box 62 and in close proximity to or contact with the support fabric 32 (FIG. 3). The plenum cover 66 is formed with slots 68 (FIG. 5) extending perpendicular to the machine direction across substantially the entire width of the wet web 24 but desirably slightly less than the width of the fabrics to permit passage of pressurized fluid from the air plenum 60 through the fabrics and the wet web.
The vacuum box 62 is operatively connected to a vacuum source and fixedly mounted to a support structure (not shown). The vacuum box 62 comprises a cover 70 having a top surface 72 over which the forming fabric 22 travels. The vacuum box cover 70 is formed with a pair of slots 74 (FIGS. 3 and 5) that correspond to the location of the slots 68 in the plenum cover 66. The pressurized fluid dewaters the wet web 24 as the pressurized fluid is drawn from the air plenum 60 into and through the vacuum box 62.
The fluid pressure within the air plenum 60 is desirably maintained at about 5 pounds per square inch (psi) (0.35 bar) or greater, and particularly within the range of from about 5 to about 30 psi (0.35-2.07 bar), such as about 15 psi (1.03 bar). The fluid pressure within the air plenum 60 is desirably monitored and controlled to a predetermined level.
The bottom surface 67 of the plenum cover 66 is desirably gently curved to facilitate web control. The surface 67 is curved toward the vacuum box 62, that is curved about an axis disposed on the vacuum box side of the web 24. The curvature of the bottom surface 67 allows a change in angle of the combination of the supporting fabric 32, the wet web 24, and the forming fabric 22 resulting in a net downward force that seals the vacuum box 62 against the entry of outside air and supports the wet web 24 during the dewatering process. The angle of curvature allows the loading and unloading of the air press 30 as required from time to time, based on process conditions. The change in angle necessary is dependent on the pressure differential between the pressure and vacuum sides and is desirably above 5 degrees, and particularly within the range of 5 to 30 degrees, typically about 7.5 degrees.
The top and bottom surfaces 72 and 67 desirably have differing radii of curvature. In particular, the radius of curvature of the bottom surface 67 is desirably larger than the radius of curvature of the top surface 72 so as to form contact lines between the air plenum 60 and the vacuum box 62 at the leading and trailing edges 76 of the air press 30. With proper attention to the position of the supporting fabric 32 and the forming fabric 22 sandwich and loading and unloading mechanisms, the radii of curvature of these surfaces may be reversed.
The leading and trailing edges 76 of the air press 30 may also be provided with end seals 78 (FIG. 3) that are maintained in very close proximity to or contact with the support fabric 32 at all times. The end seals 78 minimize the escape of pressurized fluid between the air plenum 60 and the vacuum box 62 in the machine direction. Suitable end seals 78 may be formed of low friction materials such as resilient plastic compounds, materials that preferentially wear relative to the fabrics, or the like. The end seals desirably have curved edges to prevent snagging the fabrics.
With additional reference to FIGS. 4 and 5, the air press 30 is desirably provided with side seal members 80 to prevent the loss of pressurized fluid along the side edges 82 of the air press. The side seal members 80 comprise a semi-rigid material that is adapted to deform or flex slightly when exposed to the pressurized fluid of the air plenum 60. The illustrated side seal members 80 define a slot 84 for attachment to the vacuum box cover 70 using a clamping bar 85 and fastener 86 or other suitable means. In cross section, each side seal member 80 is L-shaped with a leg 88 projecting upward from the vacuum box cover 70 into a side seal slot 89 formed in the plenum cover 66. Pressurized fluid from the air plenum 60 causes the legs 88 to bend outward into sealing contact with the outward surface of the side seal slot 89 of the plenum cover 66, as shown in FIGS. 4 and 5. Alternatively, the position of the side seal members 80 could be reversed, such that they are fixedly attached to the plenum cover 66 and make sealing contact with contact surfaces defined by the vacuum box cover 70 (not shown). In any such alternative designs, it is desirable for the side seal member to be urged into engagement with the sealing contact surface by the pressurized fluid.
A position control mechanism 90 maintains the air plenum 60 in close proximity to the vacuum box 62 and in contact with the support fabric 32. The position control mechanism 90 comprises a pair of levers 92 connected by crosspieces 93 and fixedly attached to the air plenum 60 by suitable fasteners 94 (FIG. 3). The ends of the levers 92 opposite the air plenum 60 are rotatably mounted on a shaft 96. The position control mechanism 90 also comprises a counterbalance cylinder 98 operably connecting a fixed structural support 99 and one of the crosspieces 93. The counterbalance cylinder 98 is adapted to extend or retract and thereby cause the levers 92 to rotate about the shaft 96, which causes the air plenum 60 to move closer to or further from the vacuum box 62.
In use, a control system causes the counterbalance cylinder 98 to extend sufficiently for the end seals 78 to contact the support fabric 32 and the side seal members 80 to be positioned within the side seal slots 89. The air press 30 is activated such that pressurized fluid fills the air plenum 60 and the semi-rigid side seal members 80 are forced into sealing engagement with the plenum cover 66. The pressurized fluid also creates an upward force tending to move the air plenum 60 away from the support fabric 32. The control system directs operation of the counterbalance cylinder 98 to offset this upward force based on continuous measurements of the fluid pressure within the air plenum 60 by the pressure monitoring system. The end seals 78 are thereby maintained in very close proximity to or contact with the support fabric 32 at all times. The control system counters random pressure drops or peaks within the air plenum 60 by proportionately decreasing or increasing the force applied by the counterbalance cylinder 98. The air flow within the air press may also be monitored. Consequently, the end seals 78 do not clamp the fabrics 32 and 22, which would otherwise lead to excessive wear of the fabrics.
An alternative sealing system for the air press 30 is representatively shown in FIG. 6. The air plenum 100 is provided with a pivotable arm 102 defining or carrying a sealing bar 104 that is adapted to ride on the support fabric 32 across the width of the wet web 24 to minimize escape of pressurized fluid in the machine direction. While only one arm 102 is illustrated in FIG. 6, it should be understood that a second arm at the opposite end of the air plenum 100 may be employed and constructed in a similar manner. The sides of the air plenum 100 may incorporate side seal members 80 as described in relation to FIGS. 2-5 or be fixedly mounted on the vacuum box 62 to minimize or eliminate side leakage of pressurized fluid.
The pivotable arm 102 desirably comprises a rigid material such as structural steel, graphite composites, or the like. The arm 102 has a first portion 106 disposed at least partially inside the air plenum 100 and a second portion 108 preferably disposed outside the air plenum. The arm 102 is pivotally mounted on the air plenum 100 by a hinge 110. A hinge seal 112 impervious to the pressurized fluid is attached to both the interior surface of a wall 114 of the air plenum 100 and the first portion 106 to prevent escape of the pressurized fluid. The sealing bar 104 is desirably a separate element mounted on the first portion 106 and motivated toward the support fabric 32 (not shown in FIG. 6) by contact of the pressurized fluid on the first portion. Suitable sealing bars 104 may be formed of a low-resistance, low friction coefficient, durable material such as ceramic, heat resistant polymers, or the like.
A counterbalance bladder 120 having an inflatable chamber 122 is mounted on the second portion 108 of the arm 102 with brackets 124 or other suitable means. The chamber 122 is operably connected to a source of pressurized fluid such as air to inflate the chamber. The arm 102 and the bladder 120 are positioned so that the bladder when inflated (not shown) presses against the exterior surface of the wall 114 of the air plenum 100 causing the arm to pivot about the hinge 110. Alternatively, a mechanism using pressurized cylinders (not shown) could be used in place of the counterbalance bladder as a means for pivoting the arm 102.
A control system is operable to inflate or deflate the bladder 120 proportionally in response to the pressure of the fluid within the air plenum 100. For example, as pressure within the air plenum 100 increases, the control system is adapted to increase pressure within or inflation of the counterbalance bladder 120 so that the sealing bar 104 does not clamp down excessively against the support fabric 32.
The design of the vacuum transfer shoe 37 used in the transfer fabric section of the process (FIG. 1) is more clearly illustrated in FIGS. 7 and 8. The vacuum transfer shoe 37 defines a vacuum slot 130 (FIG. 7) connected to a source of vacuum and having a length of "L" which is suitably from about 0.5 to about 1 inch (12.7-25.4 mm). For producing uncreped throughdried bath tissue, a suitable vacuum slot length is about 1 inch (25.4 mm). The vacuum slot 130 has a leading edge 132 and a trailing edge 133, forming corresponding incoming and outgoing land areas 134 and 135 of the vacuum transfer shoe 37. The trailing edge 133 of the vacuum slot 130 is recessed relative to the leading edge 132, which is caused by the different orientation of the outgoing land area 135 relative to that of the incoming land area 134. The angle "A" between the planes of the incoming land area 134 and the outgoing land area 135 can be about 0.5 degrees or greater, more specifically about 1 degree or greater, and still more specifically about 5 degrees or greater in order to provide sufficient separation of the forming fabric 22 and the transfer fabric 36 as they are converging and diverging.
FIG. 8 further illustrates the wet tissue web 24 traveling in the direction shown by the arrows toward the vacuum transfer shoe 37. Also approaching the vacuum transfer shoe 37 is the transfer fabric 36 traveling at a slower speed. The angle of convergence between the two incoming fabrics is designated as "C". The angle of divergence between the two fabrics is designated as "D". As shown, the two fabrics simultaneously converge and diverge at point "P", which corresponds to the leading edge 132 of the vacuum slot 130. It is not necessary or desirable that the web be in contact with both fabrics over the entire length of the vacuum slot 130 to effect the transfer from the forming fabric 22 to the transfer fabric 36. As is apparent from FIG. 8, neither the forming fabric 22 nor the transfer fabric 36 need to be deflected more than a small amount to carry out the transfer, which can reduce fabric wear. Numerically, the change in direction of either fabric can be less than 5 degrees.
As previously mentioned, the transfer fabric 36 is traveling at a slower speed than the forming fabric 22. If more than one transfer fabric is used, the speed differential between fabrics can be the same or different. Multiple transfer fabrics can provide operational flexibility as well as a wide variety of fabric/speed combinations to influence the properties of the final product.
The level of vacuum used for the differential speed transfers can be from about 3 to about 15 inches of mercury, preferably about 5 inches of mercury. The vacuum shoe (negative pressure) can be supplemented or replaced by the use of positive pressure from the opposite side of the web 24 to blow the web onto the next fabric in addition to or as a replacement for sucking it onto the next fabric with vacuum. Also, a vacuum roll or rolls can be used to replace the vacuum shoe(s).
An alternative embodiment of the air press 200 for dewatering a wet web 24 is shown in FIGS. 10-13. The air press 200 generally comprises an upper air plenum 202 in combination with a lower collection device in the form of a vacuum box 204. The wet web 24 travels in a machine direction 205 between the air plenum and vacuum box while sandwiched between an upper support fabric 206 and a lower support fabric 208. The air plenum and vacuum box are operatively associated with one another so that pressurized fluid supplied to the air plenum travels through the wet web and is removed or evacuated through the vacuum box.
Each continuous fabric 206 and 208 travels over a series of rolls (not shown) to guide, drive and tension the fabric in a manner known in the art. The fabric tension is set to a predetermined amount, suitably from about 10 to about 60 pounds per lineal inch (pli), particularly from about 30 to about 50 pli, and more particularly from about 35 to about 45 pli. Fabrics that may be useful for transporting the wet web 24 through the air press 200 include almost any fluid permeable fabric, for example Albany International 94M, Appleton Mills 2164B, or the like.
An end view of the air press 200 spanning the width of the wet web 24 is shown in FIG. 10, and a side view of the air press in the machine direction 205 is shown in FIG. 11. In both Figures, several components of the air plenum 202 are illustrated in a raised or retracted position relative to the wet web 24 and vacuum box 204. In the retracted position, effective sealing of pressurized fluid is not possible. For purposes of the present invention, a "retracted position" of the air press means that the components of the air plenum 202 do not impinge upon the wet web and support fabrics.
The illustrated air plenum 202 and vacuum box 204 are mounted within a suitable frame structure 210. The illustrated frame structure comprises upper and lower support plates 211 separated by a plurality of vertically oriented support bars 212. The air plenum 202 defines a chamber 214 (FIG. 13) that is adapted to receive a supply of pressurized fluid through one or more suitable air conduits 215 operatively connected to a pressurized fluid source (not shown). Correspondingly, the vacuum box 204 defines a plurality of vacuum chambers (described hereinafter in relation to FIG. 13) that are desirably operatively connected to low and high vacuum sources (not shown) by suitable fluid conduits 217 and 218, respectively (FIGS. 11, 12 and 13). The water removed from the wet web 24 is thereafter separated from the air streams. Various fasteners for mounting the components of the air press are shown in the Figures but are not labeled.
Enlarged section views of the air press 200 are shown in FIGS. 12 and 13. In these Figures the air press is shown in an operating position wherein components of the air plenum 202 are lowered into an impingement relationship with the wet web 24 and support fabrics 206 and 208. The degree of impingement that has been found to result in proper sealing of the pressurized fluid with minimal contact force and therefore reduced fabric wear is described in greater detail hereinafter.
The air plenum 202 comprises both stationary components 220 that are fixedly mounted to the frame structure 210 and a sealing assembly 260 that is movably mounted relative to the frame structure and the wet web. Alternatively, the entire air plenum could be moveably mounted relative to a frame structure.
With particular reference to FIG. 13, the stationary components 220 of the air plenum include a pair of upper support assemblies 222 that are spaced apart from one another and positioned beneath the upper support plate 211. The upper support assemblies define facing surfaces 224 that are directed toward one another and that partially define therebetween the plenum chamber 214. The upper support assemblies also define bottom surfaces 226 that are directed toward the vacuum box 204. In the illustrated embodiment, each bottom surface 226 defines an elongated recess 228 in which an upper pneumatic loading tube 230 is fixedly mounted. The upper pneumatic loading tubes 230 are suitably centered the cross-machine direction and desirably extend over the full width of the wet web.
The stationary components 220 of the air plenum 202 also include a pair of lower support assemblies 240 that are spaced apart from one another and vertically spaced from the upper support assemblies 222. The lower support assemblies define top surfaces 242 and facing surfaces 244. The top surfaces 242 are directed toward the bottom surfaces 226 of the upper support assemblies 222 and, as illustrated, define elongated recesses 246 in which lower pneumatic loading tubes 248 are fixedly mounted. The lower pneumatic loading tubes 248 are suitably centered in the cross-machine direction and suitably extend over about 50 to 100 percent of the width of the wet web. In the illustrated embodiment, lateral support plates 250 are fixedly attached to the facing surfaces 244 of the lower support assemblies and function to stabilize vertical movement of the sealing assembly 260.
With additional reference to FIG. 14, the sealing assembly 260 comprises a pair of cross-machine direction sealing members referred to as CD sealing members 262 (FIGS. 12-14) that are spaced apart from one another, a plurality of braces 263 (FIG. 14) that connect the CD sealing members, and a pair of machine direction sealing members referred to as MD sealing members 264 (FIGS. 12 and 14). The CD sealing members 262 are vertically moveable relative to the stationary components 220. The optional but desirable braces 263 are fixedly attached to the CD sealing members to provide structural support, and thus move vertically along with the CD sealing members. In the machine direction 205, the MD sealing members 264 are disposed between the upper support assemblies 222 and between the CD sealing members 262. As described in greater detail hereinafter, portions of the MD sealing members are vertically moveable relative to the stationary components 220. In the cross-machine direction, the MD sealing members are positioned near the edges of the wet web 24. In one particular embodiment, the MD sealing members are moveable in the cross-machine direction in order to accommodate a range of possible wet web widths.
The illustrated CD sealing members 262 include a main upright wall section 266, a transverse flange 268 projecting outwardly from a top portion 270 of the wall section, and a sealing blade 272 mounted on an opposite bottom portion 274 of the wall section (FIG. 13). The outwardly-projecting flange 268 thus forms opposite, upper and lower control surfaces 276 and 278 that are substantially perpendicular to the direction of movement of the sealing assembly. The wall section 266 and flange 268 may comprise separate components or a single component as illustrated.
As noted above, the components of the sealing assembly 260 are vertically moveable between the retracted position shown in FIGS. 10 and 11 and the operating position shown in FIGS. 12 and 13. In particular, the wall sections 266 of the CD sealing members 262 are positioned inward of the position control plates 250 and are slideable relative thereto. The amount of vertical movement is determined by the ability of the transverse flanges 268 to move between the bottom surfaces 226 of the upper support assemblies 222 and the top surfaces 242 of the lower support assemblies 240.
The vertical position of the transverse flanges 268 and thus the CD sealing members 262 is controlled by activation of the pneumatic loading tubes 230 and 248. The loading tubes are operatively connected to a pneumatic source and to a control system (not shown) for the air press. Activation of the upper loading tubes 230 creates a downward force on the upper control surfaces 276 of the CD sealing members 262 resulting in a downward movement of the flanges 268 until they contact the top surfaces 242 of the lower support assemblies 240 or are stopped by an upward force caused by the lower loading tubes 248 or the fabric tension. Retraction of the CD sealing members 262 is achieved by activation of the lower loading tubes 248 and deactivation of the upper loading tubes. In this case, the lower loading tubes press upwardly on the lower control surfaces 278 and cause the flanges 268 to move toward the bottom surfaces of the upper support assemblies 222. Of course, the upper and lower loading tubes can be operated at differential pressures to establish movement of the CD sealing members. Alternative means for controlling vertical movement of the CD sealing members can comprise other forms and connections of pneumatic cylinders, hydraulic cylinders, screws, jacks, mechanical linkages, or other suitable means. Suitable loading tubes are available from Seal Master Corporation of Kent, Ohio.
As shown in FIG. 13, a pair of bridge plates 279 span the gap between the upper support assemblies 222 and the CD sealing members 262 to prevent the escape of pressurized fluid. The bridge plates thus define part of the air plenum chamber 214. The bridge plates may be fixedly attached to the facing surfaces 224 of the upper support assemblies and slideable relative to the inner surfaces of the CD sealing members, or vice versa. The bridge plates may be formed of a fluid impermeable, semi-rigid, low-fraction material such as LEXAN, sheet metal or the like.
The sealing blades 272 function together with other features of the air press to minimize the escape of pressurized fluid between the air plenum 202 and the wet web 24 in the machine direction. Additionally, the sealing blades are desirably shaped and formed in a manner that reduces the amount of fabric wear. In particular embodiments, the sealing blades are formed of resilient plastic compounds, ceramic, coated metal substrates, or the like.
With particular reference to FIGS. 12 and 14, the MD sealing members 264 are spaced apart from one another and adapted to prevent the loss of pressurized fluid along the side edges of the air press. FIGS. 12 and 14 each show one of the MD sealing members 264, which are positioned in the cross-machine direction near the edge of the wet web 24. As illustrated, each MD sealing member comprises a transverse support member 280, an end deckle strip 282 operatively connected to the transverse support member, and actuators 284 for moving the end deckle strip relative to the transverse support member. The transverse support members 280 are normally positioned near the side edges of the wet web 24 and are generally located between the CD sealing members 262. As illustrated, each transverse support member defines a downwardly directed channel 281 (FIG. 14) in which the an end deckle strip is mounted. Additionally, each transverse support member defines circular apertures 283 in which the actuators 284 are mounted.
The end deckle strips 282 are vertically moveable relative to the transverse support members 280 due to the cylindrical actuators 284. Coupling members 285 (FIG. 12) link the end deckle strips to the output shaft of the cylindrical actuators. The coupling members may comprise an inverted T-shaped bar or bars so that the end deckle strips may slide within the channel 281, such as for replacement.
As shown in FIG. 14, both the transverse support members 280 and the end deckle strips 282 define slots to house a fluid impermeable sealing strip 286, such as O-ring ring material or the like. The sealing strip helps seal the air chamber 214 of the air press from leaks. The slots in which the sealing strip resides is desirably widened at the interface between the transverse support members 280 and the end deckle strips 282 to accommodate relative movement between those components.
A bridge plate 287 (FIG. 12) is positioned between the MD sealing members 264 and the upper support plate 211 and fixedly mounted to the upper support plate. Lateral portions of the air chamber 214 (FIG. 13) are defined by the bridge plate. Sealing means such as a fluid impervious gasketing material is desirably positioned between the bridge plate and the MD sealing members to permit relative movement therebetween and to prevent the loss of pressurized fluid.
The actuators 284 suitably provide controlled loading and unloading of the end deckle strips 282 against the upper support fabric 206, independent of the vertical position of the CD sealing members 262. The load can be controlled exactly to match the necessary sealing force. The end deckle strips can be retracted when not needed to eliminate all end deckle and fabric wear. Suitable actuators are available from Bimba Corporation. Altematively, springs (not shown) may be used to hold the end deckle strips against the fabric although the ability to control the position of the end deckle strips may be sacrificed.
With reference to FIG. 12, each end deckle strip 282 has a top surface or edge 290 disposed adjacent to the coupling members 285, an opposite bottom surface or edge 292 that resides during use in contact with the fabric 206, and lateral surfaces or edges 294 that are in close proximity to the CD sealing members 262. The shape of the bottom surface 292 is suitably adapted to match the curvature of the vacuum box 204. Where the CD sealing members 262 impinge upon the fabrics, the bottom surface 292 is desirably shaped to follow the curvature of the fabric impingement. Thus, the bottom surface has a central portion 296 that is laterally surrounded in the machine direction by spaced apart end portions 298. The shape of the central portion 296 generally tracks the shape of the vacuum box while the shape of the end portions 298 generally tracks the deflection of the fabrics caused by the CD sealing members 262. To prevent wear on the projecting end portions 298, the end deckle strips are desirably retracted before the CD sealing members 262 are retracted. The end deckle strips 282 are desirably formed of a gas impermeable material that minimizes fabric wear. Particular materials that may be suitable for the end deckles include polyethylene, nylon, or the like.
The MD sealing members 264 are desirably moveable in the cross-machine direction and are thus desirably slideably positioned against the CD sealing members 262. In the illustrated embodiment, movement of the MD sealing members 264 in the cross-machine direction is controlled by a threaded shaft or bolt 305 that is held in place by brackets 306 (FIG. 14). The threaded shaft 305 passes through a threaded aperture in the transverse support member 280 and rotation of the shaft causes the MD sealing member to move along the shaft. Alternative means for moving the MD sealing members 264 in the cross-machine direction such as pneumatic devices or the like may also be used. In one alternative embodiment, the MD sealing members are fixedly attached to the CD sealing members so that the entire sealing assembly is raised and lowered together (not shown). In another alternative embodiment, the transverse support members 280 are fixedly attached to the CD sealing members and the end deckle strips are adapted to move independently of the CD sealing members (not shown).
The vacuum box 204 comprises a cover 300 having a top surface 302 over which the lower support fabric 208 travels. The vacuum box cover 300 and the sealing assembly 260 are desirably gently curved to facilitate web control, as described previously in relation to other embodiments. The illustrated vacuum box cover is formed, from the leading edge to the trailing edge in the machine direction 205, with a first exterior sealing shoe 311, a first sealing vacuum zone 312, a first interior sealing shoe 313, a series of four high vacuum zones 314, 316, 318 and 320 surrounding three interior shoes 315, 317 and 319, a second interior sealing shoe 321, a second sealing vacuum zone 322, and a second exterior sealing shoe 323 (FIG. 13). Each of these shoes and zones desirably extend in the cross-machine direction across the full width of the web. The shoes each include a top surface desirably formed of a ceramic material to ride against the lower support fabric 208 without causing significant fabric wear. Suitable vacuum box covers and shoes may be formed of plastics, NYLON, coated steels or the like, and are available from JWI Corporation or IBS Corporation.
The four high vacuum zones 314, 316, 318 and 320 are passageways in the cover 300 that are operatively connected to one or more vacuum sources (not shown) that draw a relatively high vacuum level. For example, the high vacuum zones may be operated at a vacuum of 0 to 25 inches of mercury vacuum, and more particularly about 10 to about 25 inches of mercury vacuum. As an alternative to the illustrated passageways, the cover 300 could define a plurality of holes or other shaped openings (not shown) that are connected to a vacuum source to establish a flow of pressurized fluid through the web. In one embodiment, the high vacuum zones comprise slots each measuring 0.375 inch in the machine direction and extending across the full width of the wet web. The dwell time that any given point on the web is exposed to the flow of pressurized fluid, which in the illustrated embodiment is the time over slots 314, 316, 318 and 320, is suitably about 10 milliseconds or less, particularly about 7.5 milliseconds or less, more particularly 5 milliseconds or less, such as about 3 milliseconds or less or even about 1 millisecond or less. The number and width of the high pressure vacuum slots and the machine speed determine the dwell time. The selected dwell time will depend on the type of fibers contained in the wet web and the desired amount of dewatering.
The first and second sealing vacuum zones 312 and 322 may be employed to minimize the loss of pressurized fluid from the air press. The sealing vacuum zones are passageways in the cover 300 that may be operatively connected to one or more vacuum sources (not shown) that desirably draw a relatively lower vacuum level as compared to the four high vacuum zones. Specifically, the amount of vacuum that is desirable for the sealing vacuum zones is 0 to about 100 inches water column, vacuum.
The air press 200 is desirably constructed so that the CD sealing members 262 are disposed within the sealing vacuum zones 312 and 322. More specifically, the sealing blade 272 of the CD sealing member 262 that is on the leading side of the air press is disposed between, and more particularly centered between, the first exterior sealing shoe 311 and the first interior sealing shoe 313, in the machine direction. The trailing sealing blade 272 of the CD sealing member is similarly disposed between, and more particularly centered between, the second interior sealing shoe 321 and the second exterior sealing shoe 323, in the machine direction. As a result, the sealing assembly 260 can be lowered so that the CD sealing members deflect the normal course of travel of the wet web 24 and fabrics 206 and 208 toward the vacuum box, which is shown in slightly exaggerated scale in FIG. 13 for purposes of illustration.
The sealing vacuum zones 312 and 322 function to minimize the loss of pressurized fluid from the air press 200 across the width of the wet web 24. The vacuum in the sealing vacuum zones 312 and 322 draws pressurized fluid from the air plenum 202 and draws ambient air from outside the air press. Consequently, an air flow is established from outside the air press into the sealing vacuum zones rather than a pressurized fluid leak in the opposite direction. Due to the relative difference in vacuum between the high vacuum zones and the sealing vacuum zones, though, the vast majority of the pressurized fluid from the air plenum is drawn into the high vacuum zones rather than the sealing vacuum zones.
In an alternative embodiment which is partially illustrated in FIG. 15, no vacuum is drawn in either or both of the sealing vacuum zones 312 and 322. Rather, deformable sealing deckles 330 are disposed in the sealing zones 312 and 322 (only 322 shown) to prevent leakage of pressurized fluid in the machine direction. In this case, the air press is sealed in the machine direction by the sealing blades 272 that impinge upon the fabrics 206 and 208 and the wet web 24 and by the fabrics and the wet web being displaced in close proximity to or contact with the deformable sealing deckles 330. This configuration, where the CD sealing members 262 impinge upon the fabrics and wet web and the CD sealing members are opposed on the other side of the fabrics and the wet web by deformable sealing deckles 330, has been found to produce a particularly effective air plenum seal.
The deformable sealing deckles 330 desirably extend across the full width of the wet web to seal the leading end, the trailing end, or both the leading and the trailing end of the air press 200. The sealing vacuum zone may be disconnected from the vacuum source when the deformable sealing deckle extends across the full web width. Where the trailing end of the air press employs a full width deformable sealing deckle, a vacuum device or blow box may be employed downstream of the air press to cause the web 24 to remain with one of the fabrics as the fabrics are separated.
The deformable sealing deckles 330 desirably either comprise a material that preferentially wears relative to the fabric 208, meaning that when the fabric and the material are in use the material will wear away without causing significant wear to the fabric, or comprise a material that is resilient and that deflects with impingement of the fabric. In either case, the deformable sealing deckles are desirably gas impermeable, and desirably comprise a material with high void volume, such as a closed cell foam or the like. In one particular embodiment, the deformable sealing deckles comprise a closed cell foam measuring 0.25 inch in thickness. Most desirably, the deformable sealing deckles themselves become worn to match the path of the fabrics. The deformable sealing deckles are desirably accompanied by a backing plate 332 for structural support, for example an aluminum bar.
In embodiments where full width sealing deckles are not used, sealing means of some sort are required laterally of the web. Deformable sealing deckles as described above, or other suitable means known in the art, may be used to block the flow of pressurized fluid through the fabrics laterally outward of wet web.
The degree of impingement of the CD sealing members into the upper support fabric 206 uniformly across the width of the wet web has been found to be a significant factor in creating an effective seal across the web. The requisite degree of impingement has been found to be a function of the maximum tension of the upper and lower support fabrics 206 and 208, the pressure differential across the web and in this case between the air plenum chamber 214 and the sealing vacuum zones 312 and 322, and the gap between the CD sealing members 262 and the vacuum box cover 300.
With additional reference to the schematic diagram of the trailing sealing section of the air press shown in FIG. 16, the minimum desirable amount of impingement of the CD sealing member 262 into the upper support fabric 206, h(min), has been found to be represented by the following equation: ##EQU1## where: T is the tension of the fabrics measured in pounds per inch;
W is the pressure differential across the web measured in psi; and
d is the gap in the machine direction measured in inches.
FIG. 16 shows the trailing CD sealing member 262 deflecting the upper support fabric 206 by an amount represented by arrow "h". The maximum tension of the upper and lower support fabrics 206 and 208 is represented by arrow "T". Fabric tension can be measured by a model tensometer available from Huyck Corporation or other suitable methods. The gap between the sealing blade 272 of the CD sealing member and the second interior sealing shoe 321 measured in the machine direction and represented by arrow "d". The gap "d" of significance for the determining impingement is the gap on the higher pressure differential side of the sealing blade 272, that is, toward the plenum chamber 214, because the pressure differential on that side has the most effect on the position of the fabrics and web. Desirably, the gap between the sealing blade and the second exterior shoe 323 is approximately the same or less than gap "d".
Adjusting the vertical placement of the CD sealing members 262 to the minimum degree of impingement as defined above is a determinative factor in the effectiveness of the CD seal. The loading force applied to the sealing assembly 260 plays a lesser role in determining the effectiveness of the seal, and need only be set to the amount needed to maintain the requisite degree of impingement. Of course, the amount of fabric wear will impact the commercial usefulness of the air press 200. To achieve effective sealing without substantial fabric wear, the degree of impingement is desirably equal to or only slightly greater than the minimum degree of impingement as defined above. To minimize the variability of fabric wear across the width of the fabrics, the force applied to the fabric is desirably kept constant over the cross machine direction. This can be accomplished with either controlled and uniform loading of the CD sealing members or controlled position of the CD sealing members and uniform geometry of the impingement of the CD sealing members.
In use, a control system causes the sealing assembly 260 of the air plenum 202 to be lowered into an operating position. First, the CD sealing members 262 are lowered so that the sealing blades 272 impinge upon the upper support fabric 206 to the degree described above. More particularly, the pressures in the upper and lower loading tubes 230 and 248 are adjusted to cause downward movement of the CD sealing members 262 until movement is halted by the transverse flanges 268 contacting the lower support assemblies 240 or until balanced by fabric tension. Second, the end deckle strips 282 of the MD sealing members 264 are lowered into contact with or close proximity to the upper support fabric. Consequently, the air plenum 202 and vacuum box 204 are both sealed against the wet web to prevent the escape of pressurized fluid.
The air press is then activated so that pressurized fluid fills the air plenum 202 and an air flow is established through the web. In the embodiment illustrated in FIG. 13, high and low vacuums are applied to the high vacuum zones 314, 316, 318 and 320 and the sealing vacuum zones 312 and 322 to facilitate air flow, sealing and water removal. In the embodiment of FIG. 15, pressurized fluid flows from the air plenum to the high vacuum zones 314, 316, 318 and 320 and the deformable sealing deckles 330 seal the air press in the cross machine direction. The resulting pressure differential across the wet web and resulting air flow through the web provide for efficient dewatering of the web.
A number of structural and operating features of the air press contribute to very little pressurized fluid being allowed to escape in combination with a relatively low amount of fabric wear. Initially, the air press 200 uses CD sealing members 262 that impinge upon the fabrics and the wet web. The degree of impingement is determined to maximize the effectiveness of the CD seal. In one embodiment, the air press utilizes the sealing vacuum zones 312 and 322 to create an ambient air flow into the air press across the width of the wet web. In another embodiment, deformable sealing members 330 are disposed in the sealing vacuum zones 312 and 322 opposite the CD sealing members. In either case, the CD sealing members 262 are desirably disposed at least partly in passageways of the vacuum box cover 300 in order to minimize the need for precise alignment of mating surfaces between the air plenum 202 and the vacuum box 204. Further, the sealing assembly 260 can be loaded against a stationary component such as the lower support assemblies 240 that are connected to the frame structure 210. As a result, the loading force for the air press is independent of the pressurized fluid pressure within the air plenum. Fabric wear is also minimized due to the use of low fabric wear materials and lubrication systems. Suitable lubrication systems may include chemical lubricants such as emulsified oils, debonders or other like chemicals, or water. Typical lubricant application methods include a spray of diluted lubricant applied in a uniform manner in the cross machine direction, an hydraulically or air atomized solution, a felt wipe of a more concentrated solution, or other methods well known in spraying system applications.
Observations have shown that the ability to run at higher pressure plenum pressures depends on the ability to prevent leaks. The presence of a leak can be detected from excessive air flows relative to previous or expected operation, additional operating noise, sprays of moisture, and in extreme cases, regular or random defects in the wet web including holes and lines. Leaks can be repaired by the alignment or adjustment of the air press sealing components.
In the air press, uniform air flows in the cross-machine direction are desirable to provide uniform dewatering of a web. Cross-machine direction flow uniformity may be improved with mechanisms such as tapered ductwork on the pressure and vacuum sides, shaped using computational fluid dynamic modeling. Because web basis weight and moisture content may not be uniform in the cross-machine direction, is may be desirably to employ additional means to obtain uniform air flow in the cross-machine direction, such as independently-controlled zones with dampers on the pressure or vacuum sides to vary the air flow based on sheet properties, a baffle plate to take a significant pressure drop in the flow before the wet web, or other direct means. Alternative methods to control CD dewatering uniformity may also include external devices, such as zoned controlled steam showers, for example a Devronizer steam shower available from Honeywell-Measurex Systems Inc. of Dublin, Ohio or the like.
EXAMPLES
The following EXAMPLES are provided to give a more detailed understanding of the invention. The particular amounts, proportions, compositions and parameters are meant to be exemplary, and are not intended to specifically limit the scope of the invention.
As referenced in relation to the Examples, MD Tensile strength, MD Stretch, and CD Tensile strength are obtained according to TAPPI Test Method 494 OM-88 "Tensile Breaking Properties of Paper and Paperboard" using the following parameters: Crosshead speed is 10.0 in/min (254 mm/min); full scale load is 10 lb (4,540 g); jaw span (the distance between the jaws, sometimes referred to as the gauge length) is 2.0 inches (50.8 mm); and specimen width is 3 inches (76.2 mm). The tensile testing machine is a Sintech, Model CITS-2000 from Systems Integration Technology Inc., Stoughton, Mass., a division of MTS Systems Corporation, Research Triangle Park, N.C.
The stiffness of the Example sheets can be objectively represented by either the maximum slope of the machine direction (MD) load/elongation curve for the tissue (hereinafter referred to as the "MD Slope") or by the machine direction Stiffness (herein defined), which further takes into account the caliper of the tissue and the number of plies of the product. Determining the MD Slope will be hereinafter described in connection with FIG. 9. The MD Slope is the maximum slope of the machine direction load/elongation curve for the tissue. The units for the MD Slope are kilograms per 3 inches (7.62 centimeters). The MD Stiffness is calculated by multiplying the MD Slope by the square root of the quotient of the Caliper divided by the number of plies. The units of the MD Stiffness are (kilograms per 3 inches)-microns 0 .5.
FIG. 9 is a generalized load/elongation curve for a tissue sheet, illustrating the determination of the MD Slope. As shown, two points P1 and P2, the distance between which is exaggerated for purposes of illustration, are selected that lie along the load/elongation curve. The tensile tester is programmed (GAP [General Applications Program], version 2.5, Systems Integration Technology Inc., Stoughton, Mass.; a division of MTS Systems Corporation, Research Triangle Park, N.C.) such that it calculates a linear regression for the points that are sampled from P1 to P2. This calculation is done repeatedly over the curve by adjusting the points P1 and P2 in a regular fashion along the curve (hereinafter described). The highest value of these calculations is the Max Slope and, when performed on the machine direction of the specimen, will be referred to herein as the MD Slope.
The tensile tester program should be set up such that five hundred points such as P1 and P2 are taken over a two and one-half inch (63.5 mm) span of elongation. This provides a sufficient number of points to exceed essentially any practical elongation of the specimen. With a ten inch per minute (254 mm/min) crosshead speed, this translates into a point every 0.030 seconds. The program calculates slopes among these points by setting the 10th point as the initial point (for example P1), counting thirty points to the 40th point (for example, P2) and performing a linear regression on those thirty points. It stores the slope from this regression in an array. The program then counts up ten points to the 20th point (which becomes P1) and repeats the procedure again (counting thirty points to what would be the 50th point (which becomes P2), calculating that slope and also storing it in the array). This process continues for the entire elongation of the sheet. The Max Slope is then chosen as the highest value from this array. The units of Max Slope are kg per three-inch specimen width. (Strain is, of course, dimensionless since the length of elongation is divided by the length of the jaw span. This calculation is taken into account by the testing machine program.)
EXAMPLE 1-4. To illustrate the invention, a number of uncreped throughdried tissues were produced using the method substantially as illustrated in FIG. 1. More specifically, Examples 1-4 were all three-layered, single-ply bath tissues in which the outer layers comprised disperged, debonded eucalyptus fibers and the center layer comprised refined northern softwood kraft fibers. Cenebra eucalyptus fibers were pulped for 15 minutes at 10% consistency and dewatered to 30% consistency. The pulp was then fed to a Maule shaft disperger. The disperger was operated at 160° F. (70° C.) with a power input of 2.2 HPD/T (1.8 kilowatt-days per tonne). Subsequent to disperging, a softening agent (Witco C6027) was added to the pulp in the amount of 7.5 kg per metric ton dry fiber (0.75 weight percent).
Prior to formation, the softwood fibers were pulped for 30 minutes at 3.2 percent consistency, while the disperged, debonded eucalyptus fibers were diluted to 2.5 percent consistency. The overall layered sheet weight was split 35%/30%/35% for Examples 1, 2 and 4 and 33%/34%/33% for Example 3 among the disperged eucalyptus/refined softwood/disperged eucalyptus layers. The center layer was refined to levels required to achieve target strength values, while the outer layers provided softness and bulk. For added dry and temporary wet strength, a strength agent identified as Parez 631 NC was added to the center layer.
These examples employed a four-layer Beloit Concept III headbox. The refined northern softwood kraft stock was used in the two center layers of the headbox to produce a single center layer for the three-layered product described. Turbulence generating inserts recessed about three inches (75 millimeters) from the slice and layer dividers extending about six inches (150 millimeters) beyond the slice were employed. The net slice opening was about 0.9 inch (23 millimeters) and water flows in all four headbox layers were comparable. The consistency of the stock fed to the headbox was about 0.09 weight percent.
The resulting three-layered sheet was formed on a twin-wire, suction form roll, former with forming fabrics being Appleton Mills 2164-B fabrics. Speed of the forming fabric ranged between 11.8 and 12.3 meters per second. The newly-formed web was then dewatered to a consistency of 25-26% using vacuum suction from below the forming fabric without air press, and 32-33% with air press before being transferred to the transfer fabric which was traveling at 9.1 meters per second (29-35% rush transfer). The transfer fabric was Appleton Mills 2164-B. A vacuum shoe pulling about 6-15 inches (150-380 millimeters) of mercury vacuum was used to transfer the web to the transfer fabric.
The web was then transferred to a throughdrying fabric traveling at a speed of about 9.1 meters per second. Appleton Mills T124-4 and T124-7 throughdrying fabrics were used. The web was carried over a Honeycomb throughdryer operating at a temperature of about 350° F. (175° C.) and dried to a final dryness of about 94-98% consistency.
The sequence of producing the Example sheets was as follows: Four rolls of the Example 1 sheets were produced. The consistency data reported in Table 1 is based on 2 measurements, one at the beginning and one at the end of the 4 rolls. The other data shown in Table 1 represents an average based on 4 measurements, one per roll. The air press was then turned on. Data just prior to and just after activation of the air press is shown in Table 3 (individual data points). This data shows that the air press caused significant increases in tensile values. The process was then modified to decrease the tensile values to levels comparable to the Example 1 sheets. After this process adjustment period, four rolls of the Example 2 sheets (this invention) were produced. Later, 4 rolls of the Example 3 sheets (this invention) were produced using a different throughdrying fabric and with the air press activated. The air press was shut off and the process adjusted to regain tensile strength values comparable to the Example 3 sheets. Four rolls of Example 4 sheets were then produced. The consistency data for each Example in Table 2 is an average based on 2 measurements, one at the beginning and one at the end of each set of 4 rolls. The other data in Table 2 is based on an average of 4 measurements per Example sheet, one per roll. In Table 2, the Example 4 data is presented in the left column and the Example 3 data is presented in the right column to remain consistent with Tables 1 and 3, which show data without the air press in the left column and data with the air press in the right column.
Tables 1-3 give more detailed descriptions of the process condition as well as resulting tissue properties for examples 1-4. As used in Tables 1-3 below, the column headings have the following meanings: "Consistency @ Rush Transfer" is the consistency of the web at the point of transfer from the forming fabric to the transfer fabric, expressed as percent solids; "MD Tensile" is the machine direction tensile strength, expressed in grams per 3 inches (7.62 centimeters) of sample width; "CD Tensile" is the cross-machine tensile strength, expressed as grams per 3 inches (7.62 centimeters) of sample width; "MD Stretch" is the machine direction stretch, expressed as percent elongation at sample failure; "MD Slope" is as defined above, expressed as kilograms per 3 inches (7.62 centimeters) of sample width; "Caliper" is the 1 sheet caliper measured with a Bulk Micrometer (TMI Model 49-72-00, Amityville, N.Y.) having an anvil diameter of 41/16 inches (103.2 mm) and an anvil pressure of 220 grams/square inch (3.39 Kilo Pascals), expressed in microns; "MD Stiffness" is the Machine Direction Stiffness Factor as defined above, expressed as (kilograms per 3 inches) -microns 0 .5 ; "Basis Weight" is the finished basis weight, expressed as grams per square meter; "TAD Fabric" means throughdrying fabric; "Refiner" is power input to refine the center layer, expressed as kilowatts; "Rush" is the difference in speed between the forming fabric and the slower transfer fabric, divided by the speed of the transfer fabric and expressed as a percentage; "HW/SW" is the breakdown of weight of hardwood (HW) and softwood (SW) fibers in the three-layered, single-ply tissues, expressed as a percent of total fiber weight; and "Parez" is the add-on rate of Parez 631 NC expressed as kilograms per metric ton of the center layer fiber.
TABLE 1______________________________________ EXAMPLE 2 EXAMPLE 1 (With Air Press (No Air and Process Press) Adjustment)______________________________________Consistency @ Rush Transfer (%) 25.2-26.1 32.5-33.4MD Tensile (grams/3") 933 944CD Tensile (grams/3") 676 662MD Stretch (%) 24.5 24.7MD Slope (kg/3") 4.994 3.778Caliper (microns) 671 607MD Stiffness (kg/3"-microns.sup.0.5) 129 93Basis Weight (gsm) 34.6 35.2TAD Fabric T-124-4 T-124-4Refiner (kW) 32 26Rush (%) 32 29HW/SW (%) 70/30 70/30Parez (kg/mt) 4.0 3.2______________________________________
TABLE 2______________________________________ EXAMPLE 3 EXAMPLE 4 (With Air Press (No Air and Process Press) Adjustment)______________________________________Consistency @ Rush Transfer (%) 24.6 32.4MD Tensile (grams/3") 961 907CD Tensile (grams/3") 714 685MD Stretch (%) 23.5 24.4MD Slope (kg/3") 5.668 3.942Caliper (microns) 716 704MD Stiffness (kg/3"-microns.sup.0.5) 152 105Basis Weight (gsm) 35.0 35.1TAD Fabric T-124-7 T-124-7Refiner (kW) 40 34.5Rush (%) 35 31HW/SW (%) 66/34 70/30Parez (kg.mt) 2.5 2.5______________________________________
TABLE 3______________________________________ (No Air (With Air Press) Press)______________________________________Consistency @ Rush Transfer (%) 25.2 32.5MD Tensile (grams/3") 915 1099CD Tensile (grams/3") 661 799CD Wet Tensile 127 150MD Stretch (%) 24.4 28.5MD Slope (kg/3") 4.996 4.028Caliper (microns) 665 630MD Stiffness (kg/3"-microns.sup.0.5) 129 101Basis Weight (gsm) 34.3 34.6TAD Fabric T-124-4 T-124-4Refiner (kW) 32 32Rush (%) 32 32HW/SW (%) 70/30 70/30Parez (kg/mt) 4.0 4.0______________________________________
As shown by the previous Examples, the air press produces significantly higher consistencies upstream of the differential speed transfer which result in softer sheets as evidenced by lower modulus values. Desirably, the modulus (MD Stiffness) of tissue products is at least 20 percent less than that of a comparable tissue product made without supplementally dewatering to a consistency of greater than about 30 percent. Further, the machine direction tensile of the tissue products is at least 20 percent greater, and the cross direction tensile of the tissue products is at least 20 percent greater, than that of a comparable tissue product made without supplementally dewatering to a consistency of greater than about 30 percent. Additionally, the machine direction stretch of tissue products is at least 17 percent greater than that of a comparable tissue product made without supplementally dewatering to a consistency of greater than about 30 percent.
The foregoing detailed description has been for the purpose of illustration. Thus, a number of modifications and changes may be made without departing from the spirit and scope of the present invention. For instance, alternative or optional features described as part of one embodiment can be used to yield another embodiment. Additionally, two named components could represent portions of the same structure. Further, various process and equipment arrangements as disclosed in U.S. Pat. No. 5,667,636 issued Sep. 16, 1997 to S. A. Engel et al., may be employed. Therefore, the invention should not be limited by the specific embodiments described, but only by the claims.
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An air press for noncompressively dewatering a wet web to consistency levels not previously thought possible at industrially useful speeds without thermal dewatering.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a process for producing 5-fluorouracil derivative having the formula ##STR2## wherein R represents hydrogen atom and 2-tetrahydrofuryl group.
2. Description of the Prior Art
The 5-fluorouracil derivatives having the formula I, are useful as medicines and intermediates for medicines. Especially, the N 1 (2-tetrahydrofuryl)-5-fluorouracil (R ═ H in formula I) has been known to be oral antineoplastic agent having low toxicity.
Heretofore, the following processes have been known to produce N-substituted-fluorouracils.
(1) The process for reacting mercury salt of 5-fluorouracil with 2-chlorotetrahydrofuran. (British Pat. No. 1,168,391 and Hiller et al.; Dokl Akad. Nauk. (USSR) 176[2]332, 1967).
(2) The process for reacting 2,4-bis(trimethylsilyl)-5-fluorouracil with 2-chlorotetrahydrofuran (British Pat. No. 1,168,391).
(3) The process for reacting 2,4-bis(trimethylsilyl)-5-fluorouracil with 2-acyloxytetrahydrofuran or 2-alkoxytetrahydrofuran. (Japanese Unexamined Patent Publication Nos. 50384/1975 and 105674/1975).
(4) The process for reacting 5-fluorouracil with an alkali metal hydride and then reacting the resulting alkali metal salt of 5-fluorouracil with 2-halogenotetrahydrofuran. (Japanese Unexamined Patent Publication No. 8282/1976).
However, in these conventional processes, the starting materials such as 2-chlorotetrahydrofuran which are easily decomposed and are produced by using stimulus gas are used and the yields are low.
In the other processes, 2-acyloxytetrahydrofuran or 2-alkoxytetrahydrofuran of which manufacture causes dangerous exothermic reaction is needed or the expensive raw material such as hexamethyldisilasane is needed.
Accordingly, from the viewpoint of cost or safety of the operation, these conventional processes are not satisfactory.
In Dokl, Akad, Nauk, (USSR), it is described that a condensed product could not be obtained by direct reaction of the substituted uracil with 2,3-dihydrofuran. In C.W. Noell et al.; J. Heterocyclic Chem. 3, 5, (1966), the similar fact is described.
Accordingly, it has been considered to be impossible to directly react 5-fluorouracil with 2,3-dihydrofuran.
However, the inventors have studied the reactivity of 5-halogeno-substituted uracils in detail, and have found that the reaction of 5-halogeno-substituted uracil with 2,3-dihydrofuran is surprisingly resulted in a polar aprotic solvent at higher than specific temperature under pressure. Moreover, the inventors have found that the reaction can be promoted with a catalyst.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a novel process for producing 5-fluorouracil derivatives by a direct reaction of 5-fluorouracil with 2,3-dihydrofuran without the above-mentioned disadvantages.
The other object of the present invention is to provide an improved process for producing 5-fluorouracil derivatives with economical advantages.
The other objects of the invention will be understood from the following description.
The objects of the present invention have been attained by producing 5-fluorouracil derivative having the formula (I) by reacting 5-fluorouracil with more than equi-mole of 2,3-dihydrofuran in a polar aprotic solvent with a catalytically effective amount of a catalyst selected from the group consisting of metal halides, non-metal halides, inorganic acids and organic acids in neutral or basic condition if necessary with a tertiary amine at 50° to 150° C under pressure in a sealed reactor for enough reaction time such as 0.5 to 50 hours.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The polar aprotic solvents used in the process of the invention are preferably the solvents dissolving both of 5-fluorouracil and 2,3-dihydrofuran from the viewpoint of the operation for the reaction.
Suitable polar aprotic solvents include amides such as N,N-dimethylformamide, N,N-dimethylacetamide, tetramethyl urea, hexamethyl phosphoramide; tertiary amines such as trialkyl amines such as triethylamine; substituted morpholine such as N-methyl morpholine; substituted or nonsubstituted pyridines such as pyridine, α-picoline, β-picoline, γ-picoline, lutidine; and quinoline, isoquinoline, pyrimidine, pyrazine, N,N-dimethylaniline, etc..
It is preferable to use N,N-dimethylformamide, N,N-dimethylacetamide, pyridine, α-picoline, β-picoline, γ-picoline, etc..
The catalysts used in the process of the invention can be alkali metal halides, alkaline earth metal halides, Lewis acids of metal or non-metal halides, or inorganic acids or organic acids. The catalysts are classified depending upon the characteristics as follows:
GROUP A
Alkali metal halides and alkaline earth metal halides
calcium halides such as calcium chloride, calcium bromide, calcium iodide;
magnesium halides such as magnesium chloride, magnesium bromide, magnesium iodide;
strontium halides such as strontium chloride, strontium bromide, strontium iodide;
barium halides such as barium chloride, barium bromide, barium iodide;
alkali metal halides such as lithium chloride, sodium chloride, potassium chloride, lithium bromide, lithium iodide, potassium bromide, potassium iodide, sodium bromide.
GROUP B
(a) Metal halides except alkali metal and alkaline earth metal halides
iron halides such as ferrous chloride, ferric chloride; aluminum halides such as aluminum chloride; zinc halide such as zinc chloride; tin halides such as stannous chloride, stannic chloride, stannous bromide, stannic bromide; copper halides such as cuprous chloride, cuprous bromide, cuprous iodide, cupric chloride; antimony halides such as antimony chloride; manganese halides such as manganese chloride; chromium halides such as chromium chloride; nickel halide such as nickel chloride; cobalt halides such as cobalt chloride; lead halides such as lead chloride; titanium halide such as titanium tetrachloride; cadmium halides such as cadmium chloride, cadmium iodide; selenium halide such as selenium chloride; mercury halides such as mercurous chloride, mercuric chloride, etc..
(b) Non-metal halides
silicon tetrachloride; phosphorous halides such as phosphorus trichloride, phosphorus pentachloride, phosphorus oxychloride; boron halide such as boron trichloride, boron trifluoride and complexes thereof with ether, methanol, etc..
(c) Organic acids and inorganic acids
p-toluenesulfonic acid, benzoic acid, trifluoroacetic acid, hydroquinone, phosphoric acid, phosphorus pentoxide, hydrochloric acid, sulfuric acid.
In the catalysts of Group A, the optimum catalysts are lithium chloride, sodium chloride, potassium chloride, magnesium chloride, calcium chloride, strontium chloride, barium chloride, calcium bromide, potassium iodide, sodium bromide, etc..
In the catalysts of Group B, the optimum catalysts are antimony trichloride, boron trifluoride-etherate, stannic chloride, stannous chloride, ferric chloride, ferrous chloride, cuprous bromide, zinc chloride, cadmium iodide, aluminum chloride, phosphoric acid, phosphorus pentoxide, p-toluenesulfonic acid, etc..
In the process of the invention, the reaction is carried out at a ratio of more than equi-mole usually 1 to 10 mole preferably 2 to 6 mole of 2,3-dihydrofuran per 1 mole of 5-fluorouracil and 0.0001 to 5 mole preferably 0.001 to 1 mole of the catalyst per 1 mole of 5-fluorouracil.
When an amide type solvent is used, 0.001 to large excess of a weak basic compound is used depending upon the kind and amount of the catalyst.
In this case, it is preferable to use the weak basic compound at a ratio of more than that of the catalyst so as to adjust the reaction system to be neutral to basic condition.
The reaction is carried out at 50° to 150° C preferably 90° to 150° C especially 100° to 130° C.
The reaction time is dependent upon the kind and amount of the catalyst and the solvent, and the reaction temperature, and is usually in a range of 30 minutes to 50 hours preferably 2 to 24 hours.
In the process of the invention, 2,3-dihydrofuran has a boiling point of 54.5° C and it is vaporized at the reaction temperature. The reaction is carried out under pressure preferably an autovaporized pressure of higher in an autoclave or a sealed tube.
The optimum embodiments of the process of the invention will be illustrated.
In an autoclave, 5-fluorouracil and 2,3-dihydrofuran at a ratio of 1 to 10 mole especially 2 to 6 mole per 1 mole of 5-fluorouracil, and a polar aprotic solvent of pyridine, α-picoline, β-picoline, γ-picoline, lutidine, pyrimidine or pyradine especially pyridine, α-picoline, β-picoline or γ-picoline are charged.
Then, the catalyst of Group A or Group B especially lithium chloride, sodium chloride, potassium chloride, sodium bromide, potassium iodie, magnesium chloride, calcium chloride, strontium chloride, barium chloride, calcium bromide, calcium iodide, ferrous chloride, ferric chloride, cuprous chloride, cuprous bromide, cuprous iodide, zinc chloride, cadmium iodide, aluminum chloride, boron trifluoride-complex, stannous chloride, stannic chloride, antimony trichloride, phosphoric acid, phosphorus pentoxide or p-toluenesulfonate, is added to the mixture at a ratio of 0.0001 to 5 mole especially 0.001 to 1 mole per 1 mole of 5-fluorouracil. The mixture is heated at 50° to 150° C preferably 90° to 150° C especially 100° to 130° C for 0.5 to 50 hours especially 2 to 24 hours under an autovaporized pressure.
The other optimum embodiments of the process of the invention will be illustrated.
In an autoclave, 5-fluorouracil and 2,3-dihydrofuran at a ratio of 1 to 10 mole especially 2 to 6 mole per 1 mole of 5-fluorouracil, and a polar aprotic solvent of N,N-dimethylformamide, N,N-dimetylacetamide, tetramethyl urea or hexamethylphosphoramide, especially N,N-dimethylformamide or N,N-dimethylacetamide, are charged.
Then, the catalyst of Group A especially lithium chloride, sodium chloride, potassium chloride, sodium bromide, potassium iodide, magnesium chloride, calcium chloride, strontium chloride, barium chloride, calcium bromide or calcium iodide is added to the mixture at a ratio of 0.0001 to 5 mole especially 0.001 to 1 mole per 1 mole of 5-fluorouracil.
The mixture is heated at 50° to 150° C preferably 90° to 150° C especially 100° to 130° C for 0.5 to 50 hours especially 2 to 24 hours under an autovaporized pressure.
The other optimum embodiments of the process of the invention will be illustrated.
In an autoclave, 5-fluorouracil and 2,3-dihydrofuran at a ratio of 1 to 10 mole preferably 2 to 6 mole per 1 mole of 5-fluorouracil and a polar aprotic solvent of N,N-dimethylformamide, N,N-dimethylacetamide, tetramethyl urea or hexamethyl phosphoramide especially N,N-dimethylformamide or N,N-dimethylacetamide, are charged.
Then, the catalyst of Group B especially, ferrous chloride, ferric chloride, cuprous chloride, cuprous bromide, cuprous iodide, zinc chloride, cadmium iodide, aluminum chloride, boron trifluoridecomplex, stannous chloride, stannic chloride, antimony trichloride, phosphoric acid, phosphorus pentoxide or p-toluenesulfonic acid is added to the mixture at a ratio of 0.0001 to 5 mole especially 0.001 to 1 mole per 1 mole of 5-fluorouracil.
A weak basic compound especially an amine such as triethylamine, pyridine, α-picoline, β-picoline, γ-picoline, lutidine, pyradine, pyrimidine, quinoline, isoquinoline, N-methyl morphorine, or N,N-dimethylaniline, is added to adjust pH to neutral to basic condition.
The mixture is heated at 50° to 150° C preferably 90° to 150° C especially 100° to 130° C for 0.5 to 50 hours especially 2 to 24 hours under an autovaporized pressure.
In accordance with the process of the invention, N 1 ,N 3 -bis(2-tetrahydrofuryl)-5-fluorouracil (R ═ 2-tetrahydrofuryl in formula I) is treated in an inert solvent in the presence of an acid at the room temperature for a short time (longer than 5 min. preferably longer than 15 min.) to easily convert it into N 1 -(2-tetrahydrofuryl)-5-fluorouracil.
Suitable inert solvents include toluene, benzene, dichloromethane, methanol, ethanol, etc..
Suitable acids include inorganic acids such as hydrogen chloride, sulfuric acid, phosphoric acid, and organic acids such as acetic acid, trifluoroacetic acid; p-toluenesulfonic acid, etc.. It is preferable to use hydrogen chloride, acetic acid, trifluoroacetic acid.
The inert solvents should be inert to 5-fluorouracil derivatives.
It is possible to carry out the acid treatment to the reaction mixture without separating N 1 ,N 3 -bis(2-tetrahydrofuryl)-5-fluorouracil from the reaction mixture.
In order to separate N 1 -(2-tetrahydrofuryl)-5-fluorouracil and N 1 ,N 3 -bis(2-tetrahydrofuryl)-5-fluorouracil, it is possible to easily attain the purpose by the known methods such as a solvent extraction, a crystallization, and a column chromatography and a combination thereof.
In accordance with the process of the invention, the steps for producing 5-fluorouracil derivative especially N 1 -(2-tetrahydrofuryl)-5-fluorouracil can be remarkably shorten and economical raw materials can be used and the reaction conditions are relatively mild and the yield is remarkably high and the cost of the production can be remarkably reduced, advantageously.
The invention will be further illustrated by certain examples.
EXAMPLE 1
In a sealed tube, 780 mg (6 m mole) of 5-fluorouracil, 5 ml of pyridine, 100 mg (0.90 m mole) of calcium chloride and 1.26 g (18 m mole) of 2,3-dihydrofuran were heated at 100° C for 3 hours. The reaction mixture further admixed with 800 mg (11.5 m mole) of 2,3-dihydrofuran and the mixture was heated for 17 hours. After the reaction, the insoluble matters in the reaction mixture were separated by a filtration. Pyridine was distilled off from the filtrate under a reduced pressure. The residue was dissolved in chloroform and a small amount of the insoluble matter was separated by a filtration.
Chloroform was distilled off from the filtrate and the residue was purified by a column chromatography using a silica gel column (mixture of chloroform and acetone = 8 : 1 (V/V) as a developing medium) to obtain 1.11 g of N 1 ,N 3 -bis(2-tetrahydrofuryl)-5-fluorouracil (yield: 68.5%) and 2.83 g of N 1 -(2-tetrahydofuryl)-5-fluorouracil (yield: 23.6%).
The former product was recrystallized from ether to obtain a purified product having a melting point of 99° to 101° C.
Nmr τ(cdcl 3 , TMS, 60 Mz)
4.04 (1H), 3.35 (1H),
2.93 (1hd, J=7Hz).
The latter product was recrystallized from ethanol to obtain a purified product having a melting point of 166° to 168° C.
Elementary Analysis (C 8 H 9 N 2 O 3 F)
______________________________________ C H N______________________________________Calculated 48.00% 4.53% 13.99%Found 48.12% 4.65% 14.18%NMR τ(CDCl.sub.3, TMS, 60 Mz)3.98 (1H), 2.72 (1 Hd, J = 7Hz)-0.15 (1H).______________________________________
EXAMPLES 2 TO 4
In accordance with the process of Example 1 except using potassium iodide, zinc chloride or cadmium iodide instead of calcium chloride, the reaction of 5-fluorouracil with 2,3-dihydrofuran was carried out. The results are shown in Table 1.
Table 1______________________________________ N.sub.1 -(2-tetra- hydrofuryl)- N.sub.1, N.sub.3 -bis(2- 5-fluoro- tetrahydrofuryl)- uracil 5-fluorouracilExample Catalyst (yield) (yield)______________________________________2 KI 422 mg 1,020 mg 100 mg (0.60 m mole) (35.2%) (63.2%)3 ZnCl.sub.2 493 mg 180 mg 100 mg (0.73 m mole) (41.1%) (11.1%)4 CdI.sub.2 324 mg 426 mg 100 mg (0.27 m mole) (27.0%) (26.3%)______________________________________
EXAMPLE 5
In a sealed tube, 780 mg (6 m mole) of 5-fluorouracil, 5 ml of pyridine, 100 mg (0.44 m mole) of antimony trichloride and 1.26 g (18 m mole) of 2,3-dihydrofuran were heated at 100° C for 3 hours. The reaction mixture was further admixed with 800 mg (11.5 m mole) of 2,3-dihydrofuran and the mixture was heated for 17 hours. After the reaction, pyridine was distilled off under a reduced pressure and the residue was dissolved in chloroform and the insoluble matters were separated by a filtration. Chloroform was distilled off from the filtrate and the residue was purified by a column chromatography using a silica gel column (mixture of chloroform and acetone = 8 : 1 (V/V) as a developing medium) to obtain 1.10 g of N 1 ,N 3 -bis(2-tetrahydrofuryl)-5-fluorouracil (yield: 68.0%) and 325 mg of N 1 -(2-tetrahydrofuryl)-5-fluorouracil (yield: 27%).
The former product was recrystallized from ether to obtain a purified product having a melting point of 99° to 101° C. The latter product was recrystallized from ethanol to obtain a purified product having a melting point of 166° to 168° C.
EXAMPLES 6 to 9
In accordance with the process of Example 5 except using boron trifluoride-etherate, ferric chloride, ferrous chloride or phosphoric acid instead of antimony chloride, the reaction of 5-fluorouracil with 2,3-dihydrofuran was carried out. The results are shown in Table 2.
Table 2______________________________________ N.sub.1, N.sub.3 -bis N.sub.1 -(2-tetra- (2-tetrahydro- hydrofuryl)- furyl)-5- 5-fluoroura- fluoro- cil uracilExample Catalyst (yield) (yield) Note______________________________________6 BF.sub.3 -ether 545 mg 776 mg 100 mg (45.4%) (47.9%) (0.70 m mole)7 FeCl.sub.3 . 6H.sub.2 O 682.5 mg 340.2 mg 100 mg * (0.37 m mole) (56.9%) (21.0%)8 FeCl.sub.2 588 mg 388.8 mg 100 mg (49.0%) (24.0%) **9 phosphoric 355 mg 1,090 mg acid 100 mg (1.02 m mole) (29.6%) (67.3%)______________________________________ Note: *10 ml of solvent **10 ml of solvent
EXAMPLE 10
In a sealed tube, 780 mg (6 m mole) of 5-fluorouracil, 5 ml of pyridine, 100 mg (0.70 m mole) of phosphorus pentoxide and 1.26 g (18 m mole) of 2,3-dihydrofuran were heated at 100° C for 17 hours. After the reaction, pyridine was distilled off from the reaction mixture under a reduced pressure. The residue was dissolved in chloroform and the insoluble unreacted 5-fluorouracil was separated by a filtration and the residue was purified by a column chromatography using a silica gel column (mixture of benzene; ethyl acetate and acetone = 2 : 1 : 1 (V/V) as a developing medium) to obtained 200 mg of N 1 ,N 3 -bis(2-tetrahydrofuryl)-5-fluorouracil (yield: 12.3%) and 757.6 mg of N 1 -(2-tetrahydrofuryl)-5-fluorouracil (yield: 63.0%).
The former product was recrystallized from ether to obtain a purified product having a melting point of 99° to 101° C. The latter product was recrystallized from ethanol to obtain a purified product having a melting point of 166° to 168° C.
EXAMPLES 11 to 13
In accordance with the process of Example 10 except using cuprous bromide, aluminum chloride or p-toluenesulfonic acid instead of phosphorus pentoxide, the reaction of 5-fluorouracil with 2,3-dihydrofuran was carried out. The results are shown in Table 3.
Table 3______________________________________ N.sub.1, N.sub.3 -bis N.sub.1 -(2-tetra- (2-tetrahydro- hydrofuryl)- furyl)-5- 5-fluoro- fluoro- uracil uracilExample Catalyst (yield) (yield) Note______________________________________11 CuBr 600 mg 100 mg 100 mg * (0.70 m mole) (50.0%) (6.2%)12 AlCl.sub.3 305 mg 103 mg 100 mg ** (0.75 m mole) (25.4%) (6.4%)13 p-toluene- 511 mg sulfonic acid -- *** 103 mg (0.6 m mole) (42.6%)______________________________________ Note: *reaction time: 20 hours developing medium chloroform : acetone = 8 : 1 V/V. **reaction time: 3 hours developing medium chloroform : acetone = 8 : 1 V/V. ***reaction time: 7 hours developing medium ethyl acetate : benzene = 5 : 1 V/V.
EXAMPLE 14
In accordance with the process of Example 1 except using 100 mg (0.38 m mole) of stannic chloride instead of calcium chloride, the reaction of 5-fluorouracil with 2,3-dihydrofuran was carried out. After the reaction, the insoluble matters in the reaction mixture were separated by a filtration. Pyridine was distilled off from the filtrate under a reduced pressure.
The residue was dissolved in chloroform and the insoluble matters (small amount) were separated by a filtration. Chloroform was distilled off from the filtrate and benzene was added to the residue and the precipitated crystals were separated by a filtration to obtain 150 mg of N 1 -(2-tetrahydrofuryl)-5-fluorouracil. (yield: 12.5%).
The product was recrystallized from ethanol to obtain a pure compound having a melting point of 166° to 168° C.
A mixture of benzene and trifluoroacetic acid was added to the mother liquor to make the ratio of benzene and trifluoroacetic acid is 2:1 (V/V).
The mixture was stirred for 15 minutes at the room temperature and the solvent was distilled off under a reduced pressure and the residue was recrystallized from a mixture of ethanol and ether to obtain 750 mg of N 1 -(2-tetrahydrofuryl)-5-fluorouracil. (yield: 62.5%). The product was recrystallized from ethanol to obtain a pure compound having a melting point of 166° to 168° C.
EXAMPLE 15
In accordance with the process of Example 5 except using 100 mg of stannous chloride instead of antimony trichloride, the reaction of 5-fluorouracil with 2,3-dihydrofuran was carried out.
Pyridine was distilled off from the reaction mixture under a reduced pressure and the residue was dissolved in chloroform and the insoluble matters (small amount) were separated by a filtration and chloroform was distilled off and the resulting crystals were washed with ether to obtain 919 mg of N 1 -(2-tetrahydrofuryl)-5-fluorouracil. (yield: 76.6%). The product was recrystallized from ethanol to obtain a pure compound having a melting point of 166° to 168° C.
Ether was distilled off from the ether wash liquid and 4 ml of benzene and 2 ml of trifluoroacetic acid were added to the residue, and the mixture was stirred at the room temperature for 15 minutes and benzene and trifluoroacetic acid were distilled off, and the residue was washed with ether to obtain 249 mg of N 1 -(2-tetrahydrofuryl)-5-fluorouracil. (yield: 20.7%).
The product was recrystallized from ethanol to obtain a pure compound having a melting point of 166° to 168° C.
EXAMPLE 16
In 2.5 liter autoclave, 300 g (2.31 mole) of 5-fluorouracil, 720 ml of pyridine, 1.84 g (0.017 mole) of fine powdery calcium chloride and 485 g (6.93 mole) of 2,3-dihydrofuran were charged, and the autoclave was shaken at 105° to 110° C for 6.5 hours. After the reaction, the insoluble matters in the reaction mixture were separated by a filtration. Pyridine was distilled off from the filtrate under a reduced pressure. The residue was admixed with 700 ml of toluene and 150 ml of trifluoroacetic acid and the mixture was stirred at the room temperature for one night and then toluene and trifluoroacetic acid were distilled off under a reduced pressure and the residue was washed with ether to obtain 430 g of white crystals of N 1 -(2-tetrahydrofuryl)-5-fluorouracil. (yield: 93.2%; melting point: 157° to 160° C).
The product was recrystallized from ethanol to obtain 360 g of a pure compound having a melting point of 166° to 168° C. The object product was purified from the mother liquor to obtain 35.6 g of the pure compound having a melting point of 166° to 168° C.
EXAMPLE 17
In 200 ml autoclave, 26.0 g of 5-fluorouracil (200 m mole), 60 ml of pyridine, 160 mg (1.44 m mole) of fine powdery calcium chloride and 28.0 g (400 m mole) of 2,3-dihydrofuran were charged and the autoclave was shaken at 105° to 110° C for 6.5 hours.
After the reaction, the insoluble matters in the reaction mixture were separated by a filtration. Pyridine was distilled off from a filtrate under a reduced pressure. The residue was dissolved in chloroform and the insoluble unreacted 5-fluorouracil (0.24 g) was separated by a filtration.
Chloroform was distilled off, and the residue was admixed with 130 ml of toluene and 10 ml of trifluoroacetic acid, and the mixture was stirred at the room temperature for one night and toluene and trifluoroacetic acid were distilled off and the residue was washed with ether to obtain 33.5 g of white crystals of N 1 -(2-tetrahydrofuryl)-5-fluorouracil. (yield: 83.8%; melting point: 157.5° to 160° C). The product was recrystallized from ethanol to obtain 30 g of a pure compound having a melting point of 166° to 168° C.
EXAMPLE 18
In a sealed tube, 780 mg (6 m mole) of 5-fluorouracil, 100 mg (0.90 m mole) of calcium chloride, 5 ml of N,N-dimethylformamide and 1.26 g (18 m mole) of 2,3-dihydrofuran were heated at 100° C for 3 hours.
The reaction mixture was further admixed with 800 mg (11.5 m mole) of 2,3-dihydrofuran and the mixture was heated for 17 hours. After the reaction, N,N-dimethylformamide was distilled off from the reaction mixture under a reduced pressure.
The residue was dissolved in chloroform and the insoluble matters (small amount) were separated. Chloroform was distilled off from the filtrate and the residue was admixed with 5 ml of toluene and 0.9 ml of trifluoroacetic acid and the mixture was stirred at the room temperature for one night and toluene and trifluoroacetic acid was distilled off under a reduced pressure and the residue was washed with ether to obtain 1.0223 g of white crystals of N 1 -(2-tetrahydrofuryl)-5-fluorouracil (yield: 85.2%; melting point: 155.5° to 158.5° C). The product was recrystallized from ethanol to obtain 0.915 g of a pure compound having a melting point of 166° to 168° C.
Elementary analysis: (C 8 H 9 FN 2 O 3 )
______________________________________ C H N______________________________________Calculated (%) 48.00 4.53 13.99Found (%) 48.05 4.61 14.01______________________________________
EXAMPLE 19
In a sealed tube, 780 mg (6 m mole) of 5-fluorouracil, 100 mg (0.42 m mole) of calcium bromide(CaBr 2 .2H 2 O), 5 ml of N,N-dimethylformamide and 1.26 g (18 m mole) of 2,3-dihydrofuran were heated at 100° C for 3 hours. The reaction mixture was further admixed with 800 mg (11.5 m mole) of 2,3-dihydrofuran and the mixture was heated for 17 hours. After the reaction, N,N-dimethylformamide was distilled off from the reaction mixture under a reduced pressure. The residue was dissolved in chloroform and the insoluble matter (small amount) were separated by a filtration.
Chloroform was distilled off from the filtrate and the residue was purified by a column chromatography using a silica gel column (mixture of chloroform and acetone = 8:1 (V/V) as a developing medium) to obtain 440 mg of N 1 ,N 3 -bis(2-tetrahdrofuryl)-5-fluorouracil (yield: 27.1%) and 750 mg of N 1 -(2-tetrahydrofuryl)-5-fluorouracil (yield: 62.5%).
The former was recrystallized from ether to obtain a pure compound having a melting point of 99° to 101° C.
Elementary analysis: (C 12 H 15 FN 2 O 4 )
______________________________________ C H N______________________________________Calculated (%) 53.33 5.59 10.36Found (%) 53.03 5.51 10.20______________________________________
The latter product was recrystallized from ethanol to obtain a pure compound having a melting point of 166° to 168° C.
EXAMPLES 20 TO 24
In accordance with the process of Example 19 except using sodium chloride, potassium chloride, magnesium chloride, barium chloride or calcium iodide instead of calcium bromide, the reaction of 5-fluorouracil with 2,3-dihydrofuran was carried out.
The results are shown in Table 4.
Table 4______________________________________ N.sub.1 -(2-tetrahydro- N.sub.1, N.sub.3 -bis(2- furyl)-5-fluoro- tetrahydrofuryl)- uracil 5-fluorouracilExample Catalyst (yield) (yield)______________________________________20 NaCl 706 mg 572 mg 100 mg (1.17 m mole) (58.8%) (35.3%)21 KCl 727 mg 540 mg 100 mg (1.34 m mole) (60.6%) (33.3%)22 MgCl.sub.2 685 mg 509 mg 100 mg (1.05 m mole) (57.1%) (31.4%)23 BaCl.sub.2 690 mg 505 mg 100 mg (0.48 m mole) (57.5%) (31.2%)24 CaI.sub.2 727 mg 393 mg 100 mg (60.6%) (24.2%)______________________________________
EXAMPLE 25
In 400 ml autoclave, 52.0 g of 5-fluorouracil (0.4 mole) 120 ml of pyridine, 300 mg (2.7 m mole) of fine powdery calcium chloride and 84.0 g (1.2 mole) of 2,3-dihydrofuran were charged and autoclave was shaken at 120° C for 3 hours.
After the reaction, the insoluble matters in the reaction mixture were separated by filtration. Pyridine was distilled off from a filtrate under a reduced pressure. The residue was dissolved in 56 ml of methanol, and added with 475 mg of HCl dissolved in 4 ml of methanol and stand for over night at room temperature (20°-30° C). After cooling, separated crystals were filtrated and washed with cooled ethanol. 71.96 g (yield: 90.0%) of white crystals N 1 -(2-tetrahydrofuryl)-5-fluorouracil (m.p. 166°-168° C) were obtained.
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5-Fluorouracil derivative having the formula ##STR1## wherein R represents hydrogen atom or 2-tetrahydrofuryl group is produced by reacting more than equi-mole of 2,3-dihydrofuran with 5-fluorouracil in a polar aprotic solvent with a catalytically effective amount of a catalyst selected from the group consisting of metal halides, non-metal halides, tertiary amine salt of inorganic acids and organic acids in neutral or basic condition at 50° to 150° C under pressure.
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STATEMENT AS TO GOVERNMENT FUNDING
This invention was supported in part by Government funding, NIDDK Research Grant DK-4790, and the Government, therefore, may have certain rights in the invention.
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a United States national filing under 35 U.S.C. §371 of international (PCT) application No. PCT/US99/09521 with an international filing date of May 3, 1999, which claims the benefit of U.S. patent application Ser. No. 09/072,956, filed May 5, 1998, now abandoned.
BACKGROUND OF THE ART
This invention relates to a series of PTH and PTHrP analogues that selectively bind to PTH2 receptors and as such may be useful in treating abnormal CNS functions; abnormal pancreatic functions; divergence from normal mineral metabolism and homeostasis; male infertility; regulation of abnormal blood pressure; and hypothalmic disease, to name a few potential uses.
An alternate parathyroid hormone (PTH) receptor, designated as PTH2 receptor, has been identified in rat and human brain. This receptor is selectively activated by PTH-(1-34) (SEQ ID NO:1), but not PTH-related protein PTHrP-(1-34) (SEQ ID NO:2), which has the same calcium-mobilizing activities as PTH-(1-34) (SEQ ID NO:1). Both PTH and PTHrP share a common G protein-coupled receptor, termed the PTH/PTHrP receptor. The PTH2 receptor is localized predominantly in the brain and pancreas, in contrast to PTH/PTHrP receptor, which is primarily localized in bone and the kidney, the principal target tissue for PTH action. Parathyroid hormone (PTH) is the principal physiological regulator of calcium levels in the blood (Chorev, M., Rosenblatt, M., 1994, Structure function analysis of parathyroid hormone and parathyroid hormone-related protein, Bilezikian, J. P., Marcus, R., Levine, M., (eds) The Parathyroids: Basic and Clinical Concepts. Raven Press, New York, pp 139-156; Juppner, H., et al., 1991, Science, 254:1024-1026; and Martin, T. J., et al., 1991, Crit. Rev. Biochem. Mol. Biol. 26:377-395). PTH-related protein (PTHrP) was originally identified as the agent responsible for the paraneoplastic syndrome of humoral hypercalcemia of malignancy (Suva, L. J., et al., 1987, Science, 237:893-896 and Orloff, J. J., et al., 1994, Endocrinol. Rev. 15:40-60). PTH and PTHrP are products of distinct, yet evolutionary-related genes. PTH and PTHrP show sequence similarities only in the N-terminal 13 amino acids, 8 of which are identical (Abou-Samra A B, et al., 1992, Proc. Natl. Sci. Acad. USA, 89:2732-2736). However, the expression pattern and physiological role of these two molecules are remarkably different. PTH has a highly restricted pattern of expression and acts as a classical endocrine hormone, whereas PTHrP is expressed in a wide variety of normal tissues and functions in a predominantly autocrine/paracrine fashion (Urena, P., et al., 1993, Endocrinology, 133:617-623; Lee, K., et al., 1995, Endocrinology, 136:453-463; and Martin, T. J., et al., 1995, Miner. Electrolyte Metab., 21:123-128). More recently, PTHrP has been shown to play a fundamental role in embryonic differentiation of bone and cartilage development.
PTH and PTHrP exert their wide-ranging effects via a common receptor located on the surface of target cells (Juppner, H., et al., 1988, J. Biol. Chem., 263:1071-1078; Shigeno, C., et al., 1988, J. Biol. Chem., 263:18369-18377). The PTH/PTHrP receptor is a member of a subfamily of G protein-coupled receptor superfamily, which includes the receptors for glucagon, growth hormone-releasing hormone (GHRH), vasoactive intestinal peptide (VIP), glucagon-like peptide 1 (GLP-1), gastric inhibitory polypeptide (GIP), secretin, pituitary adenylate cyclase-activating polypeptide (PACAP), calcitonin, and corticotropin-releasing factor (CRF) (Segre, G., et al., 1993, Trends Endocrinol. Metab. 4:309-314). The PTH/PTHrP receptor recognizes the N-terminal 1-34 regions of both ligands (Schipani, E., et al., 1993, Endocrinology, 132:2157-2165) and is particularly abundant in classical PTH target tissues such as bone and kidney (Urena, P., et al., 1993 Endocrinology, 133:35-38). Ligand binding to the PTH/PTHrP receptor can activate at least two signaling pathways; the adenylyl cyclase-cAMP-protein kinase A pathway (Partridge, N C, et al., 1981, Endocrinology 108:220-225), and the inositol trisphosphate-cytosolic calcium-protein kinase C pathway (Abou-Samra, A-B., et al., 1989, Endocrinology 124:1107-1113).
An homologous receptor for PTH, designated the PTH2 receptor, has been identified and partially characterized (Behar, V., et al., 1996, Endocrinology, 137:2748-2757; Gardella, T. J., et al., 1996, The J. Biol. Chem., 271:19888-19893; Behar, V., et al., 1996, Endocrinology, 137:4217-4224; and Usdin, T. B., et al., 1997, Endocrinology, 138:831-834). Amongst the seven transmembrane G protein-coupled receptors, the PTH2 receptor is most similar in sequence to the PTH/PTHrP receptor (51% of the amino acid sequence identify). Interestingly, PTH2 receptor mRNA is not detected in bone or osteosarcoma cell lines, but is expressed in a number of tissues including the exocrine pancreas, lung, heart, vasculature, and epididymis, and is most abundant in the brain (Usdin, T. B., et al., 1996, Endocrinology, 137:4285-4297). Unlike the PTH/PTHrP receptor, which binds and is activated by both PTH-(1-34) (SEQ ID NO:1) and PTHrP-(1-34) (SEQ ID NO:2), the PTH2 receptor binds and is activated only by PTH-(1-34) (SEQ ID NO:1). PTHrP (7-34) (SEQ ID NO:2) was found to recognize PTH2 receptor and weakly activate it. Moreover, His 5 in PTHrP was identified as the “specificity switch” for the PTH2 receptor. Swapping a single amino acid, His 5 from PTHrP, with Ile 5 from PTH, resulted in a PTHrP analogue, Ile 5 -PTHrP-(1-34) NH 2 (SEQ ID NO:3), which acts as a PTH-2 receptor agonist. Hence, the single amino acid switch converts inactive PTHrP into a potent PTH2 receptor agonist. But while PTHrP (SEQ ID NO:3) binds and activates both receptors, PTH/PTHrP and PTH2, it is not a selective PTH2 agonist. In transient heterologous (with respect to species) expression systems, others have found an additional contribution to hPTH2 receptor selectivity by Trp 23 (Gardella et al., JBC 1996, 271:19888-19893). Like the PTH/PTHrP receptor, PTH binding leads to PTH2 receptor-mediated activation of both cAMP and intracellular signaling pathways.
The physiological function of the PTH2 receptor because of its high abundance and distribution in the brain suggests that it may act as a neurotransmitter receptor. PTH has been found in the central nervous system (CNS) (Harvey, S., et al., 1993, J. Endocrinol. 139:353-361), therefore, it is possible that endogenous PTH2 receptor specific ligands, which are distinct from PTH, do exist in the CNS. Recently, Usdin reported the isolation of “PTH2 receptor binding activity” from the hypothalamus which was immunologically distinct from PTH.
PCT Application Number PCT/US97/13360, published as PCT Publication Number WO 98/04591, discloses the use of certain PTHrP analogs which are PTH2 receptor agonists or antagonists.
U.S. Pat. No. 5,723,577, issued Mar. 3, 1998, discloses certain PTH and PTHrP analogues. U.S. application Nos. 08/779,768 and 08/813,534, filed Jan. 7, 1997 and Mar. 7, 1997, respectively, disclose further PTH and PTHrP analogs.
The development of specific ligands which activate the PTH2 receptor but not the PTH/PTHrP receptor, would be highly useful in defining the physiological roles of the PTH2 receptor and its potential involvement in certain pathological states. We have discovered a series of PTH2 receptor-selective PTH analogues which interact selectively with the human PTH2 receptor and are practically devoid of PTH/PTHrP receptor interaction. The compounds of the present invention are not only selective toward a receptor subtype but also signal specifically through the stimulation of [Ca +2 ], transients. Therefore, the compounds of the present invention are receptor subtype and signaling pathway selective.
SUMMARY OF THE INVENTION
In one aspect, this invention provides a PTH analogue or a truncated PTH analogue or a pharmaceutically acceptable salt thereof that selectively binds to the PTH2 receptor. A preferred PTH analogue or a truncated PTH analogue or a pharmaceutically acceptable salt thereof is where the analogue is a selective PTH2 receptor agonist. Another preferred PTH analogue or a truncated PTH analogue or a pharmaceutically acceptable salt thereof is where the analogue is a selective PTH2 receptor antagonist.
A more preferred PTH analogue that selectively binds to the PTH2 receptor is an analogue of formula (I), (R 1 R 2 )-A 1 -A 2 -A 3 -A 4 -A 5 -A 6 -A 7 -A 8 -A 9 -A 10 -A 11 -A 12 -A 13 -A 14 -A 15 -A 16 -A 17 -A 18 -A 19 -A 20 -A 21 -A 22 -A 23 -A 24 -A 25 -A 26 -A 27 -A 28 -A 29 -A 30 -A 31 -A 32 -A 33 -A 34 -A 35 -A 36 -A 37 -A 38 -R 3 , (I)
or a pharmaceutically-acceptable salt thereof wherein
A 1 is a hydrophilic or a lipophilic amino acid;
A 2 is a lipophilic amino acid;
A 3 is a hydrophilic or a lipophilic amino acid;
A 4 is a hydrophilic amino acid;
A 5 is a hydrophilic or a lipophilic amino acid;
A 6 is a hydrophilic amino acid or is deleted;
A 7 is a hydrophilic or a lipophilic amino acid or is deleted;
A 8 is a lipophilic amino acid or is deleted;
A 9 is a hydrophilic amino acid or is deleted;
A 10 is a hydrophilic amino acid or is deleted;
A 11 is a hydrophilic or a lipophilic amino acid or is deleted;
A 12 is a hydrophilic or a lipophilic amino acid or is deleted;
A 13 is a hydrophilic amino acid;
A 14 is a hydrophilic amino acid or is deleted;
A 15 is a lipophilic amino acid or is deleted;
A 16 is a hydrophilic or a lipophilic amino acid or is deleted;
A 17 is a hydrophilic or a lipophilic amino acid or is deleted;
A 18 is a lipophilic amino acid or is deleted;
A 19 is a hydrophilic or a lipophilic amino acid or is deleted;
A 20 is a hydrophilic amino acid or is deleted;
A 21 is a hydrophilic or a lipophilic amino acid or is deleted;
A 22 is a lipophilic or a hydrophilic amino acid or is deleted;
A 23 is a hydrophilic or a lipophilic amino acid;
A 24 is a hydrophilic or a lipophilic amino acid;
A 25 is a hydrophilic amino acid;
A 26 is a hydrophilic amino acid;
A 27 is a lipophilic or a hydrophilic amino acid;
A 28 is a lipophilic amino acid;
A 29 is a lipophilic or a hydrophilic amino acid;
A 30 is a hydrophilic or a lipophilic amino acid;
A 31 is a lipophilic or a hydrophilic amino acid or is deleted;
A 32 is a hydrophilic amino acid or is deleted;
A 33 is a hydrophilic amino acid or is deleted;
A 34 is a lipophilic amino acid or is deleted;
A 35 is a lipophilic amino acid or is deleted;
A 36 is a lipophilic or a hydrophilic amino acid or is deleted;
A 37 is a lipophilic amino acid or is deleted;
A 38 is a lipophilic or a hydrophilic amino acid or is deleted;
R 1 and R 2 are each independently selected from the group consisting of H, (C 1 -C 30 )alkyl, (C 2 -C 30 )alkenyl, phenyl-(C 1 -C 30 )alkyl, naphthyl(C 1 -C 30 )alkyl, hydroxy(C 1 -C 30 )alkyl, hydroxy(C 2 -C 30 )alkenyl, hydroxy-phenyl(C 1 -C 30 )alkyl or hydroxy-naphthyl(C 1 -C 30 )alkyl; or one of R 1 or R 2 is COE 1 where E 1 is (C 1 -C 30 )alkyl, (C 2 -C 30 )alkenyl, phenyl(C 1 -C 30 )alkyl, naphthyl(C 1 -C 30 )alkyl, hydroxy(C 1 -C 30 )alkyl, hydroxy(C 2 -C 30 )alkenyl, hydroxy-phenyl(C 1 -C 30 )alkyl or hydroxy-naphthyl(C 1 -C 30 )alkyl; and R 3 is OH, NH 2 , (C 1 -C 30 )alkoxy or NH-Y-CH 2 -Z, where Y is a (C 1 -C 30 ) hydrocarbon moiety and Z is CO 2 H or CONH 2 ;
provided that the compound is not PTH(1-34)R 3 (SEQ ID NO:4), PTH(1-35)R 3 (SEQ ID NO:5), PTH(1-36)R 3 (SEQ ID NO:6), PTH(1-37)R 3 (SEQ ID NO:7); or PTH(1-38)R 3 (SEQ ID NO:8).
Another preferred group of PTH analogues that selectively binds to the PTH2 receptor is an analogue of formula (II), (R 1 R 2 )-A 1 -A 2 -A 3 -A 4 -A 5 -A 6 -A 7 -A 8 -A 9 -A 10 -A 11 -A 12 -A 13 -A 14 -A 15 -A 16 -A 17 -A 18 -A 19 -A 20 -A 21 -A 22 -A 23 -A 24 -A 25 -A 26 -A 27 -A 28 -A 29 -A 30 -A 31 -A 32 -A 33 -A 34 -A 35 -A 36 -A 37 -A 38 -R 3 , (II)
or a pharmaceutically-acceptable salt thereof wherein
A 1 is Ser, Ala, Dap, Thr, Aib or is deleted;
A 2 is Val, Leu, Ile, Phe, Nle, β-Nal, Aib, p-X-Phe, Acc, Cha, Met or is deleted;
A 3 is Ser, Thr, Aib or is deleted;
A 4 is Glu, Asp or is deleted;
A 5 is Leu, Val, Nle, Ile, Cha, β-Nal, Trp, Pal, Acc, Phe, p-X-Phe or is deleted;
A 6 is Gln, a hydrophilic amino acid or is deleted;
A 7 is Leu, Val, Nle, Ile, Cha, β-Nal, Trp, Pal, Acc, Phe, p-X-Phe, a lipophilic amino acid, or is deleted;
A 8 is Met, Nva, Leu, Val, Ile, Cha, Acc, Nle, p-X-Phe, Phe, β-Nal, Bpa, a lipophilic amino acid or is deleted;
A 9 is His, a hydrophilic amino acid or is deleted;
A 10 is Asn, a hydrophilic amino acid or is deleted;
A 11 is Leu, Val, Nle, Ile, Cha, β-Nal, Trp, Pal, Acc, Phe, p-X-Phe, a hydrophilic amino acid or is deleted;
A 12 is Gly, Acc, Aib, or is deleted;
A 13 is Lys, Arg or HN—CH((CH 2 ) n NH—R 4 )—C(O);
A 14 is His or is deleted;
A 15 is Leu, Val, Nle, Ile, Cha, β-Nal, Trp, Pal, Acc, Phe, p-X-Phe or is deleted;
A 16 is Ser, Asn, Ala, Aib or is deleted;
A 17 is Ser, Thr, Aib or is deleted;
A 18 is Met, Nva, Leu, Val, Ile, Nle, p-X-Phe, Phe, β-Nal, Acc, Cha, Aib or is deleted;
A 19 is Glu, Aib or is deleted;
A 20 is Arg, Lys, HN—CH((CH 2 ) n NH—R 4 )—C(O) or is deleted;
A 21 is Val, Leu, Ile, Phe, Nle, β-Nal, Aib, p-X-Phe, Acc, Cha, Met or is deleted;
A 22 is Acc, Aib, Glu or is deleted;
A 23 is Trp, Acc, Phe, p-X-Phe, Aib, β-Nal or Cha;
A 24 is Leu, Acc, Ile, Val, Phe, β-Nal, Nle, Aib, p-X-Phe or Cha;
A 25 is Arg, Lys or HN—CH((CH 2 ) n NH—R 4 )—C(O);
A 26 is Arg, Lys or HN—CH((CH 2 ) n NH—R 4 )—C(O);
A 27 is Lys, Aib, Leu, hArg, Gln, Acc, Arg, Cha, Nle, Ile, Val, Phe, β-Nal, or p-X-Phe, where the Lys is optionally substituted on the ε-amino group by an acyl group;
A 28 is Leu, Acc, Cha, Ile, Val, Phe, Nle, β-Nal, Aib or p-X-Phe;
A 29 is Gln, Acc or Aib;
A 30 is Asp, Lys, Arg or is deleted;
A 31 is Val, Leu, Nle, Acc, Cha, Phe, Ile, β-Nal, Aib, p-X-Phe or is deleted;
A 32 is His or is deleted;
A 33 is Asn or is deleted;
A 34 is Phe, Tyr, Amp, Aib, β-Nal, Cha, Nle, Leu, Ile, Acc, p-X-Phe or is deleted;
A 35 is Val, Leu, Nle, Acc, Cha, Phe, Ile, β-Nal, Aib, p-X-Phe or is deleted;
A 36 is Ala, Val, Aib, Acc, Nva, Abu or is deleted;
A 37 is Leu, Val, Nle, Ile, Cha, β-Nal, Trp, Pal, Acc, Phe, p-X-Phe, a lipophilic amino acid, or is deleted;
A 38 is Gly, Acc, Aib, or is deleted;
where X for each occurrence is independently selected from the group consisting of OH, a halo and CH 3 ; R 1 and R 2 are each independently selected from the group consisting of H, (C 1 -C 30 )alkyl, (C 2 -C 30 )alkenyl, phenyl-(C 1 -C 30 )alkyl, naphthyl(C 1 -C 30 )alkyl, hydroxy(C 1 -C 30 )alkyl, hydroxy(C 2 -C 30 )alkenyl, hydroxy-phenyl(C 1 -C 30 )alkyl or hydroxy-naphthyl(C 1 -C 30 )alkyl; or one of R 1 or R 2 is COE 1 where E 1 is (C 1 -C 30 )alkyl, (C 2 -C 30 )alkenyl, phenyl(C 1 -C 30 )alkyl, naphthyl(C 1 -C 30 )alkyl, hydroxy(C 1 -C 30 )alkyl, hydroxy(C 2 -C 30 )alkenyl, hydroxy-phenyl(C 1 -C 30 )alkyl or hydroxy-naphthyl(C 1 -C 30 )alkyl; R 3 is OH, NH 2 , (C 1 -C 30 )alkoxy or NH-Y-CH 2 -Z, where Y is a (C 1 -C 30 ) hydrocarbon moiety and Z is CO 2 H or CONH 2 ; n for each occurrence is independently an integer from 1 to 5; and R 4 for each occurrence is independently (C 1 -C 30 )alkyl, (C 1 -C 30 )acyl or —C((NH)(NH 2 ));
provided that the compound is not PTH(1-34)R 3 (SEQ ID NO:4), PTH(1-35)R 3 (SEQ ID NO:5), PTH(1-36)R 3 (SEQ ID NO:6), PTH(1-37)R 3 (SEQ ID NO:7), or PTH(1-38)R 3 (SEQ ID NO:8).
In another respect, this invention provides a PTHrP analogue that selectively binds to the PTH2 receptor of the formula (IV), (R 1 R 2 )-A 1 -A 2 -A 3 -A 4 -A 5 -A 6 -A 7 -A 8 -A 9 -A 10 -A 11 -A 12 -A 13 -A 14 -A 15 -A 16 -A 17 -A 18 -A 19 -A 20 -A 21 -A 22 -A 23 -A 24 -A 25 -A 26 -A 27 -A 28 -A 29 -A 30 -A 31 -A 32 -A 33 -A 34 -A 35 -A 36 -A 37 -A 38 -R 3 , (IV)
or a pharmaceutically acceptable salt thereof, wherein
A 1 is Ala, Ser, Dap, Thr, Aib or is deleted;
A 2 is Val or is deleted;
A 3 is Ser, Aib, Thr or is deleted;
A 4 is Glu, Asp or is deleted;
A 5 is His, Ile, Acc, Val, Nle, Phe, Leu, p-X-Phe, β-Nal, Aib, Cha or is deleted;
A 6 is Gln, a hydrophilic amino acid or is deleted;
A 7 is Leu, Val, Cha, Nle, β-Nal, Trp, Pal, Acc, Phe, p-X-Phe, Aib, a lipophilic amino acid or is deleted;
A 8 is Leu, Met, Acc, Cha, Aib, Nle, Phe, Ile, Val, β-Nal, p-X-Phe, a lipophilic amino acid or is deleted;
A 9 is His, a hydrophilic amino acid or is deleted;
A 10 is Asp, Asn, a hydrophilic amino acid or is deleted;
A 11 is Lys, Arg, Leu, Cha, Aib, p-X-Phe, Ile, Val, Nle, Acc, Phe, β-Nal, HN—CH((CH 2 ) n NH—R 4 )—C(O), a lipophilic D-amino acid, a hydrophilic amino acid or is deleted;
A 12 is Gly, Acc, Aib, or is deleted;
A 13 is Lys, Arg, HN—CH((CH 2 ) n NH—R 4 )—C(O) or is deleted;
A 14 is Ser, His or is deleted;
A 15 is Ile, Acc, Cha, Leu, Phe, Nle, β-Nal, Trp, p-X-Phe, Val, Aib or is deleted;
A 16 is Gln, Aib or is deleted;
A 17 is Asp, Aib or is deleted;
A 18 is Leu, Aib, Acc, Cha, Phe, Ile, Nle, β-Nal, Val, p-X-Phe or is deleted;
A 19 is Arg, Lys, Aib, HN—CH((CH 2 ) n NH—R 4 )—C(O) or is deleted;
A 20 is Arg, Lys, HN—CH((CH 2 ) n NH—R 4 )—C(O) or is deleted;
A 21 is Arg, Lys, HN—CH((CH 2 ) n NH—R 4 )—C(O) or is deleted;
A 22 is Phe, Glu, Aib, Acc, p-X-Phe, β-Nal, Val, Leu, Ile, Nle or Cha;
A 23 is Phe, Leu, Lys, Acc, Cha, β-Nal, Aib, Nle, Ile, p-X-Phe, Val or Trp;
A 24 is Leu, Lys, Acc, Nle, Ile, Val, Phe, β-Nal, Aib, p-X-Phe, Arg or Cha;
A 25 is His, Lys, Aib, Acc, Arg or Glu;
A 26 is His, Aib, Acc, Arg or Lys;
A 27 is Leu, Lys, Acc, Arg, Ile, Val, Phe, Aib, Nle, β-Nal, p-X-Phe or Cha;
A 28 is Ile, Leu, Lys, Acc, Cha, Val, Phe, p-X-Phe, Nle, β-Nal, Aib or is deleted;
A 29 is Ala, Gln, Acc, Aib or is deleted;
A 30 is Glu, Leu, Nle, Cha, Aib, Acc, Lys, Arg or is deleted;
A 31 is Ile, Leu, Cha, Lys, Acc, Phe, Val, Nle, β-Nal, Arg or is deleted;
A 32 is His or is deleted;
A 33 is Thr, Ser or is deleted;
A 34 is Ala, Phe, Tyr, Cha, Val, Ile, Leu, Nle, β-Nal, Aib, Acc or is deleted;
A 35 is Glu, Asp or is deleted;
A 36 is Ile, Acc, Cha, Leu, Phe, Nle, β-Nal, Trp, p-X-Phe, Val, Aib or is deleted;
A 37 is Arg, Lys, HN—CH((CH 2 ) n NH—R 4 )—C(O) or is deleted;
A 38 is Ala, Phe, Tyr, Cha, Val, Ile, Leu, Nle, β-Nal, Aib, Acc or is deleted;
R 1 and R 2 are each independently selected from the group consisting of H, (C 1 -C 30 )alkyl, (C 2 -C 30 )alkenyl, phenyl-(C 1 -C 30 )alkyl, naphthyl(C 1 -C 30 )alkyl, hydroxy(C 1 -C 30 )alkyl, hydroxy(C 2 -C 30 )alkenyl, hydroxy-phenyl(C 1 -C 30 )alkyl or hydroxy-naphthyl(C 1 -C 30 )alkyl; or one of R 1 or R 2 is COE 1 where E 1 is (C 1 -C 30 )alkyl, (C 2 -C 30 )alkenyl, phenyl(C 1 -C 30 )alkyl, naphthyl(C 1 -C 30 )alkyl, hydroxy(C 1 -C 30 )alkyl, hydroxy(C 2 -C 30 )alkenyl, hydroxy-phenyl(C 1 -C 30 )alkyl or hydroxy-naphthyl(C 1 -C 30 )alkyl; R 3 is OH, NH 2 , (C 1 -C 30 )alkoxy or NH-Y-CH 2 -Z, where Y is a (C 1 -C 30 ) hydrocarbon moiety and Z is CO 2 H or CONH 2 ; n for each occurrence is independently an integer from 1 to 5; and R 4 for each occurrence is independently (C 1 -C 30 )alkyl, (C 1 -C 30 )acyl or —C((NH)(NH 2 ));
provided that the compound is not PTHrP(1-34)R 3 (SEQ ID NO:9), PTHrP(1-35)R 3 (SEQ ID NO:10), PTHrP(1-36)R 3 (SEQ ID NO:11), PTHrP(1-37)R 3 (SEQ ID NO:12) or PTHrP(1-38)R 3 (SEQ ID NO:13), and further provided that the compound is not [Ile 5 , Trp 23 ] PTHrP(1-36) (SEQ ID NO:14) or [Trp 23 ] PTHrP(1-36) (SEQ ID NO:15).
In another aspect, this invention provides a method of selectively binding the PTH2 receptor which comprises administering to a patient in need thereof an effective amount of a PTH analogue or a truncated PTH analogue or a pharmaceutically acceptable salt thereof that selectively binds to a PTH2 receptor.
In another aspect, this invention provides a method of selectively eliciting an agonist response from the PTH2 receptor which comprises administering to a patient in need thereof an effective amount of a PTH analogue or a truncated PTH analogue or a pharmaceutically acceptable salt thereof which is a selective PTH2 receptor agonist.
In another aspect, this invention provides a method of selectively eliciting an antagonist response from the PTH2 receptor which comprises administering to a patient in need thereof an effective amount of a PTH analogue or a truncated PTH analogue or a pharmaceutically acceptable salt thereof which is a selective PTH2 receptor antagonist.
In yet another aspect, this invention provides a compound of the formula (III), (R 1 R 2 )-A 1 -A 2 -A 3 -A 4 -A 5 -A 6 -A 7 -A 8 -A 9 -A 10 -A 11 -A 12 -A 13 -A 14 -A 15 -A 16 -A 17 -A 18 -A 19 -A 20 -A 21 -A 22 -A 23 -A 24 -A 25 -A 26 -A 27 -A 28 -A 29 -A 30 -A 31 -A 32 -A 33 -A 34 -A 35 -A 36 -A 37 -A 38 -R 3 , (III)
or a pharmaceutically-acceptable salt thereof wherein
A 1 is Ser, Ala, Dap, Thr, Aib or is deleted;
A 2 is Val, Leu, Ile, Phe, Nle, β-Nal, Aib, p-X-Phe, Acc, Cha, Met or is deleted;
A 3 is Ser, Thr, Aib or is deleted;
A 4 is Glu, Asp or is deleted;
A 5 is Leu, Val, Nle, Ile, Cha, β-Nal, Trp, Pal, Acc, Phe, p-X-Phe or is deleted;
A 6 is Gln, a hydrophilic amino acid or is deleted;
A 7 is Leu, Val, Nle, Ile, Cha, β-Nal, Trp, Pal, Acc, Phe, p-X-Phe, a lipophilic amino acid, or is deleted;
A 8 is Met, Nva, Leu, Val, Ile, Cha, Acc, Nle, p-X-Phe, Phe, β-Nal, Bpa, a lipophilic amino acid or is deleted;
A 9 is His, a hydrophilic amino acid or is deleted;
A 10 is Asn, a hydrophilic amino acid or is deleted;
A 11 is Leu, Val, Nle, Ile, Cha, β-Nal, Trp, Pal, Acc, Phe, p-X-Phe, a hydrophilic amino acid or is deleted;
A 12 is Gly, Acc, Aib, or is deleted;
A 13 is Lys, Arg or HN—CH((CH 2 ) n NH—R 4 )—C(O);
A 14 is His or is deleted;
A 15 is Leu, Val, Nle, Ile, Cha, β-Nal, Trp, Pal, Acc, Phe, p-X-Phe or is deleted;
A 16 is Ser, Asn, Ala, Aib or is deleted;
A 17 is Ser, Thr, Aib or is deleted;
A 18 is Met, Nva, Leu, Val, Ile, Nle, p-X-Phe, Phe, β-Nal, Acc, Cha, Aib or is deleted;
A 19 is Glu, Aib or is deleted;
A 20 is Arg, Lys, HN—CH((CH 2 ) n NH—R 4 )—C(O) or is deleted;
A 21 is Val, Leu, Ile, Phe, Nle, β-Nal, Aib, p-X-Phe, Acc, Cha, Met or is deleted;
A 22 is Acc, Aib, Glu or is deleted;
A 23 is Trp, Acc, Phe, p-X-Phe, Aib, β-Nal or Cha;
A 24 is Leu, Acc, Ile, Val, Phe, β-Nal, Nle, Aib, p-X-Phe or Cha;
A 25 is Arg, Lys or HN—CH((CH 2 ) n NH—R 4 )—C(O);
A 26 is Arg, Lys or HN—CH((CH 2 ) n NH—R 4 )—C(O);
A 27 is Lys, Aib, Leu, hArg, Gln, Acc, Arg, Cha, Nle, Ile, Val, Phe, β-Nal, or p-X-Phe, where the Lys is optionally substituted on the ε-amino group by an acyl group;
A 28 is Leu, Acc, Cha, Ile, Val, Phe, Nle, β-Nal, Aib or p-X-Phe;
A 29 is Gln, Acc or Aib;
A 30 is Asp, Lys, Arg or is deleted;
A 31 is Val, Leu, Nle, Acc, Cha, Phe, Ile, β-Nal, Aib, p-X-Phe or is deleted;
A 32 is His or is deleted;
A 33 is Asn or is deleted;
A 34 is Phe, Tyr, Amp, Aib, β-Nal, Cha, Nle, Leu, Ile, Acc, p-X-Phe or is deleted;
A 35 is Val, Leu, Nle, Acc, Cha, Phe, Ile, β-Nal Aib, p-X-Phe or is deleted;
A 36 is Ala, Val, Aib, Acc, Nva, Abu or is deleted;
A 37 is Leu, Val, Nle, Ile, Cha, β-Nal, Trp, Pal, Acc, Phe, p-X-Phe, a lipophilic amino acid, or is deleted;
A 38 is Gly, Acc, Aib, or is deleted;
where X for each occurrence is independently selected from the group consisting of OH, a halo and CH 3 ; R 1 and R 2 are each independently selected from the group consisting of H, (C 1 -C 30 )alkyl, (C 2 -C 30 )alkenyl, phenyl-(C 1 -C 30 )alkyl, naphthyl(C 1 -C 30 )alkyl, hydroxy(C 1 -C 30 )alkyl, hydroxy(C 2 -C 30 )alkenyl, hydroxy-phenyl(C 1 -C 30 )alkyl or hydroxy-naphthyl(C 1 -C 30 )alkyl; or one of R 1 or R 2 is COE 1 where E 1 is (C 1 -C 30 )alkyl, (C 2 -C 30 )alkenyl, phenyl(C 1 -C 30 )alkyl, naphthyl(C 1 -C 30 )alkyl, hydroxy(C 1 -C 30 )alkyl, hydroxy(C 2 -C 30 )alkenyl, hydroxy-phenyl(C 1 -C 30 )alkyl or hydroxy-naphthyl(C 1 -C 30 )alkyl; R 3 is OH, NH 2 , (C 1 -C 30 )alkoxy or NH-Y-CH 2 -Z, where Y is a (C 1 -C 30 ) hydrocarbon moiety and Z is CO 2 H or CONH 2 ; n for each occurrence is independently an integer from 1 to 5; and R 4 for each occurrence is independently (C 1 -C 30 )alkyl, (C 1 -C 30 )acyl or —C((NH)(NH 2 ));
provided that when A 8 is not a lipophilic D-amino acid or is not deleted then at least one of A 6 , A 7 , A 9 , A 10 , A 11 and A 12 is a D-amino acid or at least one of A 6 , A 7 , A 9 , A 10 , A 11 , A 12 , A 13 , A 14 , A 15 , A 16 , A 17 , A 18 , A 19 , A 20 , A 21 and A 22 is deleted; and further provided that when the compound contains a D-amino acid then A 36 is deleted.
A preferred group of compounds of formula (III) are the compounds listed as Examples 1-73, shown hereinbelow. Of the compounds listed as Examples 1-73, the following compounds are preferred: [Cha 7,11 , des-Met 8 , Nle 18 , Tyr 34 ]hPTH-(1-34)NH 2 (SEQ ID NO:16), [Cha 7,11 , D-Nle 8 , des-Met 18 , Tyr 34 ]hPTH-(1-34)NH 2 , [Cha 7,11 , D-Nle 8 , Nle 18 , Tyr 34 ]hPTH-(1-34)NH 2 , [D-Nle 8 , Nle 18 , Tyr 34 ]hPTH(1-34)NH 2 and [D-Bpa 8 , Tyr 34 ]hPTH(1-34)NH 2 .
In yet another aspect, this invention provides a compound of formula (V), (R 1 R 2 )-A 1 -A 2 -A 3 -A 4 -A 5 -A 6 -A 7 -A 8 -A 9 -A 10 -A 11 -A 12 -A 13 -A 14 -A 15 -A 16 -A 17 -A 18 -A 19 -A 20 -A 21 -A 22 -A 23 -A 24 -A 25 -A 26 -A 27 -A 28 -A 29 -A 30 -A 31 -A 32 -A 33 -A 34 -A 35 -A 36 -A 37 -A 38 -R 3 , (V)
or a pharmaceutically acceptable salt thereof, wherein
A 1 is Ala, Ser, Dap, Thr, Aib or is deleted;
A 2 is Val or is deleted;
A 3 is Ser, Aib, Thr or is deleted;
A 4 is Glu, Asp or is deleted;
A 5 is His, Ile, Acc, Val, Nle, Phe, Leu, p-X-Phe, β-Nal, Aib, Cha or is deleted;
A 6 is Gln, a hydrophilic amino acid or is deleted;
A 7 is Leu, Val, Cha, Nle, β-Nal, Trp, Pal, Acc, Phe, p-X-Phe, Aib, a lipophilic amino acid or is deleted;
A 8 is Leu, Met, Acc, Cha, Aib, Nle, Phe, Ile, Val, β-Nal, p-X-Phe, a lipophilic amino acid or is deleted;
A 9 is His, a hydrophilic amino acid or is deleted;
A 10 is Asp, Asn, a hydrophilic amino acid or is deleted;
A 11 is Lys, Arg, Leu, Cha, Aib, p-X-Phe, Ile, Val, Nle, Acc, Phe, β-Nal, HN—CH((CH 2 ) n NH—R 4 )—C(O), a lipophilic D-amino acid, a hydrophilic amino acid or is deleted;
A 12 is Gly, Acc, Aib, or is deleted;
A 13 is Lys, Arg, HN—CH((CH 2 ) n NH—R 4 )—C(O) or is deleted;
A 14 is Ser, His or is deleted;
A 15 is Ile, Acc, Cha, Leu, Phe, Nle, β-Nal, Trp, p-X-Phe, Val, Aib or is deleted;
A 16 is Gln, Aib or is deleted;
A 17 is Asp, Aib or is deleted;
A 18 is Leu, Aib, Acc, Cha, Phe, Ile, Nle, β-Nal, Val, p-X-Phe or is deleted;
A 19 is Arg, Lys, Aib, HN—CH((CH 2 ) n NH—R 4 )—C(O) or is deleted;
A 20 is Arg, Lys, HN—CH((CH 2 ) n NH—R 4 )—C(O) or is deleted;
A 21 is Arg, Lys, HN—CH((CH 2 ) n NH—R 4 )—C(O) or is deleted;
A 22 is Phe, Glu, Aib, Acc, p-X-Phe, β-Nal, Val, Leu, Ile, Nle or Cha;
A 23 is Phe, Leu, Lys, Acc, Cha, β-Nal, Aib, Nle, Ile, p-X-Phe, Val or Trp;
A 24 is Leu, Lys, Acc, Nle, Ile, Val, Phe, β-Nal, Aib, p-X-Phe, Arg or Cha;
A 25 is His, Lys, Aib, Acc, Arg or Glu;
A 26 is His, Aib, Acc, Arg or Lys;
A 27 is Leu, Lys, Acc, Arg, Ile, Val, Phe, Aib, Nle, β-Nal, p-X-Phe or Cha;
A 28 is Ile, Leu, Lys, Acc, Cha, Val, Phe, p-X-Phe, Nle, β-Nal, Aib or is deleted;
A 29 is Ala, Glu, Acc, Aib or is deleted;
A 30 is Glu, Leu, Nle, Cha, Aib, Acc, Lys, Arg or is deleted;
A 31 is Ile, Leu, Cha, Lys, Acc, Phe, Val, Nle, β-Nal, Arg or is deleted;
A 32 is His or is deleted;
A 33 is Thr, Ser or is deleted;
A 34 is Ala, Phe, Tyr, Cha, Val, Ile, Leu, Nle, β-Nal, Aib, Acc or is deleted;
A 35 is Glu, Asp or is deleted;
A 36 is Ile, Acc, Cha, Leu, Phe, Nle, β-Nal, Trp, p-X-Phe, Val, Aib or is deleted;
A 37 is Arg, Lys, HN—CH((CH 2 ) n NH—R 4 )—C(O) or is deleted;
A 38 is Ala, Phe, Tyr, Cha, Val, Ile, Leu, Nle, β-Nal, Aib, Acc or is deleted;
R 1 and R 2 are each independently selected from the group consisting of H, (C 1 -C 30 )alkyl, (C 2 -C 30 )alkenyl, phenyl-(C 1 -C 30 )alkyl, naphthyl(C 1 -C 30 )alkyl, hydroxy(C 1 -C 30 )alkyl, hydroxy(C 2 -C 30 )alkenyl, hydroxy-phenyl(C 1 -C 30 )alkyl or hydroxy-naphthyl(C 1 -C 30 )alkyl; or one of R 1 or R 2 is COE 1 where E 1 is (C 1 -C 30 )alkyl, (C 2 -C 30 )alkenyl, phenyl(C 1 -C 30 )alkyl, naphthyl(C 1 -C 30 )alkyl, hydroxy(C 1 -C 30 )alkyl, hydroxy(C 2 -C 30 )alkenyl, hydroxy-phenyl(C 1 -C 30 )alkyl or hydroxy-naphthyl(C 1 -C 30 )alkyl; R 3 is OH, NH 2 , (C 1 -C 30 )alkoxy or NH-Y-CH 2 -Z, where Y is a (C 1 -C 30 ) hydrocarbon moiety and Z is CO 2 H or CONH 2 ; n for each occurrence is independently an integer from 1 to 5; and R 4 for each occurrence is independently (C 1 -C 30 )alkyl, (C 1 -C 30 )acyl or —C((NH)(NH 2 ));
provided that when A 8 is not a lipophilic D-amino acid or is not deleted then at least one of A 6 , A 7 , A 9 , A 10 , A 11 and A 12 is a D-amino acid or at least one of A 6 , A 7 , A 9 , A 10 , A 11 , A 12 , A 13 , A 14 , A 15 , A 16 , A 17 , A 18 , A 19 , A 20 , A 21 and A 22 is deleted.
A preferred group of compounds of formula (V) are the compounds listed as Examples 74-86, shown hereinbelow.
In a further aspect, this invention provides a method of selectively binding the PTH2 receptor which comprises administering to a patient in need thereof an analogue of formula (I), (II) or (III) or a pharmaceutically acceptable salt thereof.
In another aspect, this invention provides a method of selectively binding the PTH2 receptor which comprises administering to a patient in need thereof a compound of formula (III) or (V) or a pharmaceutically acceptable salt thereof. Preferred of the foregoing method is where the compound is selected from Examples 1-73 or Examples 74-86.
In another aspect, this invention is directed to a pharmaceutical composition comprising an analogue of formula (I), (II) or (III) or a pharmaceutically acceptable salt thereof and a pharmaceutically acceptable carrier.
In still another aspect, this invention is directed to a pharmaceutical composition comprising a compound of formula (III) or (V) or a pharmaceutically acceptable salt thereof and a pharmaceutically acceptable carrier. Preferred is a pharmaceutical composition comprising a compound selected from Examples 1-73 or Examples 74-86.
In still another aspect, this invention is directed to a method of treating a medical disorder that results from altered or excessive action of the PTH2 receptor, which comprises administering to a patient in need thereof an effective amount of a PTH analogue or a truncated PTH analogue or a pharmaceutically acceptable salt thereof that selectively binds to the PTH2 receptor, sufficient to inhibit the activation of the PTH2 receptor of said patient. A preferred method of the immediately foregoing method is where said medical disorder is abnormal CNS functions, abnormal pancreatic functions, divergence from normal mineral metabolism and homeostasis, male infertility, abnormal blood pressure or a hypothalmic disease. Preferred of each of the immediately foregoing methods is where the analogue is a PTH2 agonist or a PTH2 antagonist.
In another aspect, this invention provides a method of treating a medical disorder that results from altered or excessive action of the PTH2 receptor, which comprises administering to a patient in need thereof an effective amount of an analogue of formula (I), (II) or (III), sufficient to inhibit the activation of the PTH2 receptor of said patient. A preferred method of the immediately foregoing method is where said medical disorder is abnormal CNS functions, abnormal pancreatic functions, divergence from normal mineral metabolism and homeostasis, male infertility, abnormal blood pressure or a hypothalmic disease.
In another aspect, this invention is directed to a method of treating a medical disorder that results from altered or excessive action of the PTH2 receptor, which comprises administering to a patient in need thereof an effective amount of a compound of formula (III) or (V), sufficient to inhibit the activation of the PTH2 receptor of said patient. A preferred method of the immediately foregoing method is where said medical disorder is abnormal CNS functions, abnormal pancreatic functions, divergence from normal mineral metabolism and homeostasis, male infertility, abnormal blood pressure or a hypothalmic disease. Preferred of each of the foregoing methods is where the compound is selected from Examples 1-73 or Examples 74-86.
DETAILED DESCRIPTION
With the exception of the N-terminal amino acid, all abbreviations (e.g. Ala or A 1 ) of amino acids in this disclosure stand for the structure of —NH—CH(R)—CO—, wherein R is the side chain of an amino acid (e.g., CH 3 for Ala). For the N-terminal amino acid, the abbreviation stands for the structure of (R 1 R 2 )—N—CH(R)—CO—, wherein R is a side chain of an amino acid and R 1 and R 2 are as defined above. Bpa is p-benzoylphenylalanine. β-Nal, Nle, Dap, Cha, Nva, Amp, Pal, and Aib are the abbreviation of the following α-amino acids: β-(2-naphthyl)alanine, norleucine, α,β-diaminopropionic acid, cyclohexylalanine, norvaline, 4-amino-phenylalanine, β-(3-pyridinyl)alanine and α-aminoisobutyric acid, respectively. What is meant by Acc is an amino acid selected from the group of 1-amino-1-cyclopropanecarboxylic acid; 1-amino-1-cyclobutanecarboxylic acid; 1-amino-1-cyclopentanecarboxylic acid; 1-amino-1-cyclohexanecarboxylic acid; 1-amino-1-cycloheptanecarboxylic acid; 1-amino-1-cyclooctanecarboxylic acid; and 1-amino-1-cyclononanecarboxylic acid. In the above formula hydroxyalkyl, hydroxyphenylalkyl, and hydroxynaphthylalkyl may contain 1-4 hydroxy substituents. COE 1 stands for —C═O.E 1 . Examples of —C═O.E 1 include, but are not limited to, acetyl and phenylpropionyl. What is meant by “(C 1-12 ) hydrocarbon moiety” is an alkyl group, an alkenyl group or an alkynyl group.
What is meant by a “hydrophilic amino acid” is an amino acid having at least one hydrophilic functional group in addition to those required for peptide bond formation, such as: Arg, Asp, Asn, Glu, Gln, Gly, His, Lys, Orn (ornithine), Ser, Thr, β-Ala, Ala, Aad (α-aminoadipic acid), β-Aad (β-aminoadipic acid), Apm (α-aminopimolic acid), Cit (citrulline), Gla (γ-carboxy-glutamic acid), hArg (homo-Arg), hCit (homo-Cit), hSer (homo-Ser), Dba (α,γ-diamino-butyric acid), Dpa (α,β-diaminopropionic acid), Amp (p-amino-phenylalanine), Pal, and their homologues.
What is meant by a “lipophilic amino acid” is an uncharged, aliphatic or aromatic amino acid, such as: Val, Leu, Ile, Pro, Cys, Phe, Met, Trp, Tyr, Cha, β-Nal, Aib, Acc, Ala, Abu (α-aminobutyric acid), Nle, Nva (norvaline), Bpa (p-benzoyl-phenylalanine), hPhe (homo-Phe), hPro (homo-Pro), 1-Nal (β-(1-naphthyl)alanine), 2-Nal (β(2-naphthyl)alanine), Oic (octahydroindode-2-carboxylic acid), Tic (1,2,3,4-tetrahydroisoquinoline-3-carboxylic acid), Pen (penicillamine), Phg (phenylglycine), Tle (t-leucine), p-X-Phe (X=Br, F, I, Cl, CH, phenyl, CN, NO 2 ), Tal (β-(2-thienyl)-alanine), and their homologues.
Alanine, β-alanine and sarcosine (Sar) may be considered either a hydrophilic or a lipophilic amino acid.
“Physiologically active truncated homologue or analogue of PTH” refers to a polypeptide having a sequence comprising less than the full complement of amino acids found in PTH.
The full names for other abbreviations used herein are as follows: Boc for t-butyloxycarbonyl, HF for hydrogen fluoride, Fm for formyl, Xan for xanthyl, Bzl for benzyl, Tos for tosyl, DNP for 2,4-dinitrophenyl, DMF for dimethylformamide, DCM for dichloromethane, HBTU for 2-(1H-Benzotriazol-1-yl)-1,1,3,3-tetramethyl uronium hexafluorophosphate, DIEA for diisopropylethylamine, HOAc for acetic acid, TFA for trifluoroacetic acid, 2ClZ for 2-chlorobenzyloxycarbonyl and OcHex for O-cyclohexyl.
A peptide of this invention is also denoted herein by another format, e.g., [D-Nle 8 ]hPTH(1-34)NH 2 , with the substituted amino acids from the natural sequence placed between the set of brackets (e.g., D-Nle 8 for Met 8 in hPTH). The abbreviation hPTH stands for human PTH, for hPTHrP for human PTHrP. The numbers between the parantheses refer to the number of amino acids present in the peptide (e.g., hPTH(1-34) is amino acids 1 through 34 of the peptide sequence for human PTH; SEQ ID NO:1). The sequences for hPTH(1-34) (SEQ ID NO:1) and hPTHrP(1-34) (SEQ ID NO:2) are listed in Nissenson, et al., Receptor, 3:193 (1993). The designation “NH 2 ” in PTH(1-34)NH 2 (SEQ ID NO:53) indicates that the C-terminus of the peptide is amidated. PTH(1-34) (SEQ ID NO:1) means that the C-terminus is the free acid.
The peptides of this invention can be prepared by standard solid phase peptide synthesis. See, e.g., Stewart, J. M., et al., Solid Phase Synthesis (Pierce Chemical Co., 2d ed. 1984). The substituents R 1 and R 2 of the above generic formula may be attached to the free amine of the N-terminal amino acid by standard methods known in the art. For example, alkyl groups, e.g., (C 1-12 )alkyl, may be attached using reductive alkylation. Hydroxyalkyl groups, e.g., (C 1-12 )hydroxyalkyl, may also be attached using reductive alkylation wherein the free hydroxy group is protected with a t-butyl ester. Acyl groups, e.g., COE 1 , may be attached by coupling the free acid, e.g., E 1 COOH, to the free amine of the N-terminal amino acid by mixing the completed resin with 3 molar equivalents of both the free acid and diisopropylcarbodiimide in methylene chloride for one hour. If the free acid contains a free hydroxy group, e.g., p-hydroxyphenylpropionic acid, then the coupling should be performed with an additional 3 molar equivalents of HOBT.
When R 3 is NH-Y-CH 2 —CONH 2 (Z=CONH 2 ), the synthesis of the peptide starts with BocNH-Y-CH 2 —COOH which is coupled to the resin. If R 3 is NH-Y-CH 2 —COOH (Z=COOH) the synthesis of the peptide starts with Boc-HN-Y-CH 2 —COOH which is coupled to PAM resin. When R 3 is OH the first amino acid is coupled to PAM resin.
The compounds of this invention can be tested for binding to the human PTH2 (hPTH2) receptor for the ability to stimulate adenylyl cyclase and/or intracellular calcium transients by the assay described below.
Materials and Methods: Tissue culture media and sera were purchased from Life Technologies (Grand Island, N.Y.), and all tissue culture plastics were obtained from Corning (Corning, N.Y.). Adenosine and 3-isobutyl-1-methyl xanthine (IBMX) were purchased from Research Biochemicals (Natick, Mass.). Fura-2 acetoxylmethyl ester (fura-2/AM) was obtained from Molecular Probes (Eugene, Oreg.), and hPTHrP was purchased from Bachem (Torrance, Calif.). [ 3 H]-Adenine was purchased from New England Nuclear (Boston, Mass.). Na 125 I was obtained from Amersham Corp. (Arlington Heights, Ill.). All other analytical grade reagents were purchased from Sigma (St. Louis, Mo.).
Cell Culture: Human osteosarcoma Saos-2/B-10 cells (American Type Culture Collection, Rockville, Md.; ATCC #HTB 85) are maintained in RPMI 1640 medium (Sigma, St. Louis, Mo.) supplemented with 10% fetal bovine serum (FBS) and 2 mM glutamine at 37° C. in a humidified atmosphere of 5% CO 2 in air. The medium is changed every three or four days, and the cells are subcultured every week by trypsinization. Stably transfected HEK-293/BP-16 cells (Beth Israel Deaconess Medical Center-Division of Bone and Mineral Metabolism, Boston, Mass.), which express the hPTH2 receptor (160,000 receptors/cell) and stably transfected HEK-293/C-21 cells (Beth Israel Deaconess Medical Center-Division of Bone and Mineral Metabolism, Boston, Mass.), which express the hPTH/PTHrP receptor, are maintained in DMEM supplemented with 10% FBS at 37° C. in a humidified atmosphere of 95% air/5% CO 2 . The medium is changed every 2 days before confluency and every day after confluency. The cells are sub-cultured 1:10 once a week.
Receptor binding assay: Ligand binding is performed using Saos-2/B-10, HEK/C-21 cells or HEK/BP-16 cells using HPLC-purified [ 125 I][Hle 8,18 , Tyr 34 ]bPTH-(1-34)NH 2 ( 125 I-PTH) (SEQ ID NO:17) as radioligand. Saos-2 cells are maintained for four days until they reach confluence. The medium is replaced with 5% FBS in RPMI 1640 medium and incubated for about 2 hours at room temperature with 10×10 4 cpm mono- 125 I-[Nle 8,18 , Tyr 34 (3- 125 I)bPTH(1-34)NH 2 (SEQ ID NO:17) in the presence of competing peptides of the invention at various concentrations between 10 −11 M to 10 −4 M. The cells are washed four times with ice-cold PBS and lysed with 0.1 M NaOH, and the radioactivity associated with the cells is counted in a scintillation counter. Synthesis of mono- 125 I-[Nle 8,18 , Tyr 34 (3- 125 I)bPTH(1-34)NH 2 (SEQ ID NO:17) is carried out as described in Goldman, M. E., et al., Endocrinol., 123:1468 (1988).
The binding assay is conducted with various peptides of the invention, and the Kd value (half maximal inhibition of binding of mono- 125 I-[Nle 8,18 , Tyr 34 (3- 125 I)bPTH(1-34)NH 2 (SEQ ID NO:17)) for each peptide is calculated.
Adenylyl cyclase assay: Adenylyl cyclase assay is performed in Saos-2/B-10 cells, HEK/C21 cells, and HEK/BP-16 cells. The ability of the peptides of the invention to induce a biological response in Saos-2/B-10 cells is measured. More specifically, any stimulation of the adenylate cyclase is determined by measuring the level of synthesis of cAMP (adenosine 3′,5′-monophosphate) as described previously in Rodan, et al., J. Clin. Invest. 72: 1511 (1983) and Goldman, et al., Endocrinol., 123:1468 (1988). Confluent Saos-2/B-10 cells in 24 well plates at 4×10 4 cells/well in RPMI1640 medium containing 10% FBS. Cells are washed twice with Ca 2+ and Mg 2+ free Hanks' balanced salt solution and incubated with 0.5 μCi [ 3 H]adenine (26.9 Ci/mmol, New England Nuclear, Boston, Mass.) in fresh medium at about 37° C. for about 2 hrs, and washed twice with Hank's balanced salt solution (Gibco, Gaithersburg, Md.). The cells are treated with 1 mM IBMX [isobutylmethyl-xanthine, Sigma, St. Louis, Mo.] in fresh medium for 15 min, and a peptide to be tested is added to the medium to incubate for about 5 min. The reaction is stopped by the addition of 1.2 M trichloroacetic acid (TCA) (Sigma, St. Louis, Mo.) followed by sample neutralization with 4 N KOH. cAMP is isolated by the two-column chromatographic method (Salmon, et al., 1874, Anal. Biochem. 58, 541). The radioactivity is counted in a scintillation counter (Liquid Scintillation Counter 2200CA, PACKARD, Downers Grove, Ill.).
Measurements of [Ca 2+ ] i : Measurements of intracellular Ca 2+ ([Ca 2+ ]) are performed in Saos-2/B-10 cells, HEK/C-21 cells and HEK/BP-16 cells. For measurement of [Ca 2+ ] i , cells are harvested from 150-cm 2 flasks using HEPES-buffered balanced salt solution containing 0.02% (vol/vol) EDTA. The cell suspension is washed three times with Hanks' Balanced Salt Solution (1 mM CaCl 2 , 118 mM NaCl, 4.6 mM KCl, 10 mM d-glucose, and 20 mM HEPES, pH 7.4), and cells are loaded with fura-2/AM (1 μM) for about 40 min at about 37° C. The cell suspension is washed three times with Hanks' Balanced Salt Solution, and fluorescence is measured in a SPEX AR-CM system spectrofluorimeter (SPEX Industries, Edison, N.J.). Dual wavelength measurements are performed (excitation wavelengths, 340 and 380 nm; emission wavelength, 505 nm).
[Ca 2+ ] i is calculated from fura-2 ratios (R) by the equation: [Ca 2+ ] i =K(R−R min )/(R max −R), where R min and R max are the ratios (e.g. 340 nm/380 nm) for the minimal or maximal calcium concentration, respectively. K is the product K d (F O /F S ), where K d is the effective dissociation constant (224 nM), F 0 is the intensity of the 380-nm excitation signal in the absence of calcium, and F S is the intensity of the 380-nm excitation signal at saturating calcium concentrations. Maximum fluorescence intensity is obtained by permeabilizing the cells with 50 μM digitonin in the presence of 1 mM CaCl 2 , and minimal fluorescence intensity is obtained by chelating calcium with 16.6 mM EGTA [pH adjusted to 8.3 with 3M Tris-(hydroxymethyl)aminomethane base]. Addition of vehicle alone (0.1% BSA in PBS) did not change the level of [Ca 2+ ] i .
The peptides of this invention can be provided in the form of pharmaceutically acceptable salts. Examples of such salts include, but are not limited to, those formed with organic acids (e.g., acetic, lactic, maleic, citric, malic, ascorbic, succinic, benzoic, methanesulfonic, toluenesulfonic or pamoic acid), inorganic acids (e.g., hydrochloric acid, sulfuric acid, or phosphoric acid), and polymeric acids (e.g., tannic acid, carboxymethyl cellulose, polylactic, polyglycolic, or copolymers of polylactic-glycolic acids).
A therapeutically effective amount of a peptide of this invention and a pharmaceutically acceptable carrier substance (e.g., magnesium carbonate, lactose, or a phospholipid with which the therapeutic compound can form a micelle) together form a therapeutic composition (e.g., a pill, tablet, capsule, or liquid) for administration (e.g., orally, intravenously, transdermally, pulmonarily, vaginally, subcutaneously, nasally, iontophoretically, or by intratracheally) to a subject. The pill, tablet or capsule that is to be administered orally can be coated with a substance for protecting the active composition from the gastric acid or intestinal enzymes in the stomach for a period of time sufficient to allow it to pass undigested into the small intestine. The therapeutic composition can also be in the form of a biodegradable or nonbiodegradable sustained release formulation for subcutaneous or intramuscular administration. See, e.g., U.S. Pat. Nos. 3,773,919 and 4,767,628 and PCT Application No. WO 94/15587. Continuous administration can also be achieved using an implantable or external pump (e.g., INFUSAID™ pump). The administration can also be conducted intermittently, e.g., single daily injection, or continuously at a low dose, e.g., sustained release formulation.
Liquid dosage forms for oral administration include pharmaceutically acceptable emulsions, solutions, suspensions, syrups, the elixirs containing inert diluents commonly used in the art, such as water. Besides such inert diluents, compositions can also include adjuvants, such as wetting agents, emulsifying and suspending agents, and sweetening, flavoring and perfuming agents.
Preparations according to this invention for parenteral administration include sterile aqueous or non-aqueous solutions, suspensions, or emulsions. Examples of non-aqueous solvents or vehicles are propylene glycol, polyethylene glycol, vegetable oils, such as olive oil and corn oil, gelatin, and injectable organic esters such as ethyl oleate. Such dosage forms may also contain adjuvants such as preserving, wetting, emulsifying, and dispersing agents. They may be sterilized by, for example, filtration through a bacteria-retaining filter, by incorporating sterilizing agents into the compositions, by irradiating the compositions, or by heating the compositions. They can also be manufactured in the form of sterile solid compositions which can be dissolved in sterile water, or some other sterile injectable medium immediately before use.
Compositions for rectal or vaginal administration are preferably suppositories which may contain, in addition to the active substance, excipients such as coca butter or a suppository wax.
Compositions for nasal or sublingual administration are also prepared with standard excipients well known in the art.
Further, a compound of this invention can be administered in a sustained release composition such as those described in the following patents. U.S. Pat. No. 5,672,659 teaches sustained release compositions comprising a bioactive agent and a polyester. U.S. Pat. No. 5,595,760 teaches sustained release compositions comprising a bioactive agent in a gelable form. U.S. application No. 08/929,363 filed Sep. 9, 1997, teaches polymeric sustained release compositions comprising a bioactive agent and chitosan. U.S. application No. 08/740,778 filed Nov. 1, 1996, teaches sustained release compositions comprising a bioactive agent and cyclodextrin. U.S. application No. 09/015,394 filed Jan. 29, 1998, teaches absorbable sustained release compositions of a bioactive agent. The teachings of the foregoing patents and applications are incorporated herein by reference.
The dosage of active ingredient in the compositions of this invention may be varied; however, it is necessary that the amount of the active ingredient be such that a suitable dosage form is obtained. The selected dosage depends upon the desired therapeutic effect, on the route of administration, and on the duration of the treatment. Generally, dosage levels of between 0.0001 to 10 mg/kg of body weight daily are administered.
A preferred dosage range is 0.001 to 0.5 mg/kg of body weight daily which can be administered as a single dose or divided into multiple doses.
The compounds of the instant invention are illustrated by the following examples, but are not limited to the details thereof.
EXAMPLE 1
[Cha 7,11 , D-Nle 8 , Nle 18 , Tyr 34 ]hPTH(1-34)NH 2
The peptide [Cha 7,11 , D-Nle 8 , Nle 18 , Tyr 34 ]hPTH(1-34)NH 2 was synthesized on an Applied Biosystems (Foster City, Calif.) model 430A peptide synthesizer which was modified to do accelerated Boc-chemistry solid phase peptide synthesis. See Schnoize, et al., Int. J. Peptide Protein Res., 90:180 (1992). 4-Methylbenzhydrylamine (MBHA) resin (Peninsula, Belmont, Calif.) with the substitution of 0.93 mmol/g was used. The Boc amino acids (Bachem, Calif., Torrance, Calif.; Nova Biochem., LaJolla, Calif.) were used with the following side chain protection: Boc-Asn(Xanthyl), Boc-Arg(Tos)-OH, Boc-Asp(OcHex)-OH, Boc-Glu(OcHex)-OH, Boc-His(DNP)-OH, Boc-Cha-OH, Boc-D-Nle-OH, Boc-Nle-OH, Boc-Val-OH, Boc-Leu-OH, Boc-Gly-OH, Boc-Gln-OH, Boc-Ile-OH, Boc-Lys(2ClZ)-OH, Boc-Ser(Bzl)-OH; Boc-Trp(formyl)-OH and Boc-Tyr(Br-Z)-OH (where Z is benzyloxycarbonyl). The synthesis was carried out on a 0.14 mmol scale. The Boc groups were removed by treatment with 100% TFA for 2×1 min. Boc amino acids (2.5 mmol) were pre-activated with HBTU (2.0 mmol) and DIEA (1.0 mL) in 4 mL of DMF and were coupled without prior neutralization of the peptide-resin TFA salt. Coupling times were about 5 min.
At the end of the assembly of the peptide chain, the resin was treated with a solution of 20% mecaptoethanol/10% DIEA in DMF for 2×30 min. to remove the DNP group on the His side chain. The resin was washed with DMF. The N-terminal Boc group was then removed by treatment with 100% TFA for 2×2 min. The resin was washed with DMF and was treated with ethanolamine:H 2 O:DMF/15:15:70 for 2×30 min. to remove the formyl protecting group on Trp residue. The partially-deprotected peptide-resin was washed with DMF and DCM and dried in vacuo. The final cleavage was done by stirring the peptide-resin in 10 mL of HF containing 1 mL of anisole and dithiothreitol (24 mg) at about 0° C. for about 75 min. HF was removed by a flow of nitrogen. The residue was washed with ether (6×10 mL) and extracted with 4N HOAc (6×10 mL).
The peptide mixture in the aqueous extract was purified on a reverse-phase preparative high pressure liquid chromatography (HPLC) using a reverse phase VYDAC™ C 18 column (Nest Group, Southborough, Mass.). The column was eluted with a linear gradient (10% to 45% of solution B in solution A over 130 min.) at a flow rate of 10 mL/min (Solution A=water containing 0.1% TFA; Solution B=acetonitrile containing 0.1% of TFA). Fractions were collected and checked on analytical HPLC. Those containing pure product were combined and lyophilized to dryness. 114 mg of a white solid was obtained. Purity was >98% based on analytical HPLC analysis. Electro-spray mass spectrometer analysis gave the molecular weight at 4176.4 (in agreement with the calculated molecular weight of 4176.9).
EXAMPLE 2
[D-Nle 8 , Nle 18 , Tyr 34 ]hPTH(1-34)NH 2
Boc-protected amino acids, N-hydroxybenzotriazole (HOBt), N,N′-dicyclohexylcarbodilmide (DCC) and p-methylbenzhydrylamine resin were purchased from Applied Biosystems (Foster City, Calif.). Boc-(3-Iodo)Tyrosine[O-(3-BrBz)] was purchased from Peninsula Laboratories (Belmont, CA). B&J brand dichloromethane, N-methylpyrrolidone (NMP) and acetonitrile were obtained from Baxter (McGraw Park, Ill.). All other reagents are commercially available, for example from Sigma (St. Louis, Mo.). The title peptide was synthesized by solid-phase Boc/HOBt/NMP chemistry on an automated Applied Biosystems 430A peptide synthesizer using software version 1.40. The following side-chain protected N-α-Boc-amino derivatives were used in the course of the automated solid-phase peptide synthesis: Arg(N G -tosyl), Asp(O-cHex), Glu(O-Bzl), His(N n -Bom), Lys(N ε -2-Cl-Z), Ser(O-Bzl), Thr(O-Bzl), and Tyr(2-Br-Z). Synthesis started at a 0.5 mmol scale and was split into two halves after the incorporation of Glu 22 . The following residues were incorporated by double coupling cycles: Arg 25 , Leu 24 , Val 21 , Arg 20 , Glu 19 , Leu 15 , His 14 , Lys 13 , His 9 , Phe 7 , Gln 6 and Ile 5 . The Nle in positions 18 and 8 was introduced in the form of pre-dissolved NMP solution and the Activator cycle was modified accordingly. Cleavage of the peptide from the ρMBHA resin utilized liquid hydrogen fluoride and followed the “Low-High” procedure. The “Low-HF” step included mixing the suspension of the resin-bound peptide in a mixture (20 mL/g of resin-bound peptide) containing (% vol) 60% dimethylsulfide, 5% ρ-thiocresol, 5% ρ-cresol, 5% ethane dithiol, and 25% HF for about 2 hours at about 0° C. After removal of the volatile reagent under vacuum and washing the resin-bound peptide consecutively with petroleum-ether and ether it was returned to the reaction vessel for the “High-HF” step. The resin-bound peptide was resuspended in a mixture (20 mL/g or resin-bound peptide) containing (% vol) 5% butane dithiol, 5% ρ-cresol, and 90% HF for about 1 hour at about 0° C. After removing the reagents as previously described the crude peptide was dissolved in 50% (v/v) acetic acid and the solution was diluted with water and lyophilized. The peptide was purified by preparative reverse-phase high performance liquid chromatography (RP-HPLC) (PrepPak VYDAC® C18, 300Å cartridge, 15 μm, 5.5×35 cm). The solvent system employed included a two solvent system: A: 0.1% (v/v) TFA in water and B: 0.1% (v/v) TFA in acetonitrile, generating the following linear gradient: 0-15% B in A in the first 10 min followed by 15-45% B in A in the next 120 min at a flow-rate of 70 mL/min and monitored at 220 nm. Fractions were analyzed on an analytical RP-HPLC system (VYDAC® (C18, 300Å, 5 μm, 4.6×150 cm) employing a linear gradient of 20-50% B in A for 30 min at a flow rate of 1 ml/min and monitored at 220 nm, the retention time is 18.24 minutes. The pure fractions were pooled and the acetonitrile removed under vacuum. The residual was lyophilized to yield a white powder. Purity and structure of the peptides were confirmed by analytical RP-HPLC, amino acid analysis, and Fast Atom Bombardment Mass Spectrometry, mass spec.=4097.0.
EXAMPLES 3-5
Examples 3-4 were synthesized substantially according to the procedure of Example 1 using the appropriate, protected amino acids and Example 5 was synthesized substantially according to Example 2 using the appropriate, protected amino acids.
Mass
Example
Name
Spec.
3
[Cha 7,11 , des-Met 8 , Nle 18 , Tyr 34 ]hPTH(1-34)NH 2
4063.5
(SEQ ID NO:16)
4
[Cha 7,11 , D-Nle 8 , des-Met 18 , Tyr 34 ]hPTH(1-34)NH 2
4063.4
5
[D-Bpa 8 , Tyr 34 ]hPTH-(1-34)NH 2
4320.7
EXAMPLES 6-86
Examples 6 to 86 can be synthesized substantially according to the procedure of Example 1 using the appropriate, protected amino acids.
Example 6: [D-Nle 8 , Nle 18 , Tyr 34 ]hPTH(1-34)NH 2 Example 7: [D-Nle 8 ]hPTH(1-34)NH 2 Example 8: [D-Leu 8 , Nle 18 , Tyr 34 ]hPTH(1-34)NH 2 Example 9: [D-Cha 8 , Nle 18 , Tyr 34 ]hPTH(1-34)NH 2 Example 10: [D-Phe 8 , Nle 18 , Tyr 34 ]hPTH(1-34)NH 2 Example 11: [D-Nal 8 , Nle 18 , Tyr 34 ]hPTH(1-34)NH 2 Example 12: [D-Abu 8 , Nle 18 , Tyr 34 ]hPTH(1-34)NH 2 Example 13: [D-Met 8 ]hPTH(1-34)NH 2 Example 14: [Cha 7,11 , D-Met 8 ]hPTH(1-34)NH 2 Example 15: [D-Ile 8 ]hPTH(1-34)NH 2 Example 16: [Cha 7,11 , D-Ile 8 , Nle 18 , Tyr 34 ]hPTH(1-34)NH 2 Example 17: [D-Ile 8 , Nle 18 , Tyr 34 ]hPTH(1-34)NH 2 Example 18: [D-Leu 8 ]hPTH(1-34)NH 2 Example 19: [Cha 7,11 , D-Leu 8 , Nle 18 , Tyr 34 ]hPTH(1-34)NH 2 Example 20: [D-Val 8 ]hPTH(1-34)NH 2 Example 21: [Cha 7,11 , D-Val 8 , Nle 18 , Tyr 34 ]hPTH(1-34)NH 2 Example 22: [D-Val 8 , Nle 18 , Tyr 34 ]hPTH(1-34)NH 2 Example 23: [D-Cha 8 ]hPTH(1-34)NH 2 Example 24: [Cha 7,11 , D-Cha 8 , Nle 18 , Tyr 34 ]hPTH(1-34)NH 2 Example 25: [D-Ala 8 ]hPTH(1-34)NH 2 Example 26: [Cha 7,11 , D-Ala 8 , Nle 18 , Tyr 34 ]hPTH(1-34)NH 2 Example 27: [D-Ala 8 , Nle 18 , Tyr 34 ]hPTH(1-34)NH 2 Example 28: [D-Phe 8 ]hPTH(1-34)NH 2 Example 29: [Cha 7,11 , D-Phe 8 , Nle 18 , Tyr 34 ]hPTH(1-34)NH 2 Example 30: [D-Met 8 ]hPTH(1-34)NH 2 Example 31: [D-Nal 8 ]hPTH(1-34)NH 2 Example 32: [D-Trp 8 ]hPTH(1-34)NH 2 Example 33: [Cha 7,11 , D-Trp 8 , Nle 18 , Tyr 34 ]hPTH(1-34)NH 2 Example 34: [D-Trp 8 , Nle 18 , Tyr 34 ]hPTH(1-34)NH 2 Example 35: [D-Abu 8 ]hPTH(1-34)NH 2 Example 36: [Cha 7,11 , D-Abu 8 , Nle 18 , Tyr 34 ]hPTH(1-34)NH 2 Example 37: [des-Met 8 ]hPTH(1-34)NH 2 (SEQ ID NO:18) Example 38: [Cha 7,11 , des-Met 8 ]hPTH(1-34)NH 2 (SEQ ID NO:19) Example 39: [Cha 7,11 , des-Met 8 , des-Met 18 , Tyr 34 ]hPTH(1-34)NH 2 (SEQ ID NO:20) Example 40: [des-Met 8 , des-Met 18 ]hPTH(1-34)NH 2 (SEQ ID NO:21) Example 41: [Cha 7,11 , des-Met 8 , des-Met 18 ]hPTH(1-34)NH 2 (SEQ ID NO:22) Example 42: [des-Met 8 , Nle 18 , Tyr 34 ]hPTH(1-34)NH 2 (SEQ ID NO:23) Example 43: [des-Met 18 ]hPTH(1-34)NH 2 (SEQ ID NO:24) Example 44: [Cha 7,11 , des-Met 18 ]hPTH(1-34)NH 2 (SEQ ID NO:25) Example 45: [Cha 7,11 , des-Met 18 , Tyr 34 ]hPTH(1-34)NH 2 (SEQ ID NO:26) Example 46: [D-Nle 8 , des-Met 18 , Tyr 34 ]hPTH(1-34)NH 2 Example 47: [des-Gln 6 , Nle 8,18 , Tyr 34 ]hPTH(1-34)NH 2 (SEQ ID NO:27) Example 48: [des-Leu 7 , Nle 8,18 , Tyr 34 ]hPTH(1-34)NH 2 (SEQ ID NO:28) Example 49: [des-His 9 , Nle 8,18 , Tyr 34 ]hPTH(1-34)NH 2 (SEQ ID NO:29) Example 50: [des-Asn 10 , Nle 8,18 , Tyr 34 ]hPTH(1-34)NH 2 (SEQ ID NO:30) Example 51: [des-Leu 11 , Nle 8,18 , Tyr 34 ]hPTH(1-34)NH 2 (SEQ ID NO:31) Example 52: [des-Gly 12 , Nle 8,18 , Tyr 34 ]hPTH(1-34)NH 2 (SEQ ID NO:32) Example 53: [des-Lys 13 , Nle 8,18 , Tyr 34 ]hPTH(1-34)NH 2 (SEQ ID NO:33) Example 54: [des-His 14 , Nle 8,18 , Tyr 34 ]hPTH(1-34)NH 2 (SEQ ID NO:34) Example 55: [des-Leu 15 , Nle 8,18 , Tyr 34 ]hPTH(1-34)NH 2 (SEQ ID NO:35) Example 56: [des-Asn 16 , Nle 8,18 , Tyr 34 ]hPTH(1-34)NH 2 (SEQ ID NO:36) Example 57: [des-Ser 17 , Nle 8,18 , Tyr 34 ]hPTH(1-34)NH 2 (SEQ ID NO:37) Example 58: [des-Glu 19 , Nle 8,18 , Tyr 34 ]hPTH(1-34)NH 2 (SEQ ID NO:38) Example 59: [des-Arg 20 , Nle 8,18 , Tyr 34 ]hPTH(1-34)NH 2 (SEQ ID NO:39) Example 60: [des-Val 21 , Nle 8,18 , Tyr 34 ]hPTH(1-34)NH 2 (SEQ ID NO:40) Example 61: [des-Glu 22 , Nle 8,18 , Tyr 34 ]hPTH(1-34)NH 2 (SEQ ID NO:41) Example 62: [des-Gln 6 , Cha 7,11 , Nle 8,18 , Tyr 34 ]hPTH(1-34)NH 2 (SEQ ID NO:42) Example 63: [des-Leu 7 , Nle 8,18 , Cha 11 , Tyr 34 ]hPTH(1-34)NH 2 (SEQ ID NO:43) Example 64: [Cha 7,11 , des-His 9 , Nle 8,18 , Tyr 34 ]hPTH(1-34)NH 2 (SEQ ID NO:44) Example 65: [des-Gln 6 , Cha 7,11 , D-Nle 8 , Nle 18 , Tyr 34 ]hPTH(1-34)NH 2 Example 66: [des-Leu 7 , D-Nle 8 , Cha 11 , Nle 18 , Tyr 34 ]hPTH(1-34)NH 2 Example 67: [Cha 7,11 , D-Nle 8 , des-His 9 , Nle 18 , Tyr 34 ]hPTH(1-34)NH 2 Example 68: [Cha 7,11 , des-Met 8 , des-His 9 , des-Asn 10 ]hPTH(1-34)NH 2 (SEQ ID NO:45) Example 69: [Cha 7,11 , des-Ser 17 , des-Met 18 , des-Glu 19 ]hPTH(1-34)NH 2 (SEQ ID NO:46) Example 70: [D-Met 8 , Nle 18 , Tyr 34 ]hPTH(1-34)NH 2 Example 71: [D-Met 8 , Tyr 34 ]hPTH(1-34)NH 2 Example 72: [D-Nle 8 , Nle 18 , Tyr 34 ]hPTH(7-34)NH 2 Example 73: [D-Nle 8 , Nle 18 ]hPTH(7-34)NH 2 Example 74: [Ile 5 , D-Leu 8 ]hPTHrP(1-34)NH 2 Example 75: [Ile 5 , D-Leu 8 , Trp 23 ]hPTHrP(1-34)NH 2 Example 76: [Ile 5 , des-Leu 8 , Trp 23 ]hPTHrP(1-34)NH 2 (SEQ ID NO:47) Example 77: [Ile 5 , des-Leu 8 ]hPTHrP(1-34)NH 2 (SEQ ID NO:48) Example 78: [des-Leu 8 , Trp 23 ]hPTHrP(1-34)NH 2 (SEQ ID NO:49) Example 79: [Ile 5 , des-Leu 18 ]hPTHrP(1-34)NH 2 (SEQ ID NO:50) Example 80: [Ile 5 , des-Leu 18 , Trp 23 ]hPTHrP(1-34)NH 2 (SEQ ID NO:51) Example 81: [des-Leu 18 , Trp 23 ]hPTHrP(1-34)NH 2 (SEQ ID NO:52) Example 82: [Ile 5 , D-Leu 8 , Glu 22,25 , Leu 23,28,31 , Lys 26,30 , Aib 29 ]hPTHrP(1-34)NH 2 Example 83: [Ile 5 , D-Leu 8 , Glu 22,25 , Trp 23 , Lys 26,30 , Leu 28,31 , Aib 29 ]hPTHrP(1-34)NH 2 Example 84: [Ile 5 , D-Leu 8 , Glu 22,25,29 , Leu 23,28,31 , Lys 26,30 ]hPTHrP(1-34)NH 2 Example 85: [Ile 5 , D-Leu 8 , Glu 22,25,29 , Trp 23 , Lys 26,30 , Leu 28,31 ]hPTHrP(1-34)NH 2 Example 86: [D-Leu 8 , Trp 23 ]hPTHrP(7-34)NH 2
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This invention relates to a series of PTH and PTHrP analogues that selectively bind to PTH2 receptors and as such may be useful in treating abnormal CNS functions; abnormal pancreatic functions; divergence from normal mineral metabolism and homeostasis; male infertility; regulation of abnormal blood pressure; and hypothalmic disease.
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FIELD OF THE INVENTION
The invention relates to a process and to a device for the continuous disposal of an aerosol cloud, as well as to the use of this process in the elimination of toxic gases.
BACKGROUND OF THE INVENTION
In known processes, see for example patent document U.S. Pat. No. 3,606,153, unwanted particles in the atmosphere are discarded by physical and/or chemical means and measures, or are eliminated from the field of vision. Among these processes can be cited the technique of irradiation of the particles by means of sonic and ultrasonic waves transmitted from sound sources from the ground or from a ship towards the particle clouds, mostly fog. The purpose of the acoustic irradiation is to densify and coagulate the particles so as to cause them to settle to the ground due to gravity.
The patent document GB-A-1.154.020 describes an ultrasonic siren for use on board of ships, which transmits two acoustic waves of equal frequency within the range of 16 to 22 kHz, which are phase-shifted by 180°. The intensity of the radiation can be variably adjusted.
When fog is irradiated with frequencies in the audible range, very high acoustic field intensities of at least 150 dB are required in order to achieve satisfactory coagulation of the particles.
SUMMARY OF THE INVENTION
It is the aim of the present invention to provide an acoustic irradiation process, which is particularly suited for the disposal of aerosol clouds resulting from the release of radioactive and/or toxic aerosol and gas into the atmosphere in the event of major accidents at nuclear and chemical plants. The resulting danger to human life and the environment due to the atmospheric spreading of such hazardous material over possible hundreds of kilometers can thus be considerably reduced. The invention aims in particular at influencing the particles in such a way that they can be collected. This is not possible in conjunction with the above mentioned known methods.
Consequently, according to the invention, a process for the controlled disposal of an aerosol cloud by means of directed sound waves of high intensity and of frequencies in the audible range is characterized in that the sound waves are emitted by an aircraft operating close to the periphery of the cloud. The frequency spectrum of the wave consists of a basic frequency and a superposed frequency of twice the basic frequency value and phase-shifted by 90° in relation to the basic frequency, so as to cause the particles to coagulate and to migrate towards the sound source, and that the particles are then collected at the aircraft.
With regard to preferred embodiments of the process according to the invention and to the device for implementing this process, reference is made to the sub-claims.
Laboratory experiments with smoke have shown that in adopting this kind of irradiation in conjunction with a sufficiently high sound pressure, an intense coagulation of the particles is produced. In addition, the irradiation spectrum induces strong forces on the enlarged particles in the direction of the sound transmitter. For instance, when irradiating a smoke cloud at a distance of 1 m and with a sound pressure of 160 dB, a coagulation of the particles up to a size for the coagulated particles of 60 times the initial one occured within 5 seconds. Drift velocities as high as 1 ms.sup. -1 can be expected for the enlarged particles based on drift force measurements on 100 μm diameter particles suspended in the sound field.
This directed fast movement of the coagulated particles is particularly useful in the attack of dangerous aerosol clouds and their controlled disposal, if the sound source and the means for collecting the particles are brought towards the cloud by an aircraft. By this approach, the drawbacks of the known sound transmission techniques operating from the ground or water surface are avoided. These drawbacks mainly consist in that the attacked aerosols can be irradiated from only one direction, i.e. the ground surface, that generally large distances between sound transmitter and cloud have then to be bridged, causing high energy losses in the air, particularly due to acoustic saturation, and that, at best, only an uncontrolled "wash-out" of the aerosols can be realised, which again causes problems in the case of radioactive and toxic aerosols.
When the particle concentration in the cloud is low, it can be advantageous, besides the sound irradiation, to introduce seed aerosols into the cloud to be attacked, and to this effect, an aircraft is again particularly suited.
The aerosol cloud can, of course, also be attacked by more than one aircraft, if necessary of different types, and, in addition, by a stationary or mobile transmitter station on the ground.
DETAILED DESCRIPTION OF THE INVENTION
The invention will now be described in more detail by reference to three figures.
FIG. 1 illustrates an aerosol cloud emerging from a damaged nuclear plane and, schematically, the application of the process according to the invention.
FIG. 2 schematically illustrates a device for the implementation of the process adapted to being fixed to an airship.
FIG. 3 shows, schematically in cross-section, a sound source including a particle collection device.
An aerosol cloud, such as may be caused by a nuclear accident in a large scale plant, may have the following characteristics:
Diameter of the cloud: 100 meters
Volume of the cloud: 5×10 5 m 3
Concentration of particles: 10 12 m.sup. -3
Distance between particles: 100 μm
Mean particle diameter: 1 μm
Number of particles: 5×10 17
Density of particles: 1 g cm -3
Mass loading: 1 g/m 3
It can be assumed that the diameter of the particles varies considerably. When the diameter of the particles is smaller than 0.1 μm, the intermolecular movement already causes the particles to rapidly collide and coagulate with each other. If, however, the diameter of the particles is very large, e.g. larger than 15 μm, gravity leads to a fast sedimentation of the particles and to their settling on the ground in the immediate vicinity of the damaged plant. Consequently, the particles with diameters between 0.1 and 15 μm are particularly dangerous, because they are carried far away by the atmospheric movements, and must be treated by the process according to the invention.
In order to understand the interaction between a sound wave and such particles, it is necessary to take into account the mass of the particles: Small particles behave like gas particles in a sound wave and are carried away by it. For heavier particles, inertia effects attenuate the movement of the particle. The movement of such particles thus decreases with increasing mass or increasing frequency of the sound wave. At a given sound frequency, particles with different masses move with very different speed, so that the particles collide and coagulate. It is thus possible, as is known, to increase the size of a particle in an aerosol by the impact of sound waves with sufficient intensity and adequate frequency, so that the particles "rain off"]the cloud by gravity and do not propagate farther away with the atmospheric currents.
Now, the invention adds a further step by preventing the aerosols from falling to the ground due to the creation of drift movement of the particles towards the sound source and to the collection of the particles in a collection device fixed to the aircraft. The forces responsible for the overall coagulation and drifting process are the average Stokes force and the average Oseen force.
The Stokes force originates from the viscosity of a fluid which depends on temperature. With an adiabatic compression of the fluid, caused by a sound wave, the temperature of the fluid first increases and then decreases again in the second half-cycle of the sound wave. The product of fluid speed times viscosity yields an average value over a cycle, which generates a drift of the particles in the direction of the sound source. It can be demonstrated that in air at 20° C. and at atmospheric pressure, a sound wave having a pressure value of 151 dB is able to establish a drift of 0.66 cm/s.
In addition, the so-called Oseen force becomes effective. This force is for instance defined in the Journal of the Acoustic Society of America, Vol. 22, 1950, p. 319 ff. and Vol. 23, 1951, pp 312-315. It originates from the distortion of the wave shape at higher amplitudes and is independent of the temperature variation in the sound wave. On the contrary, the value and the direction of this force depend upon the degree of distortion, particularly upon the phase shift between the basic frequency and the double of the base frequency, provided the sound wave contains particularly these components. This force is highest towards the source for a phase difference of +90° between these components.
Practical embodiments of the process according to the invention and of the devices needed for its implementation are now described with reference to the drawings.
FIG. 1 shows a nuclear power plant 1 comprising a reactor enclosure 2, which has a crack 3 in its roof because of an accident. Radioactive substances escape through this crack and form an aerosol cloud 4 in the surrounding air with the above mentioned characteristics. The propagation of the radioactive particles through atmospheric movements is to be prevented by the invention.
The attack of the cloud and its disposal is demonstrated here for the case of two aircrafts, namely an airship 8 and a helicopter 10. Both crafts are equipped with a sound transmitter, e.g. a siren 7 respectively 9 for radiating the sound signals according to the invention, the irradiated space being marked by the dotted lines. In the place of a single siren, a matrix arrangement of transducer-controlled loudspeakers 12 may be provided, as can be seen schematically in FIG. 2.
A remotely controlled aircraft may also be flown directly into the cloud, so that the effects of coagulation and drifting will become even more intense than in the case of irradiating the cloud from its periphery.
The effect of the sound is particularly intense, when the particles in the aerosol cloud are exposed to a field of stationary sound waves. This can be achieved, as shown in FIG. 2, for a sound emitter device equipped with loudspeakers 12 in a matrix structure 11, if a reflection wall 13 is mounted in juxtaposition to the structure 11, leaving a distance in between. The wall 13 as well as the structure 11 are of course fixed to the airship 8. The structure 11 may, when used with an aircraft, be provided with fewer sirens than when used with ground stations. The distance between the reflection wall 13 and the structure 11 may for instance amount to 10 m. With a drift speed of 20 cm per second, the space volume between the matrix structure 11 and the reflection wall 13 would be `cleaned` within some seconds, so that the airship may be moved slowly within the cloud for treating the various portions of the cloud. It should be also noted that an airship offers the advantage of being able to drift with the wind, while in the cloud, without further steering means.
In FIG. 3, there is shown, in a cross-sectional view, a single arrangement operating simultaneously as a loudspeaker and as a collection device, in which sound energy is transformed from electrical energy. In front of the sound producing membrane of the loudspeaker 12, there is disposed a reception wall 14 permeable to sound, upon which impact the drifting particles and which constitutes, in conjunction with a vertically mobile wiper 15, a collecting device for the arriving particles. The wiper is moved periodically across the surface and conveys the particles into a collecting groove 16, from whereon they are discharged or sucked off.
As has already been mentioned, the average Oseen-force generates particularly high drift speeds, if the sound waves contain, according to the invention, a basic frequency (e.g. 20 kHz) and a first harmonic (40 kHz) phase-shifted by 90°, as being the main components of the transmission spectrum. Such a spectrum may be produced for instance by electrically controlled piezo-electric or magneto-strictive converters. Also, acoustic transducers have been developed more recently which transform up to 80% of the input electrical power into acoustic power. But also whistles or sirens or combustion engines operating as sound sources may be applied in the process according to the invention, provided the sound power is high enough.
The invention is not limited to the treatment of radioactive aerosol clouds, but may be employed in all situations where undesired aerosol clouds are to be eliminated from the atmosphere. This is particularly true in case of chemical accidents, traffic accidents with tank trucks or in conjunction with the treatment of ground fog banks in airfield areas.
When especially a gas cloud is to be attacked and eliminated, the cloud may be pre-treated by means of injecting see particles like activated carbon or zeolite. the adsorption of the gas by the carbon or zeolite particles is enhanced when the intensity of the sound field is high by the destruction of the viscous boundary layer around the particle. Then, the seed particles together with the adsorbed gas molecules are `sucked` by the sound source in the above explained way.
Also, when the mass loading of a particle cloud to be attacked falls or is below 1 g/m 3 , spraying of seed particles into the cloud is to be recommended, in order to reactivate the coagulation effect or to bring it about.
A seed aerosol which is easy to be produced is smoke from burning automobile tyres. Burning tyre rubber produces a dense black smoke, which not only increases the total mass loading of the cloud, but also enables the optical observation of the movement of the cloud and of the efficiency of the sound attack. There are species of rubber which produce, while burning, amounts of water vapour, whereby the efficiency of the acoustic coagulation process is further increased. If, for instance, 5% of an amount of rubber optimized with regard to the density and diameter of the smoke particles were converted into aerosol particles, it would be possible to create a mass loading of 1 gm -3 in a volume of 5×10 5 m 3 with an amount 10 4 kg of rubber, to be stored near the place of the endangered nuclear or chemical plant.
Another appropriate aerosol is fine water mist or water vapour. The spray devices are not shown in the drawings since they are of any conventional type.
Principally, frequencies in the range of 100 Hz to 50 kHz apply to the process according to the invention. The lower the frequencies, the lower the absorption of the sound energy by the surrounding air. Because, however, of the close range type attack of the aerosol cloud by means of aircraft, the use of frequencies higher than 20 kHz is possible.
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The invention relates to a process for the controlled disposal of an aerosol cloud by means of directed sound waves of high intensity in the audible frequency range. According to the invention, sound waves are emitted by an aircraft (8, 10) operating close to the periphery of the cloud (4). The frequency spectrum of the wave consists of a basic frequency and a superposing frequency of twice the basic frequency valve and phase-shifted in relation to the basic frequency at substantially 90°, so as to cause the particles to coagulate and to migrate towards the sound source, and to be collected at the aircraft.
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TECHNICAL FIELD OF THE INVENTION
BACKGROUND OF THE INVENTION
The present invention relates to a device for producing cold and/or heat by solid-gas reaction.
The device to which the invention refers is based on the use of the so-called "thermochemical pump" system, whose main characteristics are as follows:
- heat energy is employed for operating the system itself; electrical energy is optionally employed only for circulating the heat-transfer fluids,
- the "chemical engine" employed is a reversible reaction between a solid and a gas of the type: ##STR1##
The reaction is exothermic in direction 1, which means that, in this direction, it produces heat, and endothermic in direction 2, that is to say that, in this direction, it produces cold.
Such a system makes it possible to store energy in chemical form and has varied fields of application.
In addition, such a system makes it possible to produce, from a source of heat at the temperature Ts, heat at the temperature Tu such that:
Tu<Ts
In this case, this system is called "chemical heat pump".
Such a system also makes it possible to produce, from a source of heat at the temperature T's, heat at the temperature T'u such that:
T'u>T's
In this case, the system is called "chemical thermoconverter".
By virtue of this system it is possible to produce refrigeration energy from a source of heat and simultaneously to produce, from a source of heat at the temperature T"s, heat at the temperature T"u (T"u<T"s) and refrigeration energy.
Depending on circumstances, the use of the heat or of the cold produced is simultaneous with the consumption of energy at high temperature (Ts, T's, T"s) or delayed in time (storage effect).
Document EP-A-0,382,586 discloses a device for the production of cold and/or heat by solid-gas reaction, comprising two reactors, each containing a salt capable of reacting chemically with a gas, a condenser and an evaporator for the gas. The components of the device are arranged so as to allow the gas to follow a path from one reactor to the other, passing through the condenser and the evaporator. At the end of the chemical reaction the reactor which is depleted in gas is at a higher temperature than that of the reactor containing the gas which has just reacted with the salt, the two reactors being at different pressure levels. Heat is conveyed by a heat transfer system from the reactor which is at the higher temperature to the reactor which is at the lower temperature in order to increase the temperature of the latter. The chemical reaction then takes place in the reverse direction, part of the heat of one reactor being used as a source of heat for desorption of the gas from the other reactor. This heat transfer between the two reactors is used to improve the efficiency of the system.
However, this improved efficiency of the system does not completely satisfy the commercial requirements demanded in the case of such a system.
SUMMARY OF THE INVENTION
The objective of the present invention is therefore to propose a device for the production of cold and/or heat by solid-gas reaction, in which the heat transfer between the various reaction chambers of the device is optimized.
To do this, the invention proposes a device for producing cold and/or heat by chemical reaction comprising at least four reactors, each containing a salt capable of reacting chemically with a gas, a vessel intended to receive the gas from the reactors and a vessel intended to deliver the gas to the reactors, the device being arranged so that, during the chemical reaction, two reactors are at the same higher pressure level and two reactors are at the same lower pressure level, characterized in that the device additionally comprises a heat transfer fluid circuit intended to transfer heat between the reactors which are at the same pressure level.
The advantages and the operation of the present invention will appear more clearly on reading the following description, given without any limitation being applied, with reference to the attached drawings,
BRIEF DESCRIPTION OF THE FIGURES OF DRAWING
- each of FIGS. 1A and 1B is a Clapeyron diagram for a device according to a first embodiment of the invention,
- each of FIGS. 2A and 2B is a diagrammatic view of a device according to the first embodiment,
- each of FIGS. 3A and 3B is a Clapeyron diagram for a device according to a second embodiment of the invention,
- each of FIGS. 4A and 4B is a diagrammatic view of a device according to the second embodiment,
- FIG. 5 is a diagrammatic view of another device according to the second embodiment.
The operation of the devices according to the invention is based on the reaction between a salt and a gas. Since a true chemical reaction is involved, a monovariant system is present at equilibrium, that is to say that a univocal relationship exists between the temperature and the pressure, of the form log P=A-B/T, in which expression P is the pressure, T is the temperature in K, and A and B are constants characteristic of the salt/gas pair employed.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
In the following description the stages of operation will be shown in a Clapeyron diagram as shown in FIGS. 1A and 1B, which include equilibrium straight lines for the salts employed.
FIGS. 2A and 2B show a device for producing cold by solid-gas reaction according to a first embodiment of the invention. The device comprises four reaction chambers 10, 12, 14, 16, called reactors, made up of a vessel containing a mixture of a salt and of expanded graphite, optionally recompressed. The device additionally comprises an evaporator 18 for the gas and a condenser 20, which are arranged so as to be capable of exchanging heat with their environment.
In the example illustrated in FIG. 2A the reactors 10 and 12 are connected to the condenser 20 by conduits 22 and 24 which are provided with a valve 26 in order to be capable of selectively allowing gas to pass between the reactors 10, 12 and the condenser 20. Similarly, reactors 14 and 16 are connected to the evaporator 18 by conduits 30 and 32 which are provided with a valve 34 in order to make it possible, selectively, to allow the gas to pass between the reactors 14, 16 and the evaporator 18.
At a given instant of the reaction cycle the reactors 10, 12, 14, 16 are at the temperatures and pressures shown in the diagram in FIG. 1A. As follows from the diagram, the reactor 10 is at a temperature higher than that of the reactor 12, and the reactor 14 is at a temperature lower than that of the reactor 16.
According to the invention, instead of transferring heat from a first reactor, at a high temperature and a low pressure level, to a second reactor at a lower temperature and a higher pressure level, the heat transfer is performed between two reactors situated at the same pressure level.
As shown in FIGS. 2A and 2B, each of the reactors 10, 12, 14, 16 is provided with an associated heat exchanger 38, 40, 42 and 44, these exchangers being connected together by a conduit 46 in order to form a heat transfer circuit 45. A cooler 48 is fitted in the conduit 46 between the reactors 12 and 14, and a heating device, for example a burner 50, is fitted in the conduit 46 between the reactors 16 and 10.
When the device is started up, gas passes via the conduits 22, 24 and 30, 32 between the reactors, the condenser 20 and the evaporator 18 in accordance with the cycle shown in FIG. 1A. At a given instant in the cycle, the reactors 10, 12, 14 and 16 are at the temperatures and pressures illustrated in FIGS. 1A and 1B, the reactors 10 and 12 being at a high pressure and the reactors 14 and 16 being at a lower pressure. The heat transfer circuit 45 is started up, the heat transfer fluid circulating in the direction of the arrows 52 under the effect of a pump (not shown).
Heat originating from the reactor 10, which is at a temperature T 1 , is conveyed to the reactor 12 which is at a lower temperature T 2 . The heat transfer fluid, cooled after passing through the reactor 12, is next cooled further by the cooler 48 and leaves the latter at a temperature T 3 . The cooled heat transfer fluid then passes through the reactor 14 and then through the reactor 16, which is at a temperature T 4 , before passing through the burner 50 in order to regain the initial temperature level T 1 .
The reaction between the salts employed in the reactors and the gas, which is, for example, ammonia, is reversible, the reactions in both directions together forming a cycle. To terminate a cycle, the reactors 10 and 12 are connected via conduits 52 and 54 to the evaporator 18, and the reactors 14 and 16 are connected to the condenser 20 by conduits 56 and 58, as shown in FIG. 2B. At the end of reaction the reactors 10 and 12 and the reactors 14 and 16 are in reversed positions in relation to those shown in FIG. 1A. The heat transfer circuit is then started up in the reverse direction, as shown by arrows 60 in FIG. 1B. The heat transfer effect produced by the passage of the heat transfer fluid is analogous to that described above.
FIGS. 4A and 4B show a device for producing cold or heat by solid-gas reaction according to a second embodiment of the invention. This device differs from that in FIGS. 2A and 2B in that the condenser 20 and the evaporator 18 have been replaced with reactors. The device thus comprises six reactors 80, 82, 84, 86, 88 and 90, of which four 82, 84, 88 and 90 are connected to a burner 92 and to a cooler 94 by a heat transfer circuit 96.
At a given moment in the reaction cycle the reactors are at the temperatures and pressures illustrated in FIG. 3A, the reactors 80, 82 and 84 being at the same pressure level but at different temperatures, the reactors 86, 88 and 90 being at the same lower pressure level, but also at different temperatures. The heat transfer circuit 96 is then started up, the heat transfer fluid circulating in the direction of the arrows 98. As in the case of the device of FIGS. 2A and 2B, the heat transfer fluid transfers the heat successively between the reactors 84 and 82 which are at the higher pressure level, the reactors being at associated temperatures T 1 and T 2 . The heat transfer fluid then passes through the cooler 94 in order to reduce its temperature to T 3 before passing successively through the reactors 88 and 90, the temperature of the fluid rising from T 3 to T 4 during this passage. As in the example of FIGS. 1A and 1B, the heat transfer fluid is then heated in the burner 92 to a temperature T 1 .
In a manner similar to that of the device of FIG. 1B, the reaction then takes place in the reverse direction and, at a given instant of the cycle, the reactors are at the temperatures and pressures shown in FIG. 3B. As shown in FIGS. 3B and 4B, the heat transfer fluid circulates in reverse direction, as shown by the arrows 100.
Thus, according to the invention, during each stage of the reaction cycle, a heat transfer circuit ensures the heat transfer between the reactors which are at the same high pressure level, the heat flowing from a reactor which is at a given temperature to a reactor at a lower temperature. As for the reactors which are at the same lower pressure level, the heat transfer fluid is heated during its passage through the successive reactors, the heat transfer fluid passing from a reactor at a given temperature to a reactor at a higher temperature.
Each of the devices of FIGS. 1A,B-4A,B comprises a heat transfer circuit intended to transfer heat from a first reactor to a second one. FIG. 5 shows a device in which the heat flows from one reactor to another of the same series solely by conduction, that is to say without any resort to a heat transfer circuit between the reactors.
In this example, a cylindrical reactor 112 is arranged inside a first annular reactor 114, itself arranged inside a second annular reactor 116, the three reactors being arranged so as to ensure good thermal conductivity between them. A heat exchanger 118 connected to a heat transfer circuit shown diagrammatically as 120 is arranged inside the cylindrical reactor 112. In the example illustrated, this set of three reactors 112, 114 and 116 is connected to a similar second set which is made up of three reactors 122, 124 and 126. After passing through the heat exchanger 118, the heat transfer fluid passes through another heat exchanger 128, which is in thermal communication with the reactor 116. The fluid then passes through a cooler 130, a heat exchanger 132 in thermal communication with the reactor 126 an exchanger 134 arranged inside the reactor 122, and a burner 136, before passing again through the exchanger 118. The operation of a device of this type is similar to that of the device of FIGS. 3A,B and 4A,B.
The performance of a device for producing cold and/or heat by chemical solid-gas reaction can be evaluated by employing the economic concept of the coefficient of performance or COP.
By way of example, the COP of a device corresponding to that of FIG. 2A is calculated.
In this example each of the reactors 12 and 14 contains CaCl 2 reacting with 4 moles of ammonia, that is CaCl 2 · 8NH 3 to 4NH 3 , and each of the reactors 10 and 16 contains NiCl 2 reacting with 4 moles of ammonia, that is NiCl 2 · 6NH 3 to 2NH 3 .
The temperature of the heat transfer fluid leaving the burner 50 is 285° C., the temperature T3 is 35° C. and at the exit of the evaporator is 5° C.
The COP defined by the ratio of the cold energies produced in relation to the high temperature energy is equal to 1.07, given that the heating or the cooling of the heat transfer fluid in a reactor during absorption or desorption of the gas corresponds to 80% of the maximum possible rise or of the maximum possible decrease. This corresponds to the difference between the entry temperature of the heat transfer fluid and the equilibrium temperature of the reactant at the pressure being considered.
If, in the case of the same device, the condenser is replaced with a reactor 80 containing BaCl 2 (8-ONH 3 ), and the evaporator is replaced with a reactor 86 containing the same salt, the COP is 1.60.
In each embodiment heat is transferred between the reactors which are at the same given pressure level at an instant of the cycle. This heat transfer can be performed by a heat transfer fluid or by simple conduction. The reactors which are at the same pressure level can be connected to an associated heat transfer circuit or to a circuit which is common to all the reactors of the device.
The device according to the invention may comprise two series of reactors, each series being made up of a number of reactors and being intended to be connected together to a condenser or to an evaporator. Alternatively, the condenser and the evaporator may each be replaced by an associated reactor which is intended to receive or to release the gas.
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A cooling and heating device using a chemical reaction comprising at least four reactors, each containing a salt capable of chemically reacting with a gas, an enclosure for receiving gas from the reactors and an enclosure for conveying gas to the reactors. The device is arranged so that, during the chemical reaction, two reactors are at the same higher pressure level, while two reactors are at the same lower pressure level. According to the invention, the device also comprises a heat-transporting fluid circuit for transferring heat between the reactors, operating at the same presure level.
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BACKGROUND
Technical Field
The present invention is related to a metal laminate, in particular to adhesive-free metal laminate whose insulating layer is made of polyimide resin.
Description of Related Art
Flexible printed circuit board (FPCB) has been widely used in high-density portable electronic devices due to its flexible features. Traditional polyimide (PI) FPCBs use a thermosetting polyimide resin as insulating layer. An adhesive (such as epoxy) is coating on one side of thermosetting polyimide resin to bond with metal layer (such as copper foil). The product is called single-side metal laminate. If the laminate needs to support more circuits, the adhesive could be coated on both side of the thermosetting polyimide resin to bond metal layer. The product is called double-side metal laminate. However, the adhesive may decrease the flexibility, solder resistance, dimensional stability and limit the thickness of the metal laminate. Also, the adhesive may cause environmental problem.
SUMMARY
In view of the above problems, the present invention provides a metal laminate and a method for manufacturing the same. The metal laminate of present invention uses specific polyimide resin as its insulating layer, and the insulating layer (polyimide resin) directly contacts the metal layer without adhesive. The metal laminate of the present invention is characterized by a low dielectric constant and a low dissipation factor, thus is suitable for high frequency electronic devices.
According to one aspect of the present invention, a metal laminate is provided. The metal laminate comprises a first metal layer and an insulating layer. The insulating layer is made of a polyimide resin, disposed on the metal layer and directly contacts the metal layer. The polyimide resin is derived from at least two dianhydride monomers and at least two diamine monomers. The dianhydride monomers are selected from the group consisting of p-phenylenebis(trimellitate anhydride), 4,4′-(hexafluoroisopropylidene)-diphthalic anhydride, 4,4′-(4,4′-isopropylidenediphenoxy)bis(phthalic anhydride) and the combination thereof. One of the diamine monomers is 2,2′-bis(trifluoromethyl)benzidine, and the other diamine monomers are selected from a group consisting of 2,2-bis[4-(4-aminophenoxy)phenyl, 1,3-bis(4-aminophenoxy)benzene, p-phenylenediamine, 4,4′-oxydianiline, 4,4′-methylenedianiline, 4,4′-diaminobenzanilide, 4,4′-diaminodiphenyl-sulfone, m-tolidine, 2,2-bis[4-(4-aminophenoxy)phenyl]hexafluoropropane and the combination thereof. A molar ratio of the dianhydride monomers to the diamine monomers is between 0.85 and 1.15.
According to another aspect of present invention, a method for manufacturing a metal laminate is provided. The method comprises the following steps: providing a first metal layer; coating a precursor of a polyimide resin on the first metal layer, wherein the precursor of the polyimide resin is polymerized by at least two dianhydride monomers and at least two diamine monomers. The dianhydride monomers are selected from the group consisting of p-phenylenebis(trimellitate anhydride), 4,4′-(hexafluoroisopropylidene)-diphthalic anhydride, 4,4′-(4,4′-isopropylidenediphenoxy)bis(phthalic anhydride) and the combination thereof. One of the diamine monomers is 2,2′-bis(trifluoromethyl)benzidine, and the other diamine monomers are selected from a group consisting of 2,2-bis[4-(4-aminophenoxy)phenyl, 1,3-bis(4-aminophenoxy)benzene, p-phenylenediamine, 4,4′-oxydianiline, 4,4′-methylenedianiline, 4,4′-diaminobenzanilide, 4,4′-diaminodiphenyl-sulfone, m-tolidine, 2,2-bis[4-(4-aminophenoxy)phenyl]hexafluoropropane and the combination thereof. A molar ratio of the dianhydride monomers to the diamine monomers is between 0.85 and 1.15; and imidizing the precursor of the polyimide resin to form a first polyimide layer.
According to another aspect of the present invention, a method for manufacturing a metal laminate is provided. The method comprises providing a polyimide film made of the polyimide resin by foregoing step; disposing a first metal layer on one side of the polyimide film and a second metal layer on the other side of the polyimide film; and bonding the first and the second metal layer and the polyimide film by thermocompression.
Many of the attendant features and advantages of the present invention will be better understood with reference to the following detailed description considered in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A shows an IR spectrum of polyimide resin according to Example 1; FIG. 1B shows a DSC (Differential scanning calorimetry) spectrum of polyimide resin according to Example 1.
FIG. 2A shows an IR spectrum of Polyimide resin according to Example 2; FIG. 2B shows a DSC (Differential scanning calorimetry) spectrum of polyimide resin according to Example 2.
FIG. 3A shows an IR spectrum of polyimide resin according to Example 3; FIG. 3B shows a DSC (Differential scanning calorimetry) spectrum of polyimide resin according to Example 3.
FIG. 4A shows an IR spectrum of polyimide resin according to Example 4; FIG. 4B shows a DSC (Differential scanning calorimetry) spectrum of polyimide resin according to Example 4.
FIG. 5A shows an IR spectrum of polyimide resin according to Example 5; FIG. 5B shows a DSC (Differential scanning calorimetry) spectrum of polyimide resin according to Example 5.
FIG. 6 shows a metal laminate according to one embodiment of present invention.
FIG. 7 shows a metal laminate according to another embodiment of present invention.
DETAILED DESCRIPTION
The metal laminate of the present invention uses a specific polyimide resin as its insulating layer. The synthesis of said polyimide resin was carried out in a polymerization reaction with dianhydride monomer and diamine monomer first. The polymerization reaction formed polyamic acid (the precursor of the polyimide resin). Next, the polyimide resin was produced by an imidization reaction of the polyamic acid.
The polymerization reaction could be carried out by dissolving dianhydride monomer and diamine monomer in a solvent, mixing the dissolved dianhydride monomer and the dissolved diamine monomer, and then obtaining polyamic acid (the precursor of the polyimide resin).
The solvent suitable for the present invention can be an aprotic solvent, such as N, N-dimethylacetamide, N, N-diethylacetamide, N, N-dimethylformamide or N-methyl-2-pyrrolidone, but is not limited thereto. Other suitable aprotic solvents can also be used in the polymerization reaction.
In one embodiment, the dianhydride monomers and the diamine monomers are in an amount of from 5 to 40 weight percent, based on a total weight of the dianhydride monomers, the diamine monomers and the solvent.
The imidization reaction (imidizing step) could be carried out in thermal condition. For example, heating the polyamic acid (the precursor of the polyimide resin) continuously or at intervals could trigger the imidization reaction. The polyimide resin thin film or insulating layer can be formed by coating the polyamic acid (the precursor of the polyimide resin) on a substrate, and then heating the whole substrate in an oven. Besides, the imidization reaction could be carried out with other known methods, and the present invention is not limited thereto.
The dianhydride monomer used for synthesizing the polyimide resin of the present invention is an aromatic dianhydride monomer. Preferably, the molecular weight of the dianhydride monomer is between 400 and 600. Aromatic dianhydride monomers with low molecular weights (about 200-350, such as PMDA, BPDA and BTDA) will increase the density of the polar aldimine group in the polyimide resin. The polyimide resin derived by aromatic dianhydride monomers with low molecular weights has a high dielectric constant.
The aromatic dianhydride monomer used in the present invention may comprise the following compounds:
The diamine monomer used for synthesizing the polyimide resin of the present invention is an aromatic diamine, which may comprise the following compounds:
It is to be noted that the polyimide resin of the present invention is synthesized by two or more dianhydride monomers and two or more diamine monomers.
In the polyimide resin of the present invention, the molar ratio of dianhydride monomers to diamine monomers is between 0.85 and 1.15.
In one embodiment of the present invention, if the dianhydride monomer comprises p-phenylenebis(trimellitate anhydride), p-phenylenebis has an amount of moles accounting for 80 to 95% of total moles of the dianhydride monomers.
In one embodiment, if the dianhydride monomers comprise 4,4′-(hexafluoroisopropylidene)-diphthalic anhydride, 4,4′-(hexafluoroisopropylidene)-diphthalic anhydride has an amount of moles accounting for at most 15% of total moles of the dianhydride monomers.
In one embodiment, if the dianhydride monomers comprise 4,4′-(4,4′-isopropylidenediphenoxy)bis(phthalic anhydride), 4,4′-(4,4′-isopropylidenediphenoxy)bis(phthalic anhydride) has an amount of moles accounting for at most 15% of total moles of the dianhydride monomers.
In one embodiment, if the diamine monomers comprise 2,2′-bis(trifluoromethyl)benzidine, 2,2′-bis(trifluoromethyl)benzidine has an amount of moles accounting for 70 to 90% of total moles of the diamine monomers.
The polyimide resin described above is produced by mixing two or more dianhydride monomers and two or more diamine monomers at a specific ratio, and has a dielectric dissipation factor less than 0.007 and a coefficient of linear thermal expansion between 15 to 35 ppm/K.
Various examples will now be described to show the preparing methods of the polyamic acid (the precursor of the polyimide resin) of the present invention, and its physical or chemical property will be measured.
Preparation of the Polyamic Acid Solution (the Precursor of the Polyimide Resin)
Example 1
24.20 g (0.076 mole) of 2,2′-bis(trifluoromethyl)benzidine (TFMB), 1.85 g (0.017 mole) of p-phenylenediamine (PDA), 2.36 g (0.008 mole) of 1,3-bis(4-aminophenoxy)benzene (TPE-R) and 244.37 g of N-methyl-2-pyrrolidone (NMP) were added in a three-necked flask and stirred at 30° C. until completely dissolved. 41.75 g (0.091 mole) of p-phenylenebis(trimellitate anhydride) (TAHQ) and 2.83 g (0.005 mole) of 4,4′-(4,4′-isopropylidenediphenoxy)bis(phthalic anhydride) (PBADA) were then added and stirred at 25° C. for 24 hrs. The polymerization reaction was carried out to produce the polyamic acid solution of Example 1. In this example, the dianhydride and diamine monomers are in an amount of 23 weight percent of the total weight of the reaction solution [(24.20+1.85+2.36+41.75+2.83)/(24.20+1.85+2.36+41.75+2.83+244.37)×100%=23%].
Example 2
26.28 g (0.082 mole) of 2,2′-bis(trifluoromethyl)benzidine (TFMB), 3.74 g (0.009 mole) of 2,2-bis[4-(4-aminophenoxy)phenyl]propane (BAPP) and 215.78 g of N-methyl-2-pyrrolidone (NMP) were added in a three-necked flask and stirred at 30° C. until completely dissolved. 47.12 g (0.102 mole) of p-phenylenebis(trimellitate anhydride) (TAHQ) and 2.02 g (0.005 mole) of 4,4′-(hexafluoroisopropylidene)diphthalic anhydride (6FDA) were then added and stirred at 25° C. for 24 hrs. The polymerization reaction was carried out to produce the polyamic acid solution of Example 2. In this example, the dianhydride and diamine monomers are in an amount of 25 weight percent of the total weight of the reaction solution [(26.28+3.74+39.88+2.02)/(26.28+3.74+39.88+2.02+215.78)×100%=25%]
Example 3
29.13 g (0.091 mole) of 2,2′-bis(trifluoromethyl)benzidine (TFMB), 1.84 g (0.017 mole) of p-phenylenediamine (PDA), 1.66 g (0.006 mole) of 1,3-bis(4-aminophenoxy)benzene (TPE-R) and 271.31 g of N-methyl-2-pyrrolidone (NMP) were added in a three-necked flask and stirred at 30° C. until completely dissolved. 39.88 g (0.087 mole) of p-phenylenebis(trimellitate anhydride) (TAHQ) and 5.92 g (0.011 mole) of 4,4′-(4,4′-isopropylidenediphenoxy)bis(phthalic anhydride) (PBADA) were then added and stirred at 25° C. for 24 hrs. The polymerization reaction was carried out to produce the polyamic acid solution of Example 3. In this example, the dianhydride and diamine monomers are in an amount of 24 weight percent of the total weight of the reaction solution [(29.13+1.84+1.66+47.12+5.92)/(29.13+1.84+1.66+47.12+5.92+271.31)×100%=24%].
Example 4
23.56 g (0.074 mole) of 2,2′-bis(trifluoromethyl)benzidine (TFMB), 1.49 g (0.014 mole) of p-phenylenediamine (PDA), 1.89 g (0.005 mole) of 2,2-bis[4-(4-aminophenoxy)phenyl]propane (BAPP) and 260.06 g of N-methyl-2-pyrrolidone (NMP) were added in a three-necked flask and stirred at 30° C. until completely dissolved. 38.10 g (0.083 mole) of p-phenylenebis(trimellitate anhydride) (TAHQ) and 4.09 g (0.009 mole) of 4,4′-(hexafluoroisopropylidene)diphthalic anhydride (6FDA) were then added and stirred at 25° C. for 24 hrs. The polymerization reaction was carried out to produce the polyamic acid solution of Example 4. In this example, the dianhydride and diamine monomers are in an amount of 21 weight percent of the total weight of the reaction solution [(23.56+1.49+1.89+38.10+4.09)/(23.56+1.49+1.89+38.10+4.09+260.06)×100%=21%].
Example 5
25.00 g (0.078 mole) of 2,2′-bis(trifluoromethyl)benzidine (TFMB), 1.49 g (0.014 mole) of p-phenylenediamine (PDA) and 244.32 g of N-methyl-2-pyrrolidone (NMP) were added in a three-necked flask and stirred at 30° C. until completely dissolved. 35.94 g (0.078 mole) of p-phenylenebis(trimellitate anhydride) (TAHQ), 4.08 g (0.009 mole) of 4,4′-(hexafluoroisopropylidene)diphthalic anhydride (6FDA) and 2.39 g (0.005 mole) of 4,4′-(4,4′-isopropylidenediphenoxy)bis(phthalic anhydride) (PBADA) were then added and stirred at 25° C. for 24 hrs. The polymerization reaction was carried out to produce the polyamic acid solution of Example 5. In this example, the dianhydride and diamine monomers are in an amount of 22 weight percent of the total weight of the reaction solution [(25.00+1.49+35.94+4.08+2.39)/(25.00+1.49+35.94+4.08+2.39+244.32)×100%=22%].
Comparative Examples 1-3 of the polyamic acid will be described in the following paragraphs. The Comparative Examples merely used one dianhydride monomer and one diamine monomer to produce the polyamic acid (the precursor of the polyimide resin). In contrast with the Comparative Examples, the polyamic acid of Examples 1-5 was produced by two or more dianhydride monomers and two or more diamine monomers.
Comparative Example 1
31.25 g (0.098 mole) of 2,2′-bis(trifluoromethyl)benzidine (TFMB) and 227.16 g of N-methyl-2-pyrrolidone (NMP) were added in a three-necked flask and stirred at 30° C. until completely dissolved. 44.47 g (0.097 mole) of p-phenylenebis(trimellitate anhydride) (TAHQ) was then added and stirred at 25° C. for 24 hrs. The polymerization reaction was carried out to produce the polyamic acid solution of Comparative Example 1. In this comparative example, the dianhydride and diamine monomers are in an amount of 25 weight percent of the total weight of the reaction solution [(31.25+44.47)/(31.25+44.47+227.16)×100%=25%].
Comparative Example 2
13.78 g (0.127 mole) of p-phenylenediamine (PDA) and 250.58 g of N-methyl-2-pyrrolidone (NMP) were added in a three-necked flask and stirred at 30° C. until completely dissolved. 56.90 g (0.124 mole) of p-phenylenebis(trimellitate anhydride) (TAHQ) was then added and stirred at 25° C. for 24 hrs. The polymerization reaction was carried out to produce the polyamic acid solution of Comparative Example 2. In this comparative example, the dianhydride and diamine monomers are in an amount of 22 weight percent of the total weight of the reaction solution [(13.78+56.90)/(13.78+56.90+250.58)×100%=22%].
Comparative Example 3
25.75 g (0.088 mole) of 1,3-bis(4-aminophenoxy)benzene (TPE-R) and 260.28 g of N-methyl-2-pyrrolidone (NMP) were added in a three-necked flask and stirred at 30° C. until completely dissolved. 39.33 g (0.085 mole) of p-phenylenebis(trimellitate anhydride) (TAHQ) was then added and stirred at 25° C. for 24 hrs. The polymerization reaction was carried out to produce the polyamic acid solution of Comparative Example 3. In this comparative example, the dianhydride and diamine monomers are in an amount of 20 weight percent of the total weight of the reaction solution [(25.74+39.33)/(25.74+39.33+260.28)×100%=20%].
Property and Measurement of Polyimide Resin
The compositions of respective polyimide films derived from the polyamic acid solutions of various Examples and Comparative Examples are listed in Table 1. Thin films were formed from the polyamic acid solutions (the precursor of the polyimide resin) of Examples and Comparative Example by the imidization reaction. The IR spectrum, dielectric constant (Dk), dissipation factor (Df), coefficient of linear thermal expansion (CTE), glass transition temperature (Tg) and crystallization temperature (Tc) of these thin film were measured. FIGS. 1A, 2A, 3A, 4A and 5A show the IR spectrums of the polyimide films of Example 1-5, respectively; FIGS. 1B, 2B, 3B, 4B and 5B show the DSC (Differential Scanning calorimeter) spectrums of polyimide films of Example 1-5, respectively. The measured properties are listed in Table 2.
TABLE 1
Compositions of Polyimide Films
Dianhydride +
Dianhydride +
Dianhydride monomers
Diamine monomers
Diamine
Diamine
TAHQ
6FDA
PBADA
TFMB
PDA
TPE-R
BAPP
monomer
monomer
(mole)
(mole)
(mole)
(mole)
(mole)
(mole)
(mole)
(wt %)
(molar ratio)
Example 1
0.091
0.005
0.076
0.017
0.008
23
0.95
Example 2
0.087
0.005
0.082
0.009
25
1.01
Example 3
0.102
0.011
0.091
0.017
0.006
24
0.99
Example 4
0.083
0.009
0.074
0.014
0.005
21
0.99
Example 5
0.078
0.009
0.005
0.078
0.014
22
1.00
Comparative
0.097
0.098
25
0.99
Example 1
Comparative
0.124
0.127
22
0.98
Example 2
Comparative
0.085
0.088
20
0.97
Example 3
TABLE 2
Properties of Polyimide Films
Dk
Df
CTE
Tg
Tc
Example 1
3.18
0.005
27
207
266
Example 2
3.08
0.004
29
200
252
Example 3
3.14
0.005
31
211
278
Example 4
3.11
0.005
32
213
270
Example 5
3.20
0.006
28
206
245
Comparative
3.17
0.011
28
N/A
N/A
Example 1
Comparative
3.30
0.015
15
N/A
N/A
Example 2
Comparative
3.09
0.007
56
233
N/A
Example 3
Properties in Table 2 were measured from polyimide films derived from polyamic acid solutions. The methods of measurement are described as follows:
Dielectric Constant (Dk):
This property is measured by RF Impedance/Material Analyzer (Agilent HP4291) at 10 GHz with IPC-TM-650-2.5.5.9 test method.
Dissipation Factor (Df):
This property is measured by RF Impedance/Material Analyzer (Agilent HP4291) at 10 GHz with IPC-TM-650-2.5.5.9 test method.
Coefficient of (Linear) Thermal Expansion (CTE):
This property is measured by thermal mechanical analysis. The thin film is extended under condition of weight 3 g/thickness 20 μ and heating rate 10° C./min, and the CTE is the average of values calculated from 50 to 200° C. The material with a low CTE is hard to deform during the PCB baking process, so that the production system has a high yield rate.
Glass Transition Temperature (Tg) and Crystallization Temperature (Tc):
This property is measured by Differential Scanning calorimeter (SII Nano Technology DSC-6220). The polyimide resin underwent the following steps in N 2 atmosphere heating at 10° C./min and then cooling at 30° C./min; and heating again at rate of 10° C./min. Glass transition temperature was determined by the value measured in the first or second heating process. Crystallization temperature was determined by the exothermic peak value measured in first cooling process.
The requirements for a high-frequency circuit are the transmission speed and the signal quality. Electrical properties such as dielectric constant (Dk) and dissipation factor (Df) are main factors that affect these criteria. The reason could be explained by the following formula:
α d =0.9106×√{square root over (∈ R )}× F GHz ×tan δ
wherein α d : transmission loss ∈ R : dielectric constant (Dk) F GHZ : frequency tan δ: dissipation factor (Df)
The above formula shows that the Df is more relative to transmission loss than Dk: the lower the Df, the lower the transmission loss. Thus, the material with a lower Df is more suitable for high frequency PCBs.
Table 1 and Table 2 show that the dissipation factors (Df) and coefficients of thermal expansion (CTE) of Examples 1-5 of the present invention (use of two or more dianhydride and two or more diamine monomers) are lower than those of Comparative Examples (use of only one dianhydride and one diamine monomer). The reason is that the aromatic ester functional group of single dianhydride monomer (such as TAHQ) and the aldimine functional group form a huge plane resonance structure. The huge plane structure affects the arrangement of the polyamic acid solution (the precursor of the polyimide resin) and polyimide resin. Thus the polyimide resin derived from single dianhydride and diamine monomer has a random arrangement and a low crystallinity. In addition to TAHQ which serves as a main dianhydride monomer, another dianhydride monomer with a molecular weight between 400 to 600 is introduced to the polyimide resin of the present Examples. Introducing another dianhydride monomer to the polyimide resin not only helps maintain the amount of aldimine group to prevent the dielectric constant from increasing but also enhances the arrangement of aromatic polyester group to improve the crystallinity. Referring to the experimental results in Table 2, the polyimide films of Comparative Example 1-3 (without the use of additional dianhydride monomers such as 6FDA and PBADA) are non-crystalline transparent films. In contrast with Comparative Example 1-3, the polyimide films of Examples 1-5 (use of 6FDA and/or PBADA) are translucent films, and their Tg and Tc are different from those of Comparative Examples.
Besides, the Comparative Examples show how different diamine monomers would affect properties of the polyimide resin. Comparative Example 1 has a CTE similar to those of Examples, and has a higher Df than Examples. Comparative Example 2 (PDA diamine monomer) has a lower CTE but a higher Df than other Comparative Examples. Comparative Example 3 (TPE-R diamine monomer) has a lower Df than other Comparative Examples, but its Df is still higher than those of Examples 1-5. The reason is that the non-linear diamine monomer (such as TPE-R, BAPP) has a lower rotation barrier, lower Df changes but a higher CTE. In contrast, the linear diamine monomer (such as PDA, TFMB) has a higher Df but a lower CTE. The polyimide resin of the present invention mixes two or more diamine monomers (for example the linear and non-linear diamine monomers) to attain a balance between a low CTE and a low Df, thereby obtaining a polyimide resin suitable for high frequency PCBs.
Manufacture of Metal Laminates
The polyimide of the present invention is characterized by a low dissipation factor, a good dimensional stability, a high heat resistance, a high coefficient of thermal expansion, an enhanced mechanical strength and a high resistance insulation, and thus is suitable for serving as an insulating layer in metal laminates. Such metal laminates could be used as FPCBs in electronic devices.
FIG. 6 shows a metal laminate 1 according to one embodiment of the present invention. The metal laminate 1 is a single-sided metal laminate comprising a first metal layer 100 and an insulating layer 200 . The first metal 100 is a copper foil or a metal selected from other metals suitable for PCBs. The insulating layer 200 is made of the polyimide resin in the foregoing Example and has a low dissipation factor. The first metal layer 100 directly contacts the insulating layer 200 , and there is no additional adhesive between the two layers.
The single-sided metal laminate 1 in FIG. 6 can be manufactured by the following steps: coating the foregoing polyamic acid solution (the precursor of the polyimide resin) on the first metal layer 100 ; imidizing the precursor (i.e. heating it in an oven) to form a polyimide insulating layer 200 ; and obtaining the metal laminate 1 in FIG. 6 .
FIG. 7 shows a metal laminate 2 according to another embodiment of the present invention. The metal laminate 2 is a metal laminate with double sides. The difference between the double-sided metal laminate in FIG. 7 and the single-sided metal laminate in FIG. 6 is the number of metal layers. The double-sided metal laminate further comprises a second metal layer 300 . The second metal layer 300 , like the first metal layer 100 , directly contacts the insulating layer 200 . In other words, the insulating layer 200 bonds the first metal layer 100 and the second metal layer 300 , and there is no additional adhesive between the layers.
The materials for the first metal layer 100 and the second metal layer 300 can be the same or different metal(s). The thickness of the insulating layer 200 can be controlled by adjusting the amount of polyamic acid solution (the precursor of the polyimide resin). In one embodiment, the thickness of the insulating layer is between 5 to 50 μm.
The double-sided metal laminate 2 in FIG. 7 can be manufactured by one of the following methods:
The manufacturing method (1) comprises the steps of: obtaining the single-sided metal laminate 1 in FIG. 6 ; providing a second metal layer 300 ( FIG. 7 ) on the other side of the polyimide insulating layer 200 ; and bonding the second metal layer 300 and the polyimide insulating layer 200 by thermocompression so as to obtain the double-sided metal laminate 2 in FIG. 7 .
The manufacturing method (2) comprises the steps of: coating the polyamic acid solution (the precursor of the polyimide resin) on the first metal layer 100 and the second metal layer 300 respectively; heating the polyamic acid solution to induce the imidization reaction and thereby to form polyimide insulating layers on the first metal layer and the second metal layer; and bonding the polyimide insulating layers on the first metal layer and the second metal layer by thermocompression so as to obtain the double-sided metal laminate 2 .
The manufacturing method (3) comprises the steps of: coating the polyamic acid solution (the precursor of polyimide resin) on a detachable carrier; imidizing the precursor to form the polyimide resin; peeling the polyimide resin to obtain a polyimide film (like the insulating layer 200 ); disposing the first metal layer 100 and the second metal layer 300 on both sides of the insulating layer 200 respectively; and bonding the first metal layer 100 with one side of the insulating layer 200 and the second metal layer 300 with the other side of the insulating layer 200 by thermocompression so as to obtain the double-sided metal laminate.
Various examples of the metal laminate of the present invention and respective physical or chemical properties measured will now be described.
Example 6
The polyamic acid solution (the precursor of the polyimide resin) of Example 1 was coated on a copper foil metal layer (with a thickness of 18 μm). The metal layer was heated at 130° C. for 10 minutes first, and then heated at 380° C. for another 10 minutes to induce the imidization reaction so as to obtain a single-sided metal laminate (the 1 st metal laminate). The above process was repeated to obtain another single-sided metal laminate (the 2 nd metal laminate). The insulating layer of the 1 st metal laminate and the insulating layer of the 2 nd metal laminate were disposed opposite to each other, and then bonded by thermocompression. The resultant double-sided metal laminate has only one polyimide insulating layer between the metal layers (the manufacturing method (2)).
Example 7
The polyamide acid solution (the precursor of the polyimide resin) of Example 1 was coated on a copper foil metal layer (with a thickness of 18 μm). The metal layer was heated at 130° C. for 10 minutes first, and then heated at 380° C. for another 10 minutes to induce the imidization reaction. The product is a single-sided metal laminate. Another metal layer was disposed opposite to the insulating layer of the metal laminate, and then the insulating layer and the metal layer were bonded by thermocompression. The resultant double-sided metal laminate has only one polyimide insulating layer between the metal layers (the manufacturing method (1)).
Example 8
The polyamide acid solution (the precursor of the polyimide resin) of Example 1 was coated on a detachable carrier. The carrier was heated at 130° C. for 10 minutes first, and then heated at 380° C. for another 10 minutes to induce the imidization reaction, thereby forming the polyimide resin. The resin was peeled to obtain a polyimide film. The metal layers were disposed on both sides of the film, and then the polyimide film and the metal layers were bonded by thermocompression.
The resultant double-sided metal laminate has only one polyimide insulating layer between the metal layers (the manufacturing method (3)).
Example 9
The polyamide acid solution (the precursor of the polyimide resin) of Example 2 was coated on a copper foil metal layer (with a thickness of 18 μm). The metal layer was heated at 130° C. for 10 minutes first, and then heated at 380° C. for another 10 minutes to induce the imidization reaction. The product is a single-sided metal laminate (the 1 st metal laminate). The above process was repeated to obtain another single-sided metal laminate (the 2 nd metal laminate). The insulating layer of the 1 st metal laminate and the insulating layer of the 2 nd metal laminate were disposed opposite to each other, and then bonded by thermocompression. The resultant double-sided metal laminate has only one polyimide insulating layer between the metal layers (the manufacturing method (2)).
Example 10
The polyamide acid solution (the precursor of the polyimide resin) of Example 2 was coated on a copper foil metal layer (with a thickness of 18 μm). The metal layer was heated at 130° C. for 10 minutes first, and then heated at 380° C. for another 10 minutes to induce the imidization reaction. The product is a single-sided metal laminate. Another metal layer was disposed opposite to the insulating layer of the metal laminate, and then the insulating layer and the metal layer were bonded by thermocompression. The resultant double-sided metal laminate has only one polyimide insulating layer between the two metal layers (the manufacturing method (1)).
Comparative Example 4
The polyamide acid solution (the precursor of the polyimide resin) of Comparative Example 3 (a conventional thermoplastic polyimide, TPI) was coated on a copper foil metal layer (with a thickness of 18 μm). The metal layer was heated at 130° C. for 10 minutes first, and then heated at 380° C. for another 10 minutes to induce the imidization reaction. The product is a single-sided metal laminate (the 1 st metal laminate). The above process was repeated to obtain another single-sided metal laminate (the 2 nd metal laminate). The insulating layer of the 1 st metal laminate and the insulating layer of the 2 nd metal laminate were disposed opposite to each other, and then bonded by thermocompression. The resultant double-sided metal laminate has only one polyimide insulating layer between the metal layers (the manufacturing method (2)).
Comparative Example 5
The polyamide acid solution (the precursor of the polyimide resin) of Comparative Example 3 (a conventional thermoplastic polyimide, TPI) was coated on a copper foil metal layer (with a thickness of 18 μm). The metal layer was heated at 130° C. for 10 minutes first, and then heated at 380° C. for another 10 minutes to induce the imidization reaction. The product is a single-sided metal laminate. Another metal layer was disposed opposite to the insulating layer of the metal laminate, and then the insulating layer and the metal layer were bonded by thermocompression. The double-sided metal laminates of Comparative Examples 5 and 4 are different in the manufacturing methods. The metal laminate of Comparative Example 5 is made by the manufacturing method (1).
Comparative Example 6
Comparative Example 6 relates to a conventional polyimide laminate including an adhesive. A commercial thermoplastic polyimide composite film (e.g., Kaneka FRS film) has a three-layer structure TPI-PI-TPI, and a thickness of about 25 μm. The TPI (i.e. thermoplastic polyimide film of Comparative Example 3) is an adhesive bonding the inner PI layer to the outer metal layer. Two copper foil metal layers were disposed on both sides of the Kaneka FRS film, and then the two copper metal layers and the Kaneka FRS film were bonded by thermocompression to obtain a double-sided metal laminate (the manufacturing method (3)).
Comparative Example 7
Comparative Example 7 relates to a laminate using a liquid crystal polymer (LCP) film as an insulating layer. The LCP has a molecular structure of an aromatic polyester polymer, which is different from that of the polyimide of the present invention. Comparative Example 7 uses a commercial LCP film (Kuraray LCP Film VECSTAR) as an insulating layer. Two copper foil metal layers were disposed on both sides of the LCP film, and then the two copper foil metal layers and the LCP film were bonded by thermocompression to obtain a double-sided metal laminate (the manufacturing method (3)).
After the metal laminates of Examples and Comparative Examples had been manufactured, their respective dielectric constants (Dk), dissipation factors (Df), coefficients of thermal expansion (CTE), peel strengths and dimension stability were measured. The results of the measurement are shown in Table 3. The methods for measuring Dk, Df and CTE are the same as those used in Examples 1-5. The peel strengths were measured according to IPC-TM-650-2.4.9 test method, and the dimensional stability was measured according to IPC-TM-650-2.4.4C test method.
TABLE 3
Properties of Metal laminates
Dimensional
Dk
Df
CTE
Peel-strength
stability
Example 6
3.18
0.005
26
0.92
0.07%
Example 7
3.18
0.005
27
0.88
0.09%
Example 8
3.19
0.005
27
0.89
0.08%
Example 9
3.18
0.005
26
0.92
0.08%
Example 10
3.18
0.005
27
0.88
0.09%
Comparative
3.10
0.008
55
1.03
−0.25%
Example 4
Comparative
3.09
0.009
56
0.98
−0.19%
Example 5
Comparative
3.42
0.014
24
1.16
0.08%
Example 6
Comparative
3.28
0.003
48
0.64
−0.12%
Example 7
The Comparative Examples 4 and 5 in Table 3 show that the metal laminates with a thermoplastic polyimide (TPI) insulating layer have higher CTE and lower dimensional stability than those of Examples 1-5. Thus, the TPI is only suitable for serving as an adhesive, rather than as an insulating layer. The metal laminate of the present invention employs a single polyimide resin layer to have the thermocompression property of TPI and the dimensional stability of PI, and to meet the requirements of a high-frequency material.
Besides, the double-sided metal laminates of Example 8, Comparative Example 6 and Comparative Example 7 were manufactured by the same method (the manufacturing method (3)) and their properties were compared. Table 3 shows that the metal laminate with an adhesive (Comparative Example 6) has a low CTE, a satisfactory peel strength and a good dimensional stability, but its Df and Dk are high. The metal laminate of Comparative Example 7 (LCP film) has the lowest Df (good for the high frequency device), but its CTE is high, and its peel strength and dimensional stability are low. In contrast, the metal laminate of the present invention (Example 8) has moderate peel strength, Df and Dk, and thus is suitable for designing small-sized high-density and high frequency circuits.
It will be apparent to those skilled in the art that various modifications and variations can be made to the disclosed embodiments. It is intended that the specification and examples be considered as exemplary only, with a true scope of the disclosure being indicated by the following claims and their equivalents.
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A metal laminate comprising a metal layer and an insulating layer is provided. The insulating layer is disposed on the metal layer and directly contacts the metal layer. The insulating layer is made of a polyimide resin, and the polyimide resin is derived from at least two dianhydrides and at least two diamines. The dianhydride monomers are selected from the group consisting of p-phenylenebis (trimellitate anhydride), 4,4′-(hexafluoroisopropylidene)-diphthalic anhydride, 4,4′-(4,4′-isopropylidenediphenoxy)bis(phthalic anhydride) and the combination thereof. One of the diamine monomers is 2,2′-bis(trifluoromethyl)benzidine, and the other diamine monomers are selected from the group consisting of 2,2-bis[4-(4-aminophenoxy)phenyl, 1,3-bis(4-aminophenoxy)benzene, p-phenylenediamine, 4,4′-oxydianiline, 4,4′-methylenedianiline, 4,4′-diaminobenzanilide, 4,4′-diaminodiphenyl-sulfone, m-tolidine, 2,2-bis[4-(4-aminophenoxy)phenyl]hexafluoropropane and the combination thereof. A molar ratio of the dianhydride monomers to the diamine monomers is between 0.85 and 1.15.
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TECHNICAL FIELD OF THE INVENTION
This invention relates generally to computer networking, and more particularly to a method and system for dynamically distributing updates in a network.
BACKGROUND OF THE INVENTION
Computer networks have become an increasingly important means for communicating public and private information between and within distributed locations. The Internet is one example of a public network commonly used for communicating public and private information. Internet web servers provide access to public information, such as news, business information, and government information, which the Internet makes readily available around the world. The Internet is also becoming a popular forum for business transactions, including securities transactions and sales of goods and services. A large number of people have come to depend upon reliable Internet access and secure communications on a day-by-day and even second-by-second basis. Like the Internet, private networks also have become common means for communicating important information. Private networks, such as company intranets, local area networks (LANs), and wide area networks (WANs) generally limit access on a user-by-user basis and communicate data over dedicated lines or by controlling access through passwords, encryption, or other security measures.
One danger to reliable and secure network communications is posed by hackers or other unauthorized users disrupting or interfering with network resources. The danger posed by unauthorized access to computer network resources can vary from simple embarrassment to substantial financial losses. For example, serious financial disruptions occur when hackers obtain financial account information or credit card information and use that information to misappropriate funds.
Typically, network administrators use various levels of security measures to protect the network against unauthorized use. Intrusion detection systems are commonly used to detect and identify unauthorized use of a computer network before the network resources and information are substantially disrupted or violated. In general, intrusion detection systems look for specific patterns in network traffic, known as intrusion signatures to detect malicious activity. Conventional intrusion detection systems often use finite state machines, simple pattern matching, or specialized algorithms to identify intrusion signatures in network traffic. Detected intrusion signatures are reported to network administration.
A problem with conventional intrusion detection systems is that when a new vulnerability, or type of attack on the network, is discovered, a new intrusion signature must be generated and installed for each intrusion detection system. As a result, unless a network administrator frequently checks for new signatures developed by an intrusion detection provider and installs the new signatures for each sensor in his or her system, the system will remain vulnerable to the new types of attack. Because new types of attacks appear more frequently than network administrators typically check with an intrusion detection provider for new signatures, networks often remain vulnerable to new types of attacks even though new signatures are available to identify and prevent such attacks.
SUMMARY OF THE INVENTION
The present invention provides a method and system for dynamically distributing intrusion detection and other types of updates in a network that substantially eliminate or reduce disadvantages and problems associated with prior methods and systems. In particular, the present invention automatically downloads updates from a remote site in response to a timed event.
In accordance with one embodiment of the present invention, a first version of a program operating at a network site is updated by automatically downloading from a remote site any update for the program in response to an automated event. A downloaded update is installed to generate a second version of the program. The second version of the program is operated at the network site in place of the first version.
More particularly, in accordance with a particular embodiment of the present invention, the automated event is a timed event. In this embodiment, the first version of the program is aged and the timed event is the first version reaching a specified age. The specified age may be 24 hours or other suitable age. In other embodiments, the timed event may be a specified time such that any updates are automatically downloaded once a day, once a week, or at other suitable frequency.
After installation of a downloaded update, it may be determined whether the second version of the program is operating correctly. In response to incorrect operation of the second version, the first version of the program may be restored for operation at the network site. In response to correct operation of the second version, the downloaded update may be distributed to disparate network sites operating the first version of the program. There, the downloaded update may be installed to generate the second version of the program at the disparate network sites. The second version of the program is operated in the place of the first version at the disparate network sites.
Technical advantages of the present invention include providing an improved method and system for distributing updates in a network. In particular, programs are automatically updated by downloading and distributing an update in response to an automated event, such as a timed event. As a result, systems with a common program separately running at several sites may update each site with no or minimal operator interaction. In addition, updates may be automatic or with minimal operator interaction rolled back at each site in a system in response to an upgrade problem.
Additional technical advantages of the present invention include providing an improved intrusion detection system. In particular, each intrusion detection sensor may automatically connect to a remote site and download new intrusion detection signatures. Each sensor may also distribute the new signatures to related sensors within a system. Accordingly, network vulnerability due to new types of attacks is reduced. In addition, an intrusion detection service provider may update all of its customers by simply providing new signatures on a website from which each customer's system will automatically connect to and download the new signatures in accordance with a specified frequency. Accordingly, the costs of providing intrusion detection services are reduced.
Other technical advantages will be readily apparent to one skilled in the art for the following figures, description, and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of the present invention and its advantages, reference is now made to the following description taken in conjunction with the accompanying drawings, wherein like reference numerals represent like parts, in which:
FIG. 1 is a block diagram illustrating a system for dynamically distributing intrusion detection signatures in accordance with one embodiment of the present invention;
FIG. 2 is a flow diagram illustrating a computer method for dynamically distributing intrusion detection signatures in the network of FIG. 1; and
FIG. 3 is a flow diagram illustrating a computer method for recovering from a problematic update in accordance with one embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 is a block diagram illustrating a system 10 for dynamically distributing updates in a network. In this embodiment, new intrusion signatures are distributed to remote intrusion detection sensors. The sensors use the intrusion signatures to detect and report unauthorized entry. It will be understood that the present invention may be used to distribute other suitable types of updates to intrusion detection and other suitable types of applications within a network.
Referring to FIG. 1, the system 10 includes a private network 12 and a public network 14 . For the embodiment of FIG. 1, the private network is an Intranet 20 and the public network is an Internet 22 . It will be understood that the private and public networks 12 and 14 may be other suitable types of networks.
The Intranet 20 includes a network interconnecting a plurality of hosts 24 . The network is a local area network (LAN), a wide area network (WAN), or other suitable type of link capable of communicating data between the hosts 24 . For the local area network embodiment, the network may be an Ethernet.
The hosts 24 are each a computer such as a personal computer, file server, workstation, minicomputer, mainframe or any general purpose or other computer or device capable of communicating with other computers or devices over a network. The hosts 24 operating on the border between the Intranet 20 and Internet 22 each include an intrusion detection sensor 26 for detecting and reporting unauthorized entry. As used herein, each means each of at least a subset of the identified items.
The intrusion detection sensors 26 each include a common set of intrusion signatures 28 . The intrusion signatures 28 comprise patterns of network activity that denote or indicate unauthorized access or other harmful activity capable of damaging the host 24 or other aspect of the private network 12 . Generally described, the intrusion detection sensors 26 detect such unauthorized access or attacks upon the host 24 by matching network traffic to the intrusion signatures 28 .
The Internet 22 includes a sensor update server 30 . The sensor update server 30 may be virtually any type of computer capable of storing intrusion updates 32 and communicating with other computers or devices over the Internet 22 . The intrusion update 32 includes new intrusion signatures generated by an intrusion detection service provider in response to new types of attacks. The intrusion detection service provider generates the new signatures and provides them as the update 32 on a web page at the sensor update server 30 to allow customers to access the new signatures over the Internet 22 . As described in more detail below, the update 32 is downloaded by customers over the Internet 22 and the new signatures added to the intrusion signatures 28 residing on the host 24 . In this way, the intrusion detection sensors 26 are kept up-to-date and able to detect and report new types of network and/or host based attacks.
FIG. 2 is a flow diagram illustrating a computer method for dynamically distributing intrusion detection updates over the Internet 22 or other suitable network. It will be understood that other types of updates for other types of applications may be similarly distributed over the Internet 22 or other suitable network without departing from the scope of the present invention.
Referring to FIG. 2, the method begins at step 50 in which a specified event is received. The specified event may be an automated event or a user initiated event. The automated event may be any event generated by the sensor or other software or hardware in accordance with predefined instructions or logical set of such events. In one embodiment, the automated event is a timed event that is directly or indirectly based upon the reaching or passing of a specified time. For this embodiment, the intrusion detection sensors 26 may automatically age the intrusion signatures 28 after each update to allow the intrusion detection sensors 26 to automatically determine when the intrusion signatures 28 may be in need of updating. In this embodiment, an update event is generated in response to the intrusion signatures 28 reaching a specified age. The age is twenty-four hours or other suitable time period that will allow the intrusion signatures 28 to be updated at a frequency that will minimize vulnerability of the private network 12 to new types of attacks. An event or action is in response to a specified event when the occurrence of the specified event directly or indirectly triggers, at least in part, the responding event or action. Thus, other events may also be necessary to trigger the responding event or action, or intervene between the specified event and the responding event or action. The update event may be other suitable types of timed events such as, for example, a specified or scheduled time of day, week, or the like.
In a particular embodiment, a user may select a number of sensors to be subordinate to a primary intrusion detection sensor or set of primary sensors. In this embodiment, only the primary sensors are responsible for generating the update event and only their intrusion signatures 28 are aged. Alternatively, each intrusion detection sensor 26 may independently age its own intrusion signatures 28 and generate the update event in response to its intrusion signatures 28 reaching the specified age. In this embodiment, no one intrusion section sensor 26 or limited set of sensors is solely relied upon to initiate updating.
Proceeding to step 52 , the intrusion detection sensor 26 generating the update event automatically connects to the sensor update server 30 over the Internet 22 . At decisional step 54 , the intrusion detection sensor 26 automatically determines whether the sensor update server 30 includes an update 32 for the intrusion signatures 28 . In one embodiment, the intrusion detection sensor 26 may compare a time stamp of its last update to that of a current file on the sensor update server 30 . In this embodiment, the current file is an update 32 if the time stamp for the file is later than that for the last update for the intrusion detection sensor 26 . If an update 32 is not available, then the current set of intrusion signatures 28 are up-to-date and the No branch of decisional step 54 leads to the end of the process. Accordingly, the intrusion signatures 28 are updated only when needed. However, if an update 32 is available on the sensor update server 30 , the Yes branch of decision step 54 leads to step 56 .
At step 56 , the intrusion detection sensor 26 automatically downloads the update 32 . Preferably, the update 32 is downloaded in an encrypted format to prevent tampering and decrypted at the host 24 . In addition, the update 32 may be protected by VPN, sequence numbering, other suitable form of secure communication, or a combination of forms. Next, at decisional step 58 , the intrusion detection sensor 26 automatically authenticates the update 32 . In one embodiment, the update 32 is authenticated by ensuring that the update is for the existing set of intrusion signatures 28 . If the update 32 is not authentic, then it should not be installed and the No branch of decisional step 58 leads to the end of the process. Accordingly, an update 32 that cannot be authenticated is not installed. However, if the update 32 is authentic, the Yes branch of decisional step 58 leads to step 60 .
At step 60 , the intrusion detection sensor 26 automatically installs the update 32 to add the new signatures to the preexisting intrusion signatures 28 . Next, at decisional step 62 , the intrusion detection sensor 26 automatically determines if it is operating correctly with the installed update by comparing its operation to specified parameters, limits, and the like. If the intrusion detection sensor 26 is not operating correctly, then the No branch of decisional step 62 leads to step 64 where recovery processing is automatically initiated and the update 32 is uninstalled. Accordingly, the intrusion detection sensor 26 is returned to its previous state and the private network 12 is not left vulnerable by an incorrectly operating intrusion detection sensor 26 . However, if the update intrusion sensor 26 is operating correctly, the Yes branch of decisional step 62 leads to step 66 .
At step 66 , the intrusion detection sensor 26 automatically broadcasts an update message over the Intranet 20 . The update message informs the other intrusion detection sensors 26 of the availability of the update 32 . Next, at step 68 , the update 32 is automatically transmitted to the intrusion detection sensors 26 that responded to the update message. In one embodiment, the update message identifies the update and intrusion detection sensors 26 not having that update respond to request the update 32 . The update 32 may be transmitted over the Intranet 20 in an encrypted format and a secure form and decrypted by each of the second stage intrusion detection sensors 26 as previously described for the first stage intrusion detection sensor 26 that originally received the update 32 . If a sensor hierarchy is used, relationships between primary and secondary sensors may be predefined with the primary sensors each sending updates 32 to their respective secondary sensors. In addition, the relationship may be recursive with secondary sensors having their own children.
Proceeding to decisional step 70 , each of the second stage intrusion detection sensors 26 authenticates the update 32 as previously described in connection with the first stage intrusion detection sensor 26 . If the update 32 cannot be authenticated by a second stage intrusion detection sensor 26 , the No branch of decisional step 70 returns to step 68 for that second stage intrusion detection sensor 26 where the update 32 is retransmitted to the intrusion detection sensor 26 . Alternatively, or in response to several unsuccessful attempts to transmit an authentic update 32 to a second stage, the No branch of decisional step 70 may lead to the end of the process where the update 32 is not installed for that intrusion detection sensor 26 . After an authentic update 32 is received by a second stage intrusion detection sensor 26 , the Yes branch of decisional step 70 leads to step 72 .
At step 72 , the update 32 is automatically installed for each of the second stage intrusion detection sensors 26 receiving an authentic update 32 to generate an updated set of intrusion signatures 28 . Accordingly, all intrusion detection sensors 26 in the private network 12 are automatically updated to protect all avenues of access to the private network 12 from the new types of attacks.
Proceeding to decisional step 74 , each of the second stage intrusion detection sensors 26 determine if they are operating correctly with the installed update 32 . If a second stage intrusion detection sensor 26 is not operating correctly, the No branch of decisional step 74 leads to step 76 . At step 76 , recovery process is initiated for that intrusion detection sensor 26 and the update 32 is uninstalled. In this way, it is ensured that each of the second stage intrusion detection sensors 26 will remain in operating condition. For each second stage intrusion detection sensor 26 operating correctly with the installed update 32 , the Yes branch of decisional step 74 leads to the end of the process. Accordingly, all intrusion detection sensors 26 for the private network 12 have been automatically updated. Because user interaction is not required, the intrusion detection sensors 26 may be frequently and efficiently updated to ensure that the private network 12 is not vulnerable to new types of attacks.
It will be understood that the intrusion sensors 26 may be otherwise suitably updated without departing from the scope of the present invention. For example, although the method was described with the intrusion detection sensor 26 performing the specified actions, it will be understood that another application in or remotely from the hosts 24 may carry out the updating functionality identified for the intrusion detection sensor 26 .
FIG. 3 illustrates a computer method for recovery processing in accordance with one embodiment of the present invention. Referring to FIG. 3, the method begins at step 90 in which a recovery event is received. The recovery event may be initiated by an intrusion detection sensor 26 in response to incorrect operation of the intrusion detection sensor 26 . The recovery event may also be independently initiated by an operator to uninstall the update 32 .
Proceeding to step 92 , the update 32 is uninstalled from a first intrusion detection sensor 26 . The first intrusion detection sensor 26 may be the first sensor 26 on which the update 32 was initially installed or another intrusion detection sensor 26 detecting incorrect operations or receiving a user command to initiate recovery processing. Uninstalling the update 32 returns the first intrusion detection sensor 26 to its previous state.
Next, at step 94 , the first intrusion detection sensor 26 transmits a recovery message to the remaining intrusion detection sensors 26 in the private network 12 on which the update 32 was installed. Next, at step 96 , each of the remaining intrusion detection sensors 26 uninstalls the update 32 in response to the recovery message. Accordingly, each intrusion detection sensor 26 in the private network 12 is returned to its previous state in response to a single recovery event. In this way, integrity of the private network 12 and the intrusion detection system for the private network 12 is maintained with each of the intrusion detection sensors 26 in a same state. Step 96 leads to the end of the process by which each of the intrusion detection sensors 26 have been returned to a same recovery state.
Although the present invention has been described with several embodiments, various changes and modifications may be suggested to one skilled in the art. It is intended that the present invention encompass such changes and modifications as fall within the scope of the appended claims.
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A first version of a program operating at a network site is updated by automatically downloading from a remote site any update for the program in response to an automated event. A downloaded update is installed to generate a second version of the program. The second version of the program is operated at the network site in place of the first version.
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CROSS REFERENCE TO PRIOR APPLICATION
[0001] This application is a Paris Convention Filing under 35 U.S.C. §119 and claims priority to and benefit from German Application DE 10 2009 006 292.0, filed on Jan. 27, 2009.
FIELD OF THE INVENTION
[0002] The invention relates to a locking system for a telescopic crane jib, in particular for a mobile crane.
[0003] As a means of moving several telescopic parts, such cranes and telescopic jibs are provided with a telescoping cylinder which has a locking unit. This locking unit is used to establish a lock between the telescoping cylinder and one of the telescopic parts which has to be extended or retracted.
[0004] This invention relates to a telescopic jib of the type whereby a telescoping cylinder extracts and locks jib parts. Modern mobile cranes are being used to lift increasingly heavier loads to ever greater heights. Users are also demanding an efficient mobile crane of the lowest possible intrinsic weight in order to save on logistics costs. Efforts are also being directed towards developing a mobile crane capable of handling the highest possible load on as few axes as possible within the permissible axial loads, to obtain greater flexibility on the one hand and reduce the overall cost of the crane on the other hand. The telescopic jib is a core element of the mobile crane; it determines the maximum lifting height and load-bearing capacity. The jib length is determined by the number and length of the individual telescopic parts. For static reasons, the individual telescopic parts must maintain an overlap in the extracted state to ensure good mutual traction perpendicular to the jib direction. The traction in the jib direction is obtained by locking the telescope. Depending on design, the telescopic parts may not be fully retracted one inside the other in the retracted state. Collar parts are provided at the front end to brace the telescopic parts, which project outwards. The points at which the telescope is locked are also disposed one in front of the other in the longitudinal direction. To enable the telescoping cylinder to be locked to a telescope part, therefore, it is necessary to travel a certain distance in the longitudinal direction of the jib in order to move the locking unit to a position on a level with the telescope to be locked. In the system known from the prior art, the telescoping cylinder together with the locking unit must be extracted by a certain distance for every telescopic part and thus loses a part of its overall extension. As a result, the front telescopic parts cannot be extracted as far as the rear ones, making allowance for the overall travel of the telescoping cylinder. This results in an unnecessarily big overlap of the front telescopic parts in the extracted state which is associated with a loss in terms of the total jib length.
[0005] The objective of this invention is to propose a locking system for a telescopic crane jib, which optimises the inward and outward telescoping action (movements), particularly in terms of extendable length.
[0006] This objective is achieved by the invention on the basis of a locking system as defined in claim 1 . The dependent claims define preferred embodiments of the invention.
[0007] As proposed by the invention, the locking unit is disposed on the telescoping cylinder in such a way that it is able to move longitudinally. In other words, the position of the telescoping cylinder and the position of the locking unit are not determined by one another as is the case with the system known from the prior art. This being the case, the locking unit is able to move to a locking point without the telescoping cylinder moving or even with the telescoping cylinder moving in a different direction, which significantly increases functionality and reduces or eliminates restrictions affecting the working or operating mode. In particular, the distance by which the locking unit is able to move or the point which the locking unit is able to reach is no longer restricted by the extent to which the telescoping cylinder is able to move or its choice of disposition. This results in additional telescoping distance, saving length on the telescoping cylinder, which in turn reduces the overall jib weight, thereby optimising the crane as a whole.
[0008] The invention offers the option of mounting the locking unit on the telescoping cylinder in such a way that it can be fixed, in particular in such a way that it can be fixed in every position. It may also be designed as a second stage on the telescoping cylinder or be mounted on a second stage of the telescoping cylinder. At least one length-measuring device or a length transmitter is also advantageously provided, which is able to detect the position of the locking unit and telescoping cylinder, in particular the relative position of the two or their absolute positions. As proposed by the invention, and particularly with this design, once the locking unit has assumed the correct position and has been locked to the co-operating telescope, a seat valve, for example, is closed and secured to the cylinder stage of the locking unit. The structural-steel lock to the next telescopic part can then be released and the telescopic part which has just been locked to the locking unit can be extracted, thereby making the full extension of the telescoping cylinder available.
[0009] In one embodiment of the invention, the locking unit, in particular the second stage of the telescoping cylinder with the locking unit disposed on it, moves with the telescoping cylinder in the unlocked state free of force, as a result of which only slight forces are needed to move it, which can be applied by the hydraulic supply from the cylinder inlet used for extraction purposes if the locking unit can be moved on the telescoping cylinder by applying hydraulic force—as is the case with one embodiment of the invention.
[0010] A hydraulic circuit may be provided, which controls operation and/or the securing of the movable locking unit in conjunction with the hydraulic system used to extract the telescoping cylinder. The retraction operation then preferably takes place by means of a releasable connection to the annular end of the telescoping cylinder. Using the locking system proposed by this invention, the overall stroke of an extended telescoping system can be divided between the movement of the locking unit and the telescoping distance of the telescoping cylinder, i.e. the telescoping cylinder may be made shorter in principle or the overall stroke can be increased, without having to make the telescoping cylinder longer.
[0011] In one embodiment, the locking unit can be moved on the telescoping cylinder by a distance corresponding to at least the distance of all the telescopic jib-lock deactivation means when the jib is in the retracted state. Alternatively, another option is to make the locking unit so that it is able to move by more than this distance, in which case the movement is effected in addition to the stroke of the telescoping cylinder for the above-mentioned purpose or at least partially replaces it.
[0012] Other aspects of the invention will be explained in more detail with reference to examples of embodiments illustrated in the appended drawings. It may incorporate all the features described here, either individually or in any meaningful combination, and may also be construed and described in principle as a method of retracting and extending a telescopic crane jib as well as the use of the illustrated devices for this purpose. Of the drawings:
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 shows a schematic view in longitudinal section of a telescopic jib with a telescoping cylinder and locking system as proposed by the invention, and
[0014] FIG. 2 is a schematic circuit diagram illustrating how a locking system proposed by the invention is activated as well as its hydraulic supply system.
DETAILED DESCRIPTION OF THE INVENTION
[0015] An example of an embodiment of the invention will firstly be explained in more detail with reference to FIG. 1 . A schematic view in longitudinal section shows a telescopic jib, comprising a main body 11 and four extractable telescopic parts 1 to 4 . The telescoping cylinder 10 is disposed in the main body 11 . The locking unit 21 , which comprises a second cylindrical stage 6 and the cylinder lock 5 , extends on the external cylindrical casing of the telescoping cylinder 10 . The second cylindrical stage 6 lies around the external tube 8 of the telescoping cylinder 10 , which is illustrated separately. Also disposed on the telescoping cylinder 10 is the operating means 7 for the structural-steel lock 9 , which locks the individual telescopic parts to one another when they are moved into operating mode.
[0016] The way in which the telescopic system is extended in the case of this type of embodiment—in particular automatically—is based on the sequence described below.
[0017] All the telescopic parts 1 to 4 are initially retracted and locked to one another (structural-steel lock 9 ). The second stage 6 then moves into the base piece of the telescope 4 , where it is locked in the lock (recess) specifically provided for this purpose. The structural-steel lock 9 on the telescope 3 is released and the telescoping cylinder 10 with the telescope 4 is extracted to the maximum in order to lock it to the telescope 3 there. The cylinder lock 5 is then released and the telescoping cylinder 10 completely retracted. The second cylinder stage 6 is then retracted until the telescope 3 reaches the base piece, where it is locked. All the telescopic parts 1 to 4 can be extracted one after the other in this manner.
[0018] As proposed by the invention, the telescopic system is retracted—in particular likewise automatically—in the sequence described below.
[0019] All the telescopic parts 1 to 4 are extracted and locked. The telescoping cylinder 10 is fully extracted and the cylinder lock 5 is locked to the base piece of the telescopic part 1 . The structural-steel lock of the telescopic part 1 to the main body 11 is unlocked. The telescopic part 1 is completely retracted with the telescoping cylinder 10 and then locked to the main body 11 . The telescoping cylinder 10 is unlocked and completely extracted. The second cylindrical stage 6 is now extracted until the telescopic part 2 reaches the base piece, where it is locked. All the telescopic parts can be retracted one after the other in this manner.
[0020] Taking the example of the telescopic part 4 , it will now be explained how the advantage of length is obtained by the invention compared with the prior art. The extractable length of the telescopic part 4 is equal to the length T tot , due to the movable locking unit 21 . Based on the prior art, the length would be shorter by ΔT4, whereas in the case of the invention, it is possible to obtain an increase in length of the jib as a whole in the extracted state by the sum of all the ΔT values illustrated. Accordingly, the greater the number of telescopic parts, the greater the length advantage is compared with designs known from the prior art. In one standard embodiment, the locking unit 21 may be designed so that it is able to move to the degree that the stroke of the telescoping cylinder 10 need no longer correspond to the distance by which the telescopic part is able to travel. This being the case, the overall stroke of a telescopic part 1 to 4 is divided between the telescoping cylinder 10 and locking unit 21 , and the overall length of the telescoping cylinder 10 can therefore be made significantly shorter.
[0021] Turning to the schematic circuit diagram shown in FIG. 2 , the operating means and hydraulic supply system of a design based on the invention will be explained. In the case of the embodiment illustrated, the second stage of the telescoping cylinder 20 comprises the cylinder tube 26 , which surrounds the outer cylinder tube of the actual telescoping cylinder 20 . The oil chambers 30 and 31 are supported on the ring 32 , which is fixedly joined to the telescoping cylinder 20 (or may constitute a part of it).
[0022] The cylinder inlet 35 is used to deliver the hydraulic supply to the valve unit 28 . From here, the supply is switched to the cylinder lock 25 , structural-steel locking system 29 or second cylindrical stage 26 , depending on requirements, in order to move the entire locking unit 21 . To obtain an extension in the direction of travel, the ring side 31 remote from the load is connected to the ring side 27 of the telescoping cylinder 20 relieved of pressure. The load side 30 is also connected to the pressurised cylinder inlet 35 . A releasable check valve 22 prevents the undesirable reverse movement of the locking unit 21 .
[0023] For retraction purposes, the load-side annular chamber 30 of the locking unit 21 is connected to the cylinder inlet 35 , which is relieved of pressure. The annular chamber 31 remote from the load is connected to the pressurised side 27 of the telescoping cylinder 20 , causing the releasable check valve 22 to open as a result.
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The invention relates to a locking system for a telescopic crane jib, in particular for a mobile crane, in which a lock is established between a telescoping cylinder ( 10, 20 ) and a telescopic part ( 1 - 4 ) by means of a locking unit ( 21 ) in order to extract and retract the telescopic parts, and the locking unit ( 21 ) is disposed on the telescoping cylinder ( 10, 20 ) in such a way that it can be moved longitudinally.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of application Ser. No. 155,656 filed Feb. 12, 1988 (now abandoned), which is a continuation-in-part of application Ser. No. 021,837 filed Mar. 4, 1987 (now U.S. Pat. No. 4,725,652), which is a continuation-in-part of application Ser. No. 849,087 filed Apr. 7, 1986 (now abandoned), which is a continuation-in-part of application Ser. No. 716,279 filed Mar. 25, 1985, (now U.S. Pat. No. 4,594,291), which is a continuation-in-part of application Ser. No. 631,676, filed Jul. 17, 1984 (now abandoned), all of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
The present invention concerns new compositions of matter useful as latent catalysts for reacting epoxy resins with polyhydric phenols.
It is desirable to have epoxy resin compositions which contain catalysts which will not become active until heated so as to improve storage life. Tyler, Jr. et al in U.S. Pat. No. 4,366,295, Perry in U.S. Pat. No. 3,948,855 and Dante in U.S. Pat. No. 3,477,990 disclose precatalyzed epoxy resin compositions which contain onium compounds as the catalyst. While the epoxy resin compositions containing these catalysts are relatively storage stable, it would be desirable for the precatalyzed epoxy resin composition to be even more stable.
It has now been discovered that when an onium compound or amine compound has been contacted with an acid having a weak-nucleophilic anion that the storage stability of precatalyzed epoxy resins is improved.
SUMMARY OF THE INVENTION
The present invention pertains to new catalytic compositions which result from contacting (1) an onium compound represented by the following formulas IA or IB ##STR1## wherein each R 1 , R 2 , R 3 and R 4 is independently an aliphatic hydrocarbyl group having from 1 to about 18, preferably from about 1 to about 9, carbon atoms, or a hydrocarbyl group having from 1 to about 18, preferably from 1 to about 9, carbon atoms which group also contains one or more oxygen, sulfur, halogen, or nitrogen atoms or two of such R, R 1 , R 2 and R 3 groups can combine to form a heterocyclic ring containing one or more atoms other than carbon atoms; each X is the anion portion of an acid having a relatively-strong nucleophilic anion; Z is phosphorus, nitrogen, or arsenic; m has a value equal to the valence of the anion X; and z has a value of zero or 1 depending on the valence of Z; with (2) (a) an inorganic acid free of boron, said inorganic acid having a weak-nucleophilic anion, (b) a metal salt of an inorganic acid free of boron, said inorganic acid having a weak-nucleophilic anion, (c) an inorganic acid containing boron represented by the formula BR 3 R' wherein each R is independently hydrogen or an aliphatic, cycloaliphatic or aromatic hydrocarbyl group having from 1 to about 12 carbon atoms or a halogen and R' is a group other than a hydrocarbyl group, (d) a metal salt of an inorganic acid containing boron represented by the formula BR 3 R' wherein each R is independently hydrogen or an aliphatic, cycloaliphatic or aromatic hydrocarbyl group having from 1 to about 12 carbon atoms or a halogen and R' is a group other than a hydrocarbyl group, or (e) any combination of any two or more of components (a), (b), (c) or (d); wherein components (1) and (2) are contacted in quantities which provide from about 0.6 to about 1.4 moles of acid or acid salt per mole of onium compound.
Another aspect of the present invention pertains to new catalytic compositions represented by the Formulas IA or IB ##STR2## wherein each R 1 , R 2 , R 3 and R 4 is independently an aliphatic group having from 1 to about 18, preferably from about 1 to about 9, carbon atoms, or a hydrocarbyl group having from 1 to about 18, preferably from 1 to about 9 carbon atoms which group also contains one or more oxygen, sulfur, halogen, or nitrogen atoms or two of such R, R 1 , R 2 and R 3 groups can combine to form a heterocyclic ring containing one or more atoms other than carbon atoms; each X' is the anion portion of a weak-nucleophilic acid; Z is phosphorus, nitrogen, or arsenic; m has a value equal to the valence of the anion X'; and z has a value of zero or 1 depending on the valence of Z.
Epoxy resin compositions containing these catalysts, when stored at a temperature of 52° C. for a period of nine weeks, exhibit an increase in viscosity measured in centipoise of not greater than about 22, preferably not greater than about 18, percent as compared to the viscosity of the composition prior to storing and wherein the viscosity measurements are taken at room temperature and which composition comprises a material that has an average of more than one vicinal epoxy group per molecule and a catalytic quantity of the catalyst.
The term hydrocarbyl as employed herein refers to a monovalent aliphatic hydrocarbon group such as alkyl, cycloalkyl, alkenyl and similar hydrocarbon groups.
The term weak-nucleophilic as employed herein means that the material has a necleophilicity value "n" from about zero to less than about 2.5 as described by C. G. Swain and C. B. Scott in J. Am. Chem. Soc., Vol. 75, p. 141 (1953) which is incorporated herein by reference.
The term relatively strong-nucleophilic as employed herein means that the material has a nucleophilicity value "n" of 2.5 or greater as described by C. G. Swain and C. B. Scott in J. Am. Chem. Soc., Vol. 75, p. 141 (1953) which is incorporated herein by reference.
DETAILED DESCRIPTION OF THE INVENTION
The catalysts of the present invention are prepared by simply mixing the onium compound or the amine compound with an inorganic acid or salt of an inorganic acid having a weak-nucleophilic anion in the desired proportions and stirring to insure intimate contact. The contact can be conducted at temperatures of from about 0° C. to about 100° C., preferably from about 20° C. to about 60° C. for a time sufficient to complete any reaction which occurs. The time depends upon the temperature, but usually from about 1 to about 120, preferably from about 5 to about 60 minutes is sufficient. Other methods for preparing the catalyst of the present invention is to employ an in situ method wherein the onium compound or the amine compound and the inorganic acid or salt of an inorganic acid, said acid containing a weak-nucleophilic anion are added separately to the resin formulation or component parts thereof thereby forming the catalyst in situ.
Particularly suitable onium or amine compounds which can be reacted or complexed with the inorganic acids having a weak-nucleophilic anion to form the catalysts of the present invention include, for example, tetrabutylphosphonium acetate•acetic acid complex, tetrabutylphosphonium hydroxide, tetrabutylammonium hydroxide, tetraethylammonium hydroxide, tetramethylammonium hydroxide, tetrabutylphosphonium chloride, tetrabutylammonium chloride, tetraethylammonium chloride, tetramethylammonium chloride, triethylamine hydrochloride, 2-methylimidazole hydrochloride, N-methylmorpholine hydrochloride, ethyltri(2-hydroxyethyl)ammonium chloride, triethyl(2-thioethylethyl)ammonium chloride, N-methylmorpholine, 2-methylimidazole, triethylamine, N,N,N',N'-tetramethylethylenediamine, ethyltri(2-hydroxyethyl)-ammonium hydroxide, ethyltri(2-ethoxyethyl)ammonium hydroxide, triethyl(2-thioethylethyl)ammonium hydroxide, mixtures thereof and the like.
Particularly suitable onium or amine-acid complexes which can be reacted with the salt of inorganic acids having a weak-nucleophilic anion to form the catalysts of the present invention include, for example, tetrabutylphosphonium chloride, tetrabutylammonium chloride, tetraethylammonium chloride, tetramethylammonium chloride, triethylamine hydrochloride, 2-methylimidazole hydrochloride, N-methylmorpholine hydrochloride, ethyltri(2-hydroxyethyl)ammonium chloride, triethyl(2-thioethylethyl)ammonium chloride, mixtures thereof and the like.
Suitable boron containing acids include, for example, those represented by the formula BR 3 R' wherein each R is independently hydrogen or an aliphatic, cycloaliphatic or aromatic hydrocarbon or substituted hydrocarbon group having suitably from 1 to about 12, more suitably from about 1 to about 6, most suitably from about 1 to about 4, carbon atoms; and R' is a group other than a hydrocarbyl group such as, for example, a hydrocarbonoxy, hydrocarbonamino, a hydrocarbonphosphino, or a halogen atom, particularly fluorine, chlorine or bromine. The term hydrocarbon means any aliphatic, cycloaliphatic, aromatic, arylsubstituted aliphatic, alkyl substituted aromatic groups.
Suitable such acids containing boron include, for example, hydrogen fluorotriphenylborate, hydrogen chlorotriphenylborate,, hydrogen fluorotributylborate, hydrogen phenyltrifluoborate. Most particularly suitable such acid is fluoboric acid.
Fluoboric acid is sometimes referred to as fluoroboric acid or hydrogen tetrafluoroborate. Any of these expressions refer to the chemical represented by the formula HBF 4 .
The term hydrocarbonoxy means that a hydrocarbyl group as previously defined has an oxygen atom between it and the boron atom. Likewise, the term hydrocarbonamino and hydrocarbonphosphino mean that there is an amine or phosphine group between the hydrocarbyl group and the boron atom.
Particularly suitable inorganic acids which are free of boron, said acid having a weak nucleophilic anion include, for example, fluoarsenic acid, fluoantimonic acid, fluophosphoric acid, chloroboric acid, chloroarsenic acid, chloroantimonic acid, chlorophosphoric acid, perchloric acid, chloric acid, bromic acid, iodic acid and or any combination thereof and the like.
Suitable metal salts of the aforementioned boron-free or boron containing inorganic acids having a weak nucleophilic anion include, for example, salts of the metals of Groups I and II of the Periodic Table of the Elements published by Sargent-Welch Scientific Company as catalog number S-18806. Particularly such salts include, for example, the sodium, potassium, lithium, calcium, barium magnesium and silver salts of such inorganic acids.
Suitable relatively strong-nucleophilic acid anions include, for example, carboxylates, halides, phosphates, phosphites, carbonates, bicarbonates, hydroxide, cyanide, thiol, sulfate, thiosulfate, and the like. Particularly suitable such nucleophilic acid anions include, for example, acetate, acetate•acetic acid complex, propionate, chloride, iodide, and the like.
The resultant catalyst is believed to be a material represented by the aforementioned formulas IA and IB wherein X' is the anion portion of an inorganic acid having a weak nucleophilic anion or a combination of such acids.
Suitable epoxy resins with which the catalysts of the present invention can be mixed include, for example, those represented by the following formulas II-V ##STR3## wherein each A is independently a divalent hydrocarbyl group having from 1 to about 9, preferably from 1 to about 4, carbon atoms, --O--, --S--, --S--S--, --SO--, --SO 2 --, or --CO--; each A' is independently a divalent hydrocarbyl group having from 1 to about 9, preferably from 1 to about 4 carbon atoms; Q is a hydrocarbyl group having from 1 to about 10 carbon atoms; Q' is hydrogen or an alkyl group having from 1 to about 4 carbon atoms; each R is independently hydrogen or an alkyl group having from 1 to about 4 carbon atoms; each X is independently hydrogen, bromine, chlorine, or a hydrocarbyl group having from 1 to about 9, preferably from 1 to about 4 carbon atoms; m has an average value from zero to about 12, preferably from about 0.03 to about 9, most preferably from about 0.03 to about 3; m' has a value from about 0.01 to about 10, preferably from about 0.2 to about 8, more preferably from about 0.5 to about 6; n has a value of zero or 1; and n' has an average value of from zero to about 10, preferably from zero to about 5, most preferably from about 0.1 to about 3.
Particularly suitable such epoxy resins include, for example, the diglycidyl ethers of resorcinol, catechol, hydroquinone, biphenol, bisphenol A, tetrabromobisphenol A, phenol-aldehyde novolac resins, alkyl substituted phenol-aldehyde resins, bisphenol K, tetramethylbiphenol, tetramethyltetrabromobiphenol, tetramethyltribromobiphenol, tetrachlorobisphenol A, combinations thereof and the like.
Also suitable as the epoxy resin to which the catalysts of the present invention can be mixed include those partially advanced expoxy resins of allowed copending application Ser. No. 716,279, filed Mar. 25, 1985 by Bertram et al which is incorporated herein by reference.
Suitable aromatic hydroxyl containing materials which can be employed herein include, for example, those represented by the following formulas VI-IX ##STR4## wherein A, A', Q, Q', X, n and m are as defined above in formulas II-V. Particularly suitable aromatic hydroxyl-containing materials include, for example, biphenol, bisphenol A, bisphenol K, tetrabromobisphenol A, tetrabromobisphenol K, resorcinol, phenol-aldehyde novolac resins, cresol-aldehyde novolac resins, tetramethylbiphenol, tetramethyltribromobiphenol, tetramethyltetrabromobiphenol, tetrachorobisphenol. A, combinations thereof and the like.
These and other suitable aromatic hydroxylcontaining materials are disclosed in U.S. Pat. No. 4,594,291 issued Jun. 10, 1986 by Bertra et al which is incorporated herein by reference.
The precatalyzed compositions of the present invention can contain, if desired, pigments, fillers, dyes, diluents, solvents, stabilizers, epoxy resin curing agents, combinations thereof and the like.
Suitable stabilizer materials and curing agents which can be employed herein include, for example, those disclosed in the aforementioned U.S. Pat. No. 4,594,291 by Bertram et al which is incorporated herein by reference.
The following examples are illustrative of the invention but are not to be construed as to limiting the scope thereof in any manner.
EPOXY RESIN A was a diglycidyl ether of bisphenol A having an epoxide equivalent weight of 180.8.
EXTENDER COMPOUND A was tetrabromobisphenol A having a phenolic hydroxyl equivalent weight (PHEW) of 272.
CURING AGENT A was sulfanilamide having an active hydrogen equivalent weight of about 43.
CURING AGENT B was 4,4'-diaminodiphenylsulfone having an amine hydrogen equivalent weight of about 62.
STABILIZER A was methyl-p-toluene sulfonate.
STABILIZER B was p-tolouene sulfonic acid•monohydrate.
EXAMPLES 1-21 AND COMPARATIVE EXPERIMENTS A-Z
CATALYST PREPARATION
The catalysts employed in the present invention were prepared by the following general procedure. To a methanol solution of the onium or amine compound was added a 60 percent aqueous solution of fluoboric acid. A sufficient quantity of methanol was added such that the resultant product contained 40 percent of the onium or amine compound by weight. Stirring was continued until the reaction was essentially complete. The quantities and reaction conditions are given in the following Table I.
TABLE I__________________________________________________________________________ AMOUNT OF FLUOBORICCATALYST TYPE OF ONIUM AMOUNT ACIDNUMBER OR AMINE COMPOUND GRAMS/MOLES GRAMS/MOLES__________________________________________________________________________ 1* 70 wt. % ethyltri- 58.6/0.1 17.56/0.12 phenylphonium acetate · acetic acid complex in methanol2 70 wt. % 54/0.1 17.56/0.12 tetrabutylphosphon- ium acetate · acetic acid complex in methanol3 triethylamine 101/1.0 201.2/1.14 N-methylmorpholine 10.1/0.1 17.56/1.15 N,N,N',N'- 58.0/0.1 201.2/1.1 tetramethyl ethylene diamine__________________________________________________________________________ *Comparative catalyst.
COMPARATIVE CATALYSTS
For comparative purposes, the following catalysts were utilized.
Catalyst A was ethyltriphenylphosphonium acetate•acetic acid complex.
Catalyst B was tetrabutylphosphonium acetate•acetic acid complex.
Catalyst C was ethyltriphenylphosphonium acetate•acetic acid complex plus an equimolar amount of phosphoric acid as described by Tyler, Jr. in U.S. Pat. No. 4,366,295.
Catalyst D was tetrabutylphosphonium acetate•acetic acid complex plus an equimolar amount of phosphoric acid as described by Tyler, Jr. in U.S. Pat. No. 4,366,295.
Catalyst E was 2-methylimidazole.
Catalyst F was benzyl dimethyl amine.
Catalyst G was ethyltriphenylphosphonium iodide, 30 percent active.
PRECATALYZED EPOXY RESIN FORMULATION A
Precatalyzed epoxy resins were prepared by adding to 120 grams (0.638 equiv.) of a diglycidyl ether of bisphenol A having an epoxide equivalent weight of 188 (commercially available from the Dow Chemical Company as D.E.R.™ 331 epoxy resin) 0.45 milliequivalent of catalyst and stirring. The precatalyzed resins were placed in a vacuum oven under a full vacuum (approximately 0.1 mm Hg) controlled at 50° C. to 55° C. for one hour (3600 s). The samples were then stored in a convection oven controlled at 52° C. and the viscosity of the samples were measured at periodic intervals. The samples were allowed to cool for 4 hours (14400 s) at room temperature before measuring the viscosity. The results are given in the following Table II.
TABLE II__________________________________________________________________________VISCOSITY OF PRECATALYZED EPOXY RESIN (13.599)Exampleor 1 WEEK 2 WEEKS 4 WEEKS 9 WEEKSCOMP. INITIAL (604800 s) (1209600 s) (2149200 s) (5443200 s)EXPT. centipoise centipoise centipoise centipoise centipoiseNO. CATALYST (Pa.s) (Pa.s) (Pa.s) (Pa.s) (Pa.s)__________________________________________________________________________ 1* 1 12500 11768 11538 14504 15007 (12.5) (11.768) (11.538) (14.504) (15.007)2 2 12500 12544 12397 13564 14732 (12.5) (12.544) (12.397) (13.564) (14.732)3 3 12500 12819 12225 13599 14732 (12.5) (12.819) (12.225) (12.599) (14.732)4 4 12500 13736 12809 14731 15247 (12.5) (13.736) (12.809) (14.731) (15.247)A* No Cat- 12500 12500 12362 14491 15590alyst (12.5) (12.5) (12.362) (14.491) (15.59)B* A 12500 20020 28502 70603 198485 (12.5) (20.02) (28.502) (70.603) (198.485)C* C 12500 12397 12843 14216 19059 (12.5) (12.397) (12.843) (14.216) (19.059)D* D 12500 12225 12156 13323 15075 (12.5) (12.225) (12.156) (13.323) (15.075)__________________________________________________________________________ *Not an example of this invention as presently claimed.
RESIN ADVANCEMENT A
A portion of each of the precatalyzed resins from Table II, after aging for 9 weeks (5,443,200 s) at 52° C., were mixed with 22.5 weight percent bisphenol A at 160° C. until all of the bisphenol A had dissolved. The homogeneous solutions were then held at 160° C. for two additional hours, then cooled and the resultant advanced resins analyzed for percent oxirane (epoxide) content and melt viscosity measured at 150° C. The results are given in Table III.
TABLE III______________________________________ADVANCED RESIN ANALYSIS MELTEXAMPLE RESIN FROM VISCOSITYOR COMP. EXAMPLE OR PERCENT CENTIPOISEEXPT. COMP. EXPT. EPOXIDE** (Pa.s)______________________________________ 5* 1 8.59 570 (0.57)6 2 8.66 550 (0.55)7 3 9.04 450 (0.45)8 4 9.66 260 (0.26)E* A*** 8.9 --F* B 7.35 2760 (2.76)G* C 8.44 680 (0.68)H* D 8.70 520 (0.52)______________________________________ *Not an example of this invention as presently claimed. **The theoretical percent epoxide is 9.0. ***Since this resin solution did not contain any advancement catalyst, 0.45 milliequiv. of catalyst A was employed.
RESIN ADVANCEMENT B
The procedure of Resin Advancement A was followed using 33.48 weight percent of bisphenol A instead of 22.5 weight percent. The resin/bisphenol A blends were held for 4 hours (14400 s) at 160° C. and then analyzed for oxirane content and melt viscosity measured at 200° C. The results are given in Table IV.
TABLE IV______________________________________ADVANCED EPOXY RESIN ANALYSIS MELTEXAMPLE RESIN FROM VISCOSITYOR COMP. EXAMPLE OR PERCENT CENTIPOISEEXPT. COMP. EXPT. EPOXIDE** (Pa.s)______________________________________ 9* 1 1.82 26950 (26.95)10 2 1.85 30180 (30.18)11 3 3.1 890 (0.89)12 4 4.28 510 (0.51)I* A 2.24 7940 (7.94)J* B gelled gelledK* C 1.92 11470 (11.47)L* D 2.10 7160 (7.16)______________________________________ *Not an example of this invention as presently claimed. **The theoretical percent epoxide is 2.38.
PRECATALYZED RESIN FORMULATION B
To 181 grams (1 equiv.) of the diglycidyl ether of bisphenol A having an epoxide equivalen weight of 181 (commercially available from The Dow Chemical Company as D.E.R.™ 383 epoxy resin) was added 136 grams (0.5 equiv.) of tetrabromobisphenol A and an indicated amount of catalyst. In two of the examples or comparative experiments 1 or 1.125 milliequiv. of methyl toluene sulfonate (MTS) was added as indicated. The mixture was stirred at 130° C. until the tetrabromobisphenol A was dissolved, then cooled to 80° C. and the indicated catalyst was added. The homogeneous resin was then stored at 52° C. and the viscosity measured at 100° C. was measured periodically. The results are given in Table V.
TABLE V__________________________________________________________________________RESIN VISCOSITYEXAMPLE MELT VISCOSITYOR CATA- AFTER 12 DAYSCOMP. LYST CATALYST MTS (1036800 s)EXPT. TYPE milliequiv. milliequiv. cps (Pa.s)__________________________________________________________________________ 13* 2 1 0 90 (0.09)14 2 2 1 90 (0.09)15 2 2 1.25 110 (0.16 5 1 0 90 (0.09)M* none -- 0 150 (0.15)N* none -- 1 95 (0.095)O* A 0.125 1.125 1240 (1.24)__________________________________________________________________________ *Not an example of the present invention as presently claimed.
PRECATALYZED RESIN FORMULATION C
The procedure of precatalyzed resin formulation B was employed except that 0.125 milliequiv. of sulfanilamide was added along with the tetrabromobisphenol A, and the mixture was stirred and heated to 150° C. until homogeneous, then cooled to 80° C. and the following amounts of catalyst as indicated was added. The homogeneous resin was then stored at 52° C. and the viscosity measured at 100° C. was measured periodically. The results are given in Table VI.
TABLE VI__________________________________________________________________________RESIN VISCOSITYEXAMPLE MELT VISCOSITYOR AFTER 12 DAYSCOMP. CATALYST CATALYST SULFANILAMIDE (1036800 s)EXPT. TYPE milliequiv milliequiv cps (Pa.s)__________________________________________________________________________17 2 1 0.125 450 (0.45)18 5 1 0.125 220 (0.22)P* none -- 0.125 590 (0.59)__________________________________________________________________________ *Not an example of the present invention.
PRECATALYZED RESIN FORMULATION D
To 45.3 grams (0.25 equiv) of D.E.R.™ 383 epoxy resin as described above, 34 grams (0.125 equiv.) of tetrabromobisphenol A and 5.37 grams (0.125 equiv.) of sulfanilamide were added 1 milliequiv. of the indicated catalyst. A small amount of the resin mixture was then analyzed by a DuPont model 1090 Differential Scanning Calorimeter (DSC) at a rate of 2° C. per minute (0.033° C./s). The temperature at which an exothermic reaction was indicated via baseline, drift, the actual onset of a major exotherm, and the exotherm peak were noted. The results are given in Table VII.
TABLE VII__________________________________________________________________________DSC DATA ONSET OFEXAMPLE BEGINNING MAJOR PEAKOR COMP. CATALYST OF EXOTHERM EXOTHERM EXOTHERMEXPT. TYPE °C. °C. °C.__________________________________________________________________________19 2 80-85 145 192Q* B 65 70 148R* none 80-85 80-85 222__________________________________________________________________________ *Not an example of the present invention.
PRECATALYZED RESIN FORMULATION E
The Resin Formulations D were duplicated. The formulations were stored at 80° C. and the viscosity at 100° C. was measured periodically. The results are given in the following Table VIII.
TABLE VIII__________________________________________________________________________FORMULATED VISCOSITY STABILITY VISCOSITY AFTEREXAMPLE CATA- INITIAL 12 hrs. 36 hrs.OR COMP. LYST VISCOSITY (43200 s) (129600 s)EXPT. TYPE cps (Pa.s) cps (Pa.s) cps (Pa.s)__________________________________________________________________________20 2 287 (0.287) 3594 (3.594) 154140 (154.14)S* B 287 (0.287) >1000000 (1000) --T* none 287 (0.287) 2209 (2.209) 18599 (18.599)__________________________________________________________________________ *Not an example of the present invention.
PREPARATION OF CURED COMPOSITION
A portion of the precatalyzed Resin Formulations form Table VIII was heated at 177° C. for 4 hours (14400 s) to cure the samples. The glass transition temperature (Tg) of the cured resins was determined by a DuPont model 1090 Differential Scanning Calorimeter (DSC). The results are given in Table IX.
TABLE IX______________________________________GLASS TRANSITION TEMPERATUREOF CURED RESINSEXAMPLEOR COMP. CATALYSTEXPT. TYPE Tg, °C.______________________________________20 2 135.4S* B 137.8T* none 111.2______________________________________ *Not an example of the present invention.
EXAMPLE 22
Epoxy Resin A, 180.8 grams (1.0 equiv.), Extender Compound A, 136.0 grams (0.50 equiv) and 4.3 grams (0.1 equiv.) of curing agent A were heated with stirring under a nitrogen atmosphere at 120° C. until the melt viscosity measured at 100° C. had increased from about 80 cps to 200 cps, an increase in melt viscosity of 150 percent. Then 0.19 ml of Stabilizer A was added. After 5 minutes (300 s) stirring, the homogeneous mixture was cooled to 70° C., 2.16 ml of Catalyst 2 added and the resin cooled to ambient temperature.
EXAMPLE 23
A portion (714.8 grams) of the resin from Example 22 was mixed at 130° C. with 47.0 grams (0.76 equiv.) of Curing Agent B until homogeneous, then cured for 4 hours (14400 s) at 150° C. followed by 3 hours (10800 s) at 200° C. The cured casting has a glass transition temperature of 134.9° C. and a GIC value of 0.61 kj/m 2 .
EXAMPLE 24
Epoxy Resin A (1012.5 grams, 5.6 equiv.), 761.6 grams (2.8 equiv.) of Extender A and 24.08 grams (0.56 equiv.) of Curing Agent A were heated with stirring under a nitrogen atmosphere at 120° C. until the melt viscosity measured at 100° C. had increased from about 80 cps to 200 cps, an increase in melt viscosity of 150 percent. Then 1.06 grams (5.6 milliequiv.) of Stabilizer B was added. After 5 minutes (300 s) at 120° C., the homogeneous mixture was cooled to 70° C., 12.1 ml (11.2 milliequiv.) of catalyst 2 added and the resin cooled to ambient temperature.
EXAMPLE 25
A portion (731.9 grams) of the resin from Example 24 was mixed at 130° C. with 48.06 grams (0.78 equiv.) of Curing Agent B until homogeneous, then cured for 4 hours (14400 s) at 150° C. followed by 3 hours (10800 s) at 200° C. The cured casting had a glass transition temperature of 137.3° C. and a GIC value of 0.72 kj/m 2 .
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Latent catalysts for epoxy reactions are prepared by reacting a tetrasubstituted onium compound such as tetrabutylphosphonium acetate acetic acid complex with an acid or metal salt of an acid having a weak-nucleophilic anion such as fluoboric acid. These catalysts provide stable latent catalysts for epoxy resins for advancement or curing reactions.
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This is a divisional of application Ser. No. 08/682,928 filed on Jul. 16, 1996, now U.S. Pat. No. 5,704,995.
FIELD OF THE INVENTION
The present invention relates to a method and composition for the formation of a black uniform coating on the surface of various metals, and particularly of various metals such as aluminum and its alloys, zinc and its alloys, and copper and its alloys, such as brass, including materials with surfaces of these alloys produced by plating or other methods. The process has been found to be particularly effective at forming a room temperature two step flexible, uniformly black corrosion resistant coating on the surfaces of the previously mentioned metals.
BACKGROUND OF THE INVENTION
Methods for the formation of black coatings or films on the surface of various metals are currently available. The methods vary with the particular type of metal, e.g., ferrous metals, stainless steels, copper and its alloys, zinc and its alloys, and aluminum and its alloys. The composition of the treatment solution and the treatment conditions vary from case to case. As reported in the background of U.S. Pat. No. 4,931,317, it has been previously known to provide a method of forming a black coating with an aqueous resin containing solution followed by baking to produce a coating of the desired weight. The aqueous solution contains a hexavalent chromium compound, a reducing agent and a water soluble resin.
In the treating of many aluminum or aluminum alloy articles the more common procedure is to first apply a conversion coating such as a chromium based coating and thereafter apply a black paint. The first step creates a corrosion resistant conversion coating. The second step of applying paint is virtually nothing more than a decorative and aesthetic step. Such two step processes require extra equipment and waste disposal procedures. Coatings such as those described in the background of U.S. Pat. No. 4,931,317 also require ovens to bake the coated metal to form the coating thereon.
The '317 disclosure itself teaches a method and composition for the formation of a black coating on the surface of various metals by coating and subsequent baking of a treatment solution containing ferrous metal ions, hexavalent chromium, trivalent chromium and a film forming polymer dissolved or dispersed in water. The black nature of the coating is due to the concentration of hexavalent chromium and metal salts (Co, Fe and Ni) in the solution. This disclosure requires that an air knife be used in the process to remove excess coating material from the surface of the substrate as well as the need for ovens in order to cure the coating after it has been applied to the substrate.
U.S. Pat. No. 5,470,613 discloses the composition and method of forming a single step no rinse black conversion coating. It has been found that this process can not be applied to surfaces of various substrates other than aluminum and its alloys. Also, it has been found that the so-called process solution is not stable and, in the long run, this solution breaks down and/or separates into a polymer and hexavalent chromium paste.
SUMMARY OF THE INVENTION
Throughout this description, except in the operating examples or where otherwise explicitly indicated, all numbers specifying quantities of materials or conditions of reaction or use are understood as modified by the word "about".
It has been found that a black surface coating can be formed not only on aluminum materials, but also on a variety of other materials by coating the surface with a dry loose powdery layer of zinc and antimony from a blackening treatment (i.e. solution or dispersion) and sealing the coating with a sealing treatment containing water, styrene acrylate copolymer, ethylene glycol monobutyl ether, and an alkyd resin. More specifically, the preferred sealing treatment comprises the following ingredient percentages (percentages are given on a weight basis):
______________________________________INGREDIENT PERCENTAGE______________________________________Water 79Ethylene glycol monobutyl ether 5.7(2-butoxyethanol)N-methylpyrrolidone 0.5Styrene acrylate copolymer 8Alkyd resin 6Polyethylene glycol based surfactant <1Carboxylic acid <1Polyethylene wax <1Zinc chromate (Cr + 6) <0.5______________________________________
The black coating is formed by using a sodium hydroxide base solution containing zinc and antimony compounds. More specifically, the blackening solution preferably consists of Hubbard Hall's BLACK MAGIC RT-A3 antimony-zinc dispersion. The ingredients of this product purportedly include:
______________________________________INGREDIENT PERCENTAGE______________________________________Sodium hydroxide 30-40Zinc compounds 10Antimony compounds 5Liquid Carrier Remainder______________________________________
DETAILED DESCRIPTION OF THE INVENTION
In accordance with the invention, a dry, black, adherent protective coating is formed on the desired metallic substrate. The coating may advantageously be applied to a variety of metals including iron, copper, aluminum, tin, zinc and alloys thereof. The coating has proven especially effective on aluminum, copper and brass substrates.
After the requested metal substrate has been precleaned, it is contacted with a blackening solution or dispersion (i.e. treatment) comprising a combination of zinc and antimony particles in a suitable carrier liquid, such as water. Preferably, the zinc and antimony components are present in this elemental powdered form although they could also be present in salt form such as in nitrate form or as carbonates. Additionally, they could be present as oxides. Immersion of the substrate in this blackening treatment is normally conducted under basic conditions. The amount of zinc present relative to antimony may be on the order of about 4-1:1 with zinc preferably present in an amount by weight, relative to antimony of about 2:1.
After application of the blackening treatment, the substrate is rinsed and, preferably, subjected to a acid based chromate solution or dispersion to provide enhanced corrosion protection. Any source of hexavalent chromium may be mentioned as exemplary for such treatment. Included are such compounds as chromic acid, potassium dichromate, magnesium dichromate, potassium chromate, sodium chromate, zinc chromate, and aluminum chromate, sodium chromate dihydrate, sodium chromate anhydrous, sodium chromate tetrahydrate, sodium chromate hexahydrate, sodium chromate decahydrate, and ammonium dichromate.
Solutions which contain trivalent chromium in addition to hexavalent chromium may also be mentioned. These may be prepared by partially reducing solutions containing hexavalent chromium with suitable reducing agents. For example, the addition of formaldehyde to a chromic acid solution will reduce a portion of the hexavalent chromium present to its trivalent form.
After application of the chromate treatment to the metal part, the part may be subjected to cold water and hot water rinses followed by ambient or forced air drying. The thus treated, and, blackened part is then immersed in a specially prepared sealing treatment.
The sealing treatment is a two part liquid solution wherein the first part is an emulsion comprising an organic film forming resin component such as an emulsified acrylic, vinyl acetate, styrene or phenolic polymer that forms a coherent, durable film upon drying. Acrylic polymer films are preferred. Such film forming resin components are commercially available under the "RHOPLEX" or "NEOCRYL" trademarks from Rohm and Haas and ICI respectively. Styrene/acrylic copolymers are most preferred.
The first part also includes an organic solvent such as the "CELLOSOLVE" ethylene glycol ethers sold by Union Carbide. These are all well known and commercially available mono or dialkyl ethers of ethylene glycol. Accordingly, such solvents can comprise ethylene glycol monobutyl ether, ethylene glycol monoethyl ether acetate, ethylene glycol monobutyl ether acetate, ethylene glycol monoethyl ether, ethylene glycol dibutyl ether, ethylene glycol monohexyl ether, ethylene glycol monomethyl ether, ethylene glycol monomethyl ether acetate, ethylene glycol monophenyl ether, etc.
Additionally, a plasticizer such as N-methylpyrrolidone can also be a constituent of the first part sealing solution. An additional film forming member such as an alkyd resin may also be included. The first part sealing treatment may be supplied in emulsion form with the use of suitable emulsifying agents and water present.
As to the emulsifying agents which may be present, these include the polyethylene glycol condensates of the formula H(OCH 2 CH 2 ) n OH that may vary in weight from about 200-10,000. Additionally other emulsifiers such as soaps and polyethylene waxes may be mentioned.
The first part sealing liquid is mixed with a second part sealing liquid, the latter of which includes lacquers. In the preferred form of the invention, a hexavalent chromium source, such as those referred to above may also be included in the second part. After the first and second parts are mixed, additional water is added. The first and second parts are mixed in a volumetric ratio of first part:second part of from about 1-4:4-1 with preliminary results indicating a preference for mixing of about 3:1 part one:part two. Water is then added to these mixed part one and part two components to result in the sealing treatment into which the desired metal part is immersed.
Exemplary first part liquids are listed below.
______________________________________First Part % by weight______________________________________Film Forming Resin Component 1-40%Organic Solvent 1-10%Plasticizer 1-2%Alkyd Resin 1-40%Emulsifying Agents 1-5%Water Remainder______________________________________
The invention will now be further described in conjunction with the following examples, which are to be regarded as being illustrative of the invention and not as a limitation thereof.
EXAMPLES
a) Preparation--Black treatment solutions were prepared by adding water to the basic antimony--zinc dispersion sold under the trademark BLACK MAGIC RT-A3 available from Hubbard-Hall, Inc, Waterbury, Conn. This product has been described as a clear, slightly viscous liquid having a pH in excess of 12 which comprises about 30-40% NaOH, 10% elemental zinc in blue powder form, 5% antimony black (elemental antimony). This product is soluble in water and has a specific gravity of 1.5 @70° F. The addition of water to the product caused an exotherm. The resulting solution was then allowed to cool.
The requisite metal substrate was pre-cleaned and then immersed in the black treatment solution for a period of about 1 1/2-2 minutes followed by a cold water rinsing of the part for about 2-4 minutes. In certain cases, the part was immersed in a zinc chromate containing bath (as is indicated in the following table) for a period of about 10-20 seconds, to impart increased anti-corrosion properties to the coating.
The thus coated part was subjected to a quick cold water then hot water rinse with excess water blown off the part.
Next, the part was immersed in a sealing treatment liquid for a period of about 1-2 minutes. The sealing treatment was prepared by mixing commercially available RUST PEL 66 ESMP-1 product (available from Hubbard-Hall--see above) and the commercially available "SUPER-SHIELD" product from Hubbard-Hall. RUST PEL 66ESMP-1 product has been described as a milky white liquid having a specific gravity of 1.005 @70° F. It is a water reducible acrylic emulsion containing butyl cellosolve, 1-methyl 2-pyrrolidinone, ammonium hydroxide, a styrene/acrylic polymer, and alkyd resin. The SUPER-SHIELD product is a lacquer based product available from Hubbard-Hall. The lacquer includes minor amounts of hexavalent chromium.
The "RUST PEL 66ESMP-1" and "SUPER-SHIELD" products were first mixed together before water was added to form the sealing treatment in accordance with the invention. The resulting sealing treatment had the following composition (% by volume):
______________________________________RUST PEL 66ESMP-1 product 61%SUPER-SHIELD product 19.6Water 19.4______________________________________
After the metal parts were immersed in the sealing treatment for about 1-2 minutes, they were then dried in air for a period of about 5-10 minutes with excess sealing treatment blown off. Dry, black coated substrates were provided as a result and were subjected to the efficacy tests that are described below.
b) Comparative Preparation--Procedures similar to those reported in (a) above were used to immerse metal substrates into comparative black treatment and sealing treatment liquids as specified below.
c) List of examples and comparative examples prepared. In accordance with (a) and (b) the following examples and comparative examples were prepared.
__________________________________________________________________________Metal Substrate Number Blackening Treatment Chromate Sealing Treatment__________________________________________________________________________380A A1 C-1 BLACK MAGIC RT-A-3 -- RUST PEL 47-14380A A1 C-2 BLACK MAGIC RT-A-3 -- RUST PEL 51380A A1 C-5 BLACK MAGIC RT-A-3 IRIDITE 5-3 RUST PEL 47-14380A A1 C-6 BLACK MAGIC RT-A-3 IRIDITE 5-3 RUST PEL 51380A A1 C-7 ALUMINA BLACK A 15 -- SATIN-SHIELD 10380A A1 C-8 ALUMINA BLACK A 15 IRIDITE 14-2 SATIN-SHIELD 10380A A1 C-9 ALUMINA BLACK A 15 -- RUST PEL 47-14380A A1 C-10 ALUMINA BLACK A 15 IRIDITE 14-2 RUST PEL 47-14380A A1 C-11 ALUMINA BLACK A 15 -- RUST PEL 51380A A1 C-12 ALUMINA BLACK A 15 IRIDITE 14-2 RUST PEL 51Examples380A A1 3 BLACK MAGIC RT-A3 -- GLOBE SEAL prepared as under (a) above!380A A1 4 BLACK MAGIC RT-A3 IRIDITE 5-3 GLOBE SEAL prepared as under (a) above!Copper 13 BLACK MAGIC RT-A3 -- GLOBE SEAL prepared as under (a) above!Zinc 14 BLACK MAGIC RT-A3 -- GLOBE SEAL prepared as under (a) above!Brass 15 BLACK MAGIC RT-A3 -- GLOBE SEAL prepared as under (a) above!__________________________________________________________________________
ALUMINA BLACK A-15 solution is a dilute aqueous acid solution comprising H 2 SeO 3 , CuSO 4 . 5H 2 O, (NH 4 ) 2 MoO 4 , ZnSO 4 , NaF and water available from Birchwood Chemicals.
IRIDITE 5-3 mixture is a chromic acid mixture available from MacDermid, Waterbury, Conn.
IRIDITE 14-2 mixture is a chromic acid mixture available from MacDermid, Waterbury, Conn. The product contains 30-60% chromic acid; 10-30% barium nitrate, and 10-30% sodium silico-fluoride.
RUST PEL 47-14 mixture is an organic petroleum hydrocarbon available from Hubbard-Hall. It comprises about 86% stoddard solvent CAS 8052-41-3; about 11% barium compound CAS 7440-39-3.
RUST PEL 51 mixture is an organic petroleium hydrocarbon available from Hubbard-Hall. It comprises about 80% stoddard solvent CAS 8052-41-3; 10% barium compound CAS 7440-39-3, dipropylene glycol mono methyl ether and propylene glycol methyl ether.
SATIN-SHIELD 10 emulsion is an aqueous wax/polymer emulsion comprising waxes, styrene/acrylic polymers, amine/fatty acid soap, formaldehyde and water, available from Birchwood Chemicals.
GLOBE SEAL is made in accordance with (a) above and is a mixture of RUST PEL 66ESMP-1 product, SUPER-SHIELD emulsion and water.
d. Efficacy Tests
1. Adherence efficacy and corrosion resistance of the coatings were tested in accordance with Mil-C-5541 and Mil-A-8625 under salt fog and wet tape conditions. Additional tests under 100%-humidity-ambient temperature conditions were also undertaken. Results are shown in Tables 1-3.
TABLE 1______________________________________5% Salt Fog 168 hrs. discoloration 336 hrs. discoloration______________________________________C-1 fail fail -- --C-2* fail fail -- -- 3 pass pass fail fail 4 pass pass pass passC-5 fail fail -- --C-6* pass pass fail failC-7** fail fail -- --C-8** fail fail -- --C-9 fail fail -- --C-10 fail fail -- --C-11* fail fail -- --C-12* fail fail -- --13 pass pass pass pass14 pass pass fail fail15 pass pass pass pass______________________________________
TABLE 2______________________________________WET TAPE TEST dis- dis- dis-24 hrs. coloration 168 hrs. coloration 336 hrs. coloration______________________________________ 3 pass pass pass pass pass pass 4 pass pass pass pass pass passC-6* fail fail -- -- -- --C-7** pass pass fail fail -- --C-8** pass pass fail fail -- --13 pass pass pass pass pass pass14 pass pass pass pass pass pass15 pass pass pass pass pass pass______________________________________
TABLE 3______________________________________100% HUMIDITY @ AMBIENT TEMPERATURE dis- dis- dis-168 hrs. coloration 336 hrs. coloration 500 hrs. coloration______________________________________ 3 pass pass pass pass pass pass 4 pass pass pass pass pass passC-6* fail fail -- -- -- --C-7** pass pass fail fail fail failC-8** pass pass pass pass fail fail13 pass pass pass pass pass pass14 pass pass pass pass pass pass15 pass pass pass pass pass pass______________________________________
2. Bend Tests
The coated substrates were subjected to bend tests wherein coating adhesion was assessed after a coated Al substrate (1"×3"33 3/16") was bent around a mandrel having a radius as specified in the following Table 4.
TABLE 4______________________________________BEND TEST1/2" 1/4" 1/8"radius crack radius crack radius crack______________________________________ 3 pass pass pass 4 pass pass passC-6* fail fail failC-7** fail fail failC-8** pass fail fail13 pass pass pass14 pass ***fail --15 pass pass pass______________________________________
e. Discussion of Efficacy Tests
The above results indicate that the black coatings produced in accordance with the inventive methods consistently pass the Mil-C-5541 and Mil-A-8625 salt and wet tape tests. Additionally, the 100% humidity-ambient temperature tests were also passed by the coatings made in accordance with the invention. This is surprising since many of the conventional black coatings pass the humidity but not the salt tests.
It is to be noted that the steps of contacting the requisite metal parts with treatment solutions may be effected via immersion, rolling, spraying or dipping the metal part into the requisite treatment bath.
Additionally, preliminary tests indicate that the best results are obtained when, prior to application of the antimony-zinc blackening treatment, the parts are subjected to a pre-cleaning step or steps in which for example the parts may be vapor degreased for about 1-3 minutes, then immersed in a mildly alkaline liquid cleaner, such as Hubbard-Hall Inc.'s cleaner P-732 for about 2-5 minutes. This pre-cleaning step may then be followed by a cold water rinse for about 1-3 minutes with the part then being immersed in a caustic etch solution for about 5-20 seconds. Preferably, an pursuant to this pre-cleaning function, the part may be immersed in cold water for about 1-3 minutes followed by immersion in a nitric acid treatment to remove oxides. The metal part may then be double cold water rinsed for about 2-6 minutes prior to immersion in the aforementioned blackening treatment.
The methods in accordance with the invention provide a black, adherent coating over the requisite metal substrate in contrast to many conventional products in which an oily or slippery film is provided. Moreover, none of the process steps, in accordance with the invention include any heat treatment or baking steps. All of the steps of the invention are preferably carried out at room temperature. Accordingly, the need for excessive heating equipment is eliminated.
The coatings in accordance with the invention are very thin on the order of about 0.0001-0.005", preferably 0.0005 in thickness. An oil-free dry to the touch surface is provided in accordance with the invention to which sealants and adhesives will readily adhere.
While this invention has been described with respect to particular embodiments thereof, it is apparent that numerous other forms and modifications of this invention will be obvious to those skilled in the art. The appended claims in this invention generally should be construed to cover all such obvious forms and modifications which are within the true spirit and scope of the present invention.
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A black uniform coating with excellent adhesion, bend flexibility, and corrosion resistant characteristics can be formed on metals such as aluminum and its alloys, zinc and its alloys, and copper and its alloys such as brass, with the deposition of zinc and antimony compounds through a base solution and sealed with a water base sealer. The water based sealer comprises an organic film forming resin, an organic solvent, and emulsifying agents and an alkyd resin.
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This invention relates to a method of preparing improved water-reducible alkyd resins, and products produced thereby.
Alkyd resins are the products obtained by condensation of polybasic, i.e. polycarboxylic, acids with polyols, e.g. phthalic acid and glycerol. Modified alkyd resins are prepared from modified polyols, i.e. the polyols are partially esterified with monobasic acids such as the fatty acids derived from naturally-occurring glycerides before reaction with the polybasic acid. The partial esters are prepared in several different procedures, e.g. alcoholysis of glycerides or direct esterification of polyols. For example, natural triglyceride oils such as soya bean oil are reacted with a polyol to effect alcoholysis of the triglyceride, usually until substantially no further triglyceride is present. The resulting mixture is comprised of partial esters of glycerol and the added polyol. Suitable partial esters of polyols may also be prepared by reaction of monocarboxylic acids with various polyols, e.g. hexanediol, pentaerythritol, glycerol, trimethylolpropane and the like. The monobasic acids in general use are derived from naturally occurring oils such as soya bean oil and linseed oil, and include oleic and linoleic acids. Shorter chainlength comparable acids are also used.
To render the so-produced alkyd resin water-reducible, the resin is then reacted with a polycarboxylic acid, commonly trimellitic acid, which provides free carboxyl groups in the resin. By neutralization of the so-introduced carboxyl groups with suitable bases, the resin is rendered water-reducible in that the resin can be formulated with water for production of water-based alkyd resin coating compositions.
It has now been found that incorporation of certain multifunctional polyol derivatives into the water-reducible alkyd resins improves the properties of the resins, particularly in film-forming compositions, e.g. paints, as evidenced by rapid drying in short time periods and significant improvement in hardness, gloss and drying times of enamels prepared therewith. It has also been discovered that the addition of the multifunctional polyol derivatives to the reaction can be critical in that, when added to the initial alkyd resin reaction mixture, it may lead to gelling of the reaction mixture, or increasing the viscosity of the alkyd resin which adds considerable difficulty in the second stage reaction to impart water solubility. It has been found that addition of the multifunctional polyol just prior to if not simultaneous with the trimellitic acid addition substantially obviates the aforesaid difficulties and permits the reaction to proceed to desired acid numbers (as a measure of free carboxyl groups) and desired high, but workable, viscosities of the final product.
The multifunctional polyol derivatives of the present invention are α,β-ethylenically unsaturated carboxylic acid esters of polyols, the polyols containing at least two hydroxy groups. Exemplary of such acids are acrylic, methacrylic and homologous acids thereof, and the polyols include, for example, ethylene glycol; diethylene glycol; glycerol; 1,3-propanediol; 1,3-butanediol; 1,3,4-butanetriol; 1,4-cyclohexanediol; 1,4-benzenediol; pentaerythritol; dipentaerythritol; tripentaerythritol; trimethylolpropane; trimethylolethane; sorbitol; 1,5-pentanediol; hexanediol; polyethylene glycols (Mol. wt. = 200-1500) and the like. The said polyols are also suitable for the aforesaid preparations of the polyol partial ester starting materials.
The polycarboxylic acid employed in rendering the alkyd resin water-reducible is conveniently trimellitic acid, although various equivalent acids can also be used.
The acid employed in forming the initial alkyd resin is usually phthalic or isophthalic acid, although various equivalent acids can be used, e.g. adipic, succinic, pimelic, and other such dibasic acids. Usually, unsaturated dibasic acids such as maleic and fumaric acid are avoided since their use can lead to gelation of the alkyd resin preparation mixture.
A variety of oils are suitable for the alcoholysis preparation of the partial esters as is known to the art. The most common are, for example, soya bean oil and linseed oil. Any liquid triglyceride, of course, can be employed but the preferred are usually the naturally occurring liquid triglycerides exemplified by soya bean and linseed oils. These same oils can be used as the source of the monobasic acids employed in partial esterification of polyols to form polyol partial ester starting materials.
DESCRIPTION OF PREFERRED EMBODIMENTS
The preferred multifunctional polyol derivatives are acrylic acid or methacrylic acid esters of the selected polyol in which at least two hydroxy groups are esterified. Exemplary preferred compounds include: ethylene glycol diacrylate diethylene glycol diacrylate, glycerol diacrylate, glycerol triacrylate, ethylene dimethacrylate, 1,3-propanediol dimethacrylate, 1,2,4-butanetriol trimethacrylate, 1,4-cyclohexanediol diacrylate, 1,4-benzenediol dimethacrylate, pentaerythritol tri- and tetra- acrylate and methacrylate, dipentaerythritol hexacrylate, tripentaerythritol hexacrylate, tripentaerythritol octaacrylate, trimethylolpropane triacrylate, trimethylolethane triacrylate, sorbitol hexacrylate, 1,3-propanediol diacrylate, 1,5-pentanediol dimethacrylate, hexanediol diacrylate, the bisacrylates and methacrylates of polyethylene glycols of a molecular weight of 200-1500, and the like.
The multifunctional polyol derivatives can be employed at any level to attain the desired result. As little as 0.5% by weight based on the weight of the reaction mixture will provide some beneficial results. Generally, from about 1% to about 10% can be employed for most compositions, although larger amounts can be employed. However, when high levels of the derivative are used, care should be taken to avoid gelation of the reaction mixture. A minimum of experimentation will dictate the optimum effective levels of the polyol derivative in any particular alkyd resin preparation and is within the skill of the art. As is evident, the level at which gelation will occur is dependent upon the number of unsaturated acrylic groups contained in the polyol derivative, as well as the process conditions employed.
For convenience, the initial alkyd resin is prepared in batchwise fashion by condensing the selected polyol with the monocarboxylic acid and polycarboxylic acid in a single reactor. The mixture of starting materials is heated at elevated temperature until the acid number is about 10, and preferably less than 10. Usually, reaction temperatures between about 180 and about 250° C. for time periods of from about 6 to about 12 hours are sufficient. Since water is evolved, the course of the reaction can be monitored by trapping the water evolved. As can be expected, the reaction temperature and time required for any specific mixture will vary depending upon the starting materials. Of course, when low reaction temperature is employed, the time of reaction will be longer than with higher reaction temperature.
After the initial alkyd resin formation is complete, trimellitic acid, preferably in the form of the anhydride, and the multifunctional polyol derivative are added to the mixture and the mixture heated to form the final product. The heating is continued until the acid number of the resin is about 50-60 and preferably until the viscosity is at least at a value of "T" on the Gardner scale. The reaction is also conveniently monitored by measuring the water formed during the course of the reaction. When alkyd resin formation starts, water is given off and continues until the reaction is complete. Thus, the reaction mixture is heated to a temperature where water evolution commences and the reaction is followed by merely collecting the water in a suitable trap. Heating is continued until the acid number (solids) reaches the desired value. For most such reactions, temperatures between about 180° and 220° C. are adequate to provide substantially complete reaction in time periods of from about one to several hours.
The amount of trimellitic anhydride employed in the alkyd resin formation is that normally employed in preparing such products. Generally, at least about 5% by weight based on the total reaction mixture is employed. Usually, about 10% by weight of anhydride is found to produce desired results.
The multifunctional polyol derivative can be added before the anhydride, simultaneous with or even after the anhydride addition. Preferably, the polyol derivative and anhydride are added substantially simultaneously.
The exact mechanism by which the present invention functions is not known, particularly in view of the complexity of the alkyd resin system employed. Apparently, the multifunctional compound is incorporated into the complex structure of the alkyd resin. Regardless of the mechanism, the present invention provides significant improvements in alkyd resin production by incorporation of the present multifunctional polyol derivatives into the final product, the improvements residing in better color characteristics of the alkyd resin product and rapid drying time and improved hardness for coatings prepared therefrom. Films formed with the present new alkyd resins also demonstrate improved resistance to water spotting as well as significantly higher gloss retention on weather exposure.
The final alkyd resin product is made water-reducible by neutralizing with suitable bases to a neutral pH and preferably to slightly alkaline pH. Such neutralization, of course, can be accomplished by the art-recognized procedures commonly used for this purpose. For example, the resin can be treated with ammonium hydroxide, sodium hydroxide, amines, such as triethanolamine and the like.
The neutralized alkyd resin products can be formulated into coating compositions by dilution to any desired solids concentration in water which may contain co-solvents such as glycols and glycol ethers such as monoalkyl ethers of ethylene glycol. There can be added the usual adjuvants such as pigments, e.g. titanium dioxide, aminoplast curing agents, e.g. melamine and urea formaldehyde resins, and drying agents, e.g. cobalt and lead naphthenates or octoates.
When formulated for coating applications, the present new alkyd resins form coatings which set to touch in usually less than 10 minutes and tack-free cure in less than one hour. The fims are of significantly higher hardness than control films.
The following examples further illustrate the invention.
EXAMPLE 1
Alkyd resins are prepared in accordance with the following procedures with results tabulated in Table I.
Procedure A
1. soya fatty acid, trimethylolpropane, isophthalic acid and trimethylolpropane triacrylate are charged into a three neck flask, heated under nitrogen sparge and reacted to an acid number of less than ten.
2. The contents of the flask are cooled to 180° C. and trimellitic anhydride is added. Heat to 190°-200° C. and react to an acid number of 50-60.
3. The resin is cooled to 100° C. and diluted to 50% solids with an 80/20 water/Glycocel * EB solution.
4. Neutralize to a pH of 7 to 8.5 with NH 4 OH. * Glycocel is a registered trademark (Celanese Corporation) Glycocel EB = monobutyl ether of ethylene glycol.
Procedure B
1. soya fatty acid, trimethylolpropane and isophthalic acid are charged into a three neck flask, heated under nitrogen sparge and reacted to an acid number of less than ten.
2. The contents of the flask are cooled to 180° C. and trimethylolpropane triacrylate and trimellitic anhydride are added. Heat to 190°-200° C. and react to an acid number of 50-60.
3. The resin is cooled to 100° C. and diluted to 50% solids with an 80/20 water/Glycocel * EB solution.
4. Neutralize to a pH of 7 to 8.5 with NH 4 OH.
TABLE I__________________________________________________________________________WATER SOLUBLE ALKYDS MODIFIED WITH MULTIFUNCTIONAL MONOMERS__________________________________________________________________________ SAMPLE NO.Components (Weight %) 1 2 3 4 5 6 7 8 9__________________________________________________________________________Soya Fatty Acids 357 357 357 357 357 357 357 357 357Trimethylolpropane 335 335 335 335 335 334.99 334.99 334.99 334.991,6-Hexanediol -- -- -- -- -- -- -- -- --Pentaerythritol (mono) -- -- -- -- -- -- -- -- --Ethylene Glycol -- -- -- -- -- -- -- -- --Isophthalic Acid 299 299 299 299 299 149.40 149.40 149.40 --Adipic Acid -- -- -- -- -- 131.40 131.40 131.40 --Phthalic Anydride -- -- -- -- -- -- -- -- 266.40Trimellitic Anhydride 99 99 99 99 99 98.99 98.99 98.99 98.99Trimethylolpropane Triacrylate 55 22 22 55 -- 53.58 -- 21.43 --Procedure Used A B A B -- B -- B --Viscosity at 50% in 80/20 Water/Glycocel EB Gelled Z-2 Z-6+ Z-4 Z-3 X-3/4 Z-2 Y-1/2 Z-2 SAMPLE NO.COMPONENTS (Weight %) 10 11 12 13 14 15 16 17 18__________________________________________________________________________Soya Fatty Acids 357 357 357 357 357 357 357 357 357Trimethylolpropane 334.99 334.99 -- -- -- -- -- -- 334.991,6-Hexanediol -- -- 442.56 442.56 442.56 -- -- -- --Pentaerythritol (mono) -- -- -- -- -- 127.51 127.51 127.51 --Ethylene Glycol -- -- -- -- -- 116.26 116.26 116.26 --Isophthalic Acid -- -- 298.80 298.80 298.80 298.80 298.80 298.80 --Adipic Acid -- -- -- -- -- -- -- -- --Phthalic Anhydride 266.40 266.40 -- -- -- -- -- -- 266.40Trimellitic Anhydride 98.99 98.99 98.99 98.99 98.99 98.99 98.99 98.99 --Trimethylolpropane Triacrylate 21.45 52.87 -- 23.95 59.87 -- 19.97 44.98 --Procedure Used B B -- B B -- B B ControlViscosity at 50% in 80/20 Water/Glycocel EB Z Z-1 -- -- -- Z-1 Z-1 Y --__________________________________________________________________________
EXAMPLE 2
White gloss paint formulations are prepared as follows:
A TiO 2 paste is made up by thoroughly mixing:
______________________________________TiO.sub.2 60Alkyd, 50% in 80/20 40water/Glycocel EB 100______________________________________
and grinding on a 3-roll mill to a 7-5 fineness. The enamel is prepared by mixing the following:
______________________________________ Weight______________________________________TiO.sub.2 Paste 40.0Alkyd, 50% in 80/20water/Glycocel EB 56.0Water 3.1Manganese salt(6% available manganese) 0.3Cobalt salt(6% available cobalt) 0.6 100.0______________________________________
Pigment/Resin = 24/36 in the enamel formulation. The manganese is present at 0.05% metal based on resin solids, and cobalt at 0.1%.
The alkyd resins prepared in Example 1 are formulated into white gloss paint formulations in accordance with the foregoing and tested. The results are given in Table II.
TABLE II__________________________________________________________________________ SAMPLE NO.PHYSICAL PROPERTIES 2 3 4 5 6 7 8 9__________________________________________________________________________Set to Touch (Minutes) 7 8 7 8 7 8 7 8Tack-Free Cure Before Testing 43 min. 39 min. 34 min. 45 min. Over- Over- Over- 1 hr, night night night 44 min.Tukon Hardness1 day 2.7 2.8 3.0 2.1 1.7 1.4 1.5 1.23 days 5.3 5.6 8.0 3.4 2.9 2.1 2.8 4.75 days 6.6 7.2 9.6 5.2 2.8 2.1 2.7 5.17 days 9.1 9.1 11.4 7.5 3.1 2.2 2.9 6.1Cross Hatch Adhesion (Pass) 100% 100% 100% 100% 100% 100% 100% 100%Conical Mandrel Passed Passed Passed Passed Passed Passed Passed PassedReverse Impact (Pass/Fail) 0/4 0/4 0/4 0/4 144/148 156/160 144/148 16/20Gloss (60%) 94.8 95.2 96.8 93.8 86.4 85.0 89.0 95.0PHYSICAL PROPERTIES 10 11 12 13 14 15 16 17 18__________________________________________________________________________Set to Touch (Minutes) 6 7 Did Not Did Not -- 7 6 7 19 Dry DryTack-Free Cure Before Testing 1 hr, 1 hr, -- -- -- 45 min. 45 min 40 min. Over- 5 min. 5 min. nightTukon Hardness1 day 1.7 2.7 -- -- -- 2.5 2.7 3.0 --3 days 4.9 6.3 -- -- -- 3.9 4.5 4.9 --5 days 5.9 7.2 -- -- -- 4.7 5.0 5.3 --7 days 7.7 8.1 -- -- -- 5.0 5.8 6.1 --Cross Hatch Adhesion (Pass) 100% 100% -- -- -- 100% 100% 100% --Conical Mandrel Passed Passed -- -- -- Passed Passed Passed --Reverse Impact (Pass/Fail) 4/8 8/12 -- -- -- 0/4 0/4 0/4 --Gloss (60°) 95.4 95.4 -- -- -- 94.0 95.4 96.0 --__________________________________________________________________________
EXAMPLE 3
For weathering tests, paint compositions are prepared as in Example 2 with Sample 3, 4 and 5 alkyd resins of Example 1 and tested on various substrates by outdoor exposure (45° South) with the following results after six months:
______________________________________ GlossSample Initial Retained______________________________________3 95.2 6310.sup.4 96.8 615 (conrol) 93.8 39______________________________________
All samples showed comparable excellent resistance to mildew on wood, primed or chalked, and metal substrates.
Water-spotting tests are performed on Samples 3, 4 and 5 as follows. The paint samples are sprayed on steel panels and water applied to the paint surfaces with a medicine dropper after 30 minutes up to 7 hours air dry time. The water is left on the panels for specific periods, then blotted off and the paint surface checked for spotting. The results (Table III) show that the presence of a multifunctional polyol derivative in the alkyd resin improves the stability to water spotting.
TABLE III__________________________________________________________________________WATER SPOTTING RESISTANCE EVALUATION SAMPLES Hours ExposedAir Dry Time To Water 3 4 5 (CONTROL)__________________________________________________________________________30 Minutes 8:00 Definite Definite Denuded Etch Etch1:00 hour 7:00 " " Definite Etch1:15 6:45 " " "1:30 6:30 " " "1:45 6:15 " " "2:00 6:00 " " "2:15 5:45 " " "2:30 5:30 " " "2:45 5:15 " " "3:00 5:00 " Definite " Etch.sup.15:00 3:00 " Slight Etch.sup.2 "7:00 1:00 " Very Slight Slight Etch.sup.2 Etch.sup.224 hours 4 hours.sup.2 Slight Etch Very Slight Slight Etch.sup.2 Etch.sup.2 8 hours Definite Etch Slight Etch.sup.2 Definite Etch.sup.2__________________________________________________________________________ .sup.1 70% Recovery after 24 hours. .sup.2 Complete Recovery after 24 hours.
When the foregoing examples are repeated with linseed fatty acids in place of soya fatty acids, similar results are obtained.
When the procedures of the preceding examples are repeated with the following multifunctional polyol derivatives, similar results are obtained:
1,6-hexanediol diacrylate
tetraethylene glycol diacrylate
trimethylolpropane trimethacrylate
1,6-hexanediol dimethacrylate
Color determinations are carried out using a Gardner Colorimeter (Gardner Laboratory Inc., Bethesda, Md.) and viscosity determinations with a Gardner Viscosimeter (same company).
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Improved water-reducible alkyd resins are made by incorporating α,β-ethylenically unsaturated acid esters of polyols into the final resin product.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to provisional application No. 60/335,222 filed Oct. 31, 2001, the entire contents of which are incorporated herein by reference.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable.
BACKGROUND OF THE INVENTION
[0003] Surgical correction of spinal deformity is one of the fundamental achievements of twentieth century Orthopaedics. A number of mechanical techniques have been invented. These include various braces, such as the Milwaukee Brace of Blount (REF) and a number of surgical procedures ranging from simple bone grafting (Albee, Hibbs, Moe) to the use of posterior metal hardware systems such as Harrington's rods (REFS), and pedicle fixation systems. (REFS) More recently, experts in the field have developed anterior correction and stabilization systems such as Zielke, Dwyer, Zdeblick and Kanada. (REFS)
[0004] The entire field of spinal deformity is complicated, including the classification of disease and the treatment of the conditions. Numerous classification strategies based on pathology have been suggested, such as infantile, adolescent idiopathic, post-traumatic, neoplastic and neuromuscular. (REFS)
[0005] A classification scheme based on the architectural abnormalities is simpler and more useful to those involved in developing hardware fixation systems. This scheme subdivides the deformities into a small number of sub-types based on the plane of deformity, including:
[0006] 1. Sagittal plane deformities,
[0007] 2. Coronal plane deformities, and
[0008] 3. Rotational deformities.
[0009] It must be appreciated that an individual case may possess deformity in more than one plane.
[0010] Curved portions of the spine are sometimes differentiated into two types depending on their flexibility and ease of correction with simple changes in posture. These types are:
[0011] 1) Structural curves, that tend to be stiff—they don't change much with changes in posture, and
[0012] 2) Compensatory curves, that tend to bend back toward normal by changes in posture.
[0013] Structural curves tend to be shorter in length than compensatory curves. Oftentimes, surgeons find that if they can correct the structural curves surgically, the compensatory curves will self-resolve.
[0014] For purposes of description, the spine may be divided into two portions; the anterior portion, consisting of the vertebral bodies and the spinal discs; and the posterior portion, consisting of all bony and ligamentous tissue that is posterior to the posterior aspect of the vertebral bodies.
[0015] Many, if not most forms of spinal deformity result from pathology in the anterior portion of the spine. Posterior fixation devices are less effective than anterior devices in the correction of anterior pathology. (REFS) For that reason, many popular fixation devices are designed for anterior placement. Previous attempts to design anterior devices have been troubled with several problems, limitations, and disadvantages. These include:
[0016] 1. The bulky, exposed metal of anterior devices can irritate and erode delicate visceral tissues such as the aorta, vena cava, the lung and other tissues. In fact, several deaths have resulted from bulky anterior devices used on the anterior surface of the spine. Even newer anterior devices suffer from this limitation; e.g. sturdier, plate-like devices, such as the Yuan device and the Zdeblick Z-Plate should not be applied directly to the anterior aspect of the spine because of the likelihood of aortic erosion (REFS) Ref: Jendrisak MD. Spontaneous abdominal aortic rupture from erosion by a lumbar spine fixation device: A case report. Surgery 1986;99:631-3.
[0017] 2. Smaller, thinner anterior devices, such as the Dwyer and Zielke systems are not capable of correcting and holding rotational deformities. (REFS)
[0018] 3. Large, stiff rod systems such as the Kostuik-Harrington system or the Kanada device and similar systems are difficult to custom fit to the desired degree of bending because the large stiff rods must be permanently deformed before final placement into the body. It is very difficult, if not impossible, to deform the rod to the desired bend without permanently damaging the metal structure of the device.
[0019] While the present invention is useful for posterior application, it is expected that its use would be most commonly performed from the anterior direction. The current invention teaches a novel device that allows the surgeon to correct and stabilize many types of deformities via the anterior column of the spine. The device solves most of the problems listed above. If the stacked rods of this invention were substituted for the single non-round rod of the Spineology K-Centrum® System (U.S. Pat. No. 5,591,235) the resulting system would have the advantages of containment within the external margin of the spinal bones—and therefore the safety afforded by the lack of protrusions into delicate visceral structures—and the advantages of conformability and ease of use to be described in the following device description.
[0020] For many of the reasons outlined below, it is expected that the device will be more versatile, more stable and safer to use than other forms of correction and stabilization.
[0021] Rather than a large rigid single rod, e.g. the Harrington-Kostuik device, or double large rigid rods intentionally separated by a plate, e.g., the Kanada device, or a large rigid plate, e.g., the Z-Plate, this invention utilizes several small diameter, flexible rods. When these rods are stacked closely together and compressed against each other by a tightening means, such as a screw or clamp, the group of rods develops the rigidity of the single larger rods or plates, and therefore can support spinal loads far greater than they would otherwise be capable of. The advantage offered by this invention is the ability to place the flexible rods into position without permanently deforming their structure, i.e. by not deforming them beyond the yield point defined by Young's modulus for the material, (REF) as would be necessary in more bulky rigid devices.
[0022] This allows the surgeon to place the rods with finger forces only, without damaging the structure of the rod. In a later stage of the operation, the surgeon is able to manipulate the stacked rods into the appropriate position and tighten a tightening device associated with the rods, thereby creating a rigid construct, but without the necessity of removing the rods from the construct, bending them on the back table, and then replacing the rod into position in the construct. This capability should reduce operative time, reduce blood loss, and avoid damage and permanent deformity of the rods—and consequent damage to their metallic structure. For these and other reasons, the present device is theoretically easier, faster, safer and more secure than competitive devices.
[0023] The art described in this section is not intended to constitute an admission that any patent, publication or other information referred to herein is “prior art” with respect to this invention, unless specifically designated as such. In addition, this section should not be construed to mean that a search has been made or that no other pertinent information as defined in 37 C.F.R. §1.56(a) exists.
BRIEF SUMMARY OF THE INVENTION
[0024] The invented device comprises four basic components: a bone anchor component, a plurality of rods, a means for attaching the anchors to the rods, and a means for compression or clamping the rods together.
[0025] The bone anchors ensure that the present device is properly secured to the spinal bones. The bone anchors may be slotted screws, staples, bolts, hooks or clamps. In a preferred embodiment, the bone anchors may be large hollow slotted vertebral body anchors such as the K-Centrum® bone anchors.
[0026] The rods comprise at least two moderately flexible rods which run essentially parallel together in a stacked fashion. The rods may be comprised of a variety of materials including: steel, titanium, Nitinol, a composite material such as carbon fibers mixed with a resin or cement, or any other sufficiently strong biocompatible material. In order to fit the human spine, they may be about 0.5 to 3 mm in diameter and their lengths may be sized to fit the length of the curve to be corrected.
[0027] The means of attaching the anchors to the stacked rods may be embodied in a variety of features which may be inherent in the anchor and/or rod construction. For example the anchors may include one or more slots for receiving the rods. Similarly, the rods and/or anchors may include one ore more grooves, projecting loops, or other feature for mutual engagement. Additionally or alternatively, a separate attachment device may be used to attach the rods and anchors such as one or more staples or clamps.
[0028] The means of clamping or otherwise compressing the rods together to form a compressed, multi-rod single unit may be embodied in a variety of elements such as a setscrew in a slot, a gripping jaw, or a circumferential tension band, among others.
[0029] The advantages of this novel system will be immediately apparent to those skilled in the art.
[0030] 1. The system allows the individual rods to be placed in the uncorrected spine without permanent deformation of the metal.
[0031] 2. The spinal deformity can be slowly corrected. Slow correction of the deformity is less traumatic and less likely to damage delicate nerve tissue and blood supply to the spinal cord.
[0032] 3. It is at least theoretically possible to perform the invented procedure using minimally invasive techniques such as laparoscopic or thoracoscopic techniques because the rods can be bent during insertion, allowing positioning of the hardware around delicate internal structures.
[0033] 4. The system is highly adjustable in terms of rotational and bending directions, so the surgeon can make fine adjustments without the necessity of removing the rods and force bending the rods outside of the body, as is the case in almost all competitive system. This feature will decrease the time of operation and safety factor by reducing the likelihood of over-correction or under-correction.
[0034] 5. The system, in the preferred embodiment, using deeply set slotted anchors, when fully installed, is entirely contained within the outer spinal margins. No part of the device is outside of the spine where metal parts are prone to irritate and erode visceral structures such as the aorta, vena cava, or lung or other organ tissues. (The same advantage as the K-Centrum® System).
[0035] 6. Unlike a single rod system, a stacked rod system is less prone to catastrophic failure, i.e., a stress riser leading to failure of a single rod does not immediately propagate to the other rods. In other words, one rod can fail without collapse of the entire construct.
BRIEF DESCRIPTION OF THE DRAWINGS
[0036] A detailed description of the invention is hereafter described with specific reference being made to the drawings in which:
[0037] [0037]FIG. 1 is a top view of an embodiment of the invention as seen implanted into a plurality of vertebral bodies;
[0038] [0038]FIG. 2 is a close up view of a portion of the embodiment shown in FIG. 1;
[0039] [0039]FIG. 3 is a side elevational view showing the stacked rods and bone anchors secured to multiple vertebral bodies with an aligning tool in place;
[0040] [0040]FIG. 4 is an enlarged top view showing bone anchors with stacked rods secured to multiple vertebral bodies with an aligning tool in place;
[0041] [0041]FIG. 5 is a side view of a bone anchor showing the stacked rods as they pass therethrough;
[0042] [0042]FIG. 6 is a side view of an embodiment of the invention wherein securement members are shown disposed about the rods and displaced at varying angles relative to one another; and
[0043] [0043]FIG. 7 is a top view of the embodiment shown in FIG. 6
DETAILED DESCRIPTION OF THE INVENTION
[0044] Correction of spinal deformity involves several sequential or simultaneous actions to reposition the spatial orientation of vertebral elements. In order to accomplish such repositioning, the surgeon must accomplish the following tasks:
[0045] 1. Gain exposure of the anatomy
[0046] 2. Release bony or soft tissue tethering tissues (to allow correction to happen)
[0047] 3. Gain a purchase on the vertebral element (to apply mechanical forces during correction maneuvers
[0048] 4. Apply the correcting forces (shortening, lengthening, bending, or rotation)
[0049] 5. Lock the fixation system to hold the correction.
[0050] In reference to the various figures included herein, a preferred embodiment of the inventive system is shown generally at reference numeral 100 . As may be seen in FIGS. 1 - 4 the inventive device 100 includes a plurality of rods 10 which are positioned within each of the vertebral bodies 12 by an anchor 14 and a rod securement member 16 . The anchor 14 is surgically inserted into each vertebral body 12 .
[0051] The anchors 14 each include a housing 20 which defines a longitudinal slot 22 . The housing 20 may be threaded to permit a rod securement member 16 to be threadingly engaged therein. As may best be seen in FIG. 5, each of the rod securement members 16 defines a horizontal passage or chamber 24 , through which the rods 10 are inserted and retained. As may be seen in FIGS. 1 - 4 , when each of the rod securement members 16 are inserted into the respective housing 22 of each anchor 14 , each horizontal chamber 24 is oriented in a direction corresponding to the longitudinal orientation of the slot 22 . As may be seen in FIGS. 6 and 7, the continuous longitudinal orientation of the horizontal chambers 24 ensures that the rods 10 may be freely inserted within the rod securement members 16 and extend therethrough.
[0052] As may be seen in FIGS. 1 - 4 , the rod securement members 16 also define a second or vertical passage or chamber 26 . The vertical chamber 26 may be threaded for threadingly receipt of a locking screw. As may best be seen in FIG. 2, the vertical chamber 26 intersects the horizontal chamber 24 . As a result, when the rods 10 are positioned within the horizontal chamber, a locking screw 28 , such as may be seen in IG. 5 , may be threadingly inserted into the vertical chamber 26 and advanced such that he screw 28 contacts one or more of the rods 10 . By tightening the screw 28 into the vertical chamber 26 and against the rods 10 , the screw 28 produces sufficient friction to stop relative motion between the rods 10 , thus producing a “composite rod” that behaves as a single solid rod once the screw 24 is tightened and the rods 10 are compressed together, such as is depicted in FIGS. 5 - 7 .
[0053] In FIGS. 6 and 7 a plurality of securement members 16 are shown outside of the vertebral bodies and without anchors. As may be seen, the rods 10 are secured within each of the securement members with respective screws 28 .
[0054] The present invention 100 may be constructed in a wide variety of embodiments and include a plethora of different components other than the precise examples described herein. However, in the various embodiments shown herein the anchors 14 may be comprised of a large, partly hollow, threaded, cylindrical slotted vertebral anchor, such as or similar to, the K-Centrum® System anchors described in U.S. Pat. No. 5,591,235, the entire contents of which being incorporated herein by reference.
[0055] Various means may also be used to manipulate the various elements of the invention described herein. For example, as may be seen in FIGS. 6 and 7, the rod securement members 16 may include surface features such as an engagement slot 30 to which a tool such as a screw driver may be engaged to thread the member 16 into the anchor 14 as previously described. The anchors themselves as well as the screws may likewise be equipped with additional features to aid in their respective manipulation.
[0056] Insertion of the inventive system 100 may be conducted as follows:
[0057] In the case of anterior exposures, the surgeon makes an incision and then moves non-spinal tissues aside. He then performs whatever soft tissue releases are necessary. At that point, the surgeon would insert bone anchors 14 into the involved vertebral bodies 12 and the securement members 16 , at the appropriate entrance points and to the appropriate depth, and at the appropriate angle.
[0058] Next, the surgeon installs several moderately flexible rods 10 to form the stacked rod composite 32 , such as may best be seen in FIG. 2, into the horizontal chambers provided in the securement members 16 . Then, locking screws 28 are loosely placed to hold the rods in place, but not so rigidly held as to prevent movement between the rods and the anchors. Then, the surgeon uses appropriate maneuvers and or tools 34 , such as are depicted in FIGS. 3 and 4 to manipulate the spine into the desired position. For example, he might apply forces to the appropriate anchors 14 to adjust the spatial position of the anchors, and therefore the vertebral bodies, to the corrected position and orientation. Finally, the surgeon fully tightens the locking screws 28 into position, thus producing a great deal of friction between the rods 10 , and thereby forcing the stacked rods to function as if they were a single large rod.
[0059] While this invention may be embodied in many different forms, there are shown in the drawings and described in detail herein specific preferred embodiments of the invention. The present disclosure is an exemplification of the principles of the invention and is not intended to limit the invention to the particular embodiments illustrated.
[0060] This completes the description of the preferred and alternate embodiments of the invention. Those skilled in the art may recognize other equivalents to the specific embodiment described herein which equivalents are intended to be encompassed by the claims attached hereto.
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A spinal fixation system employing bone anchors, several generally parallel rods stacked together and running through each bone anchor, a mechanism for attaching the anchors to the stacked rods and a mechanism for hold the stacked rods together to form a compressed, multi-rod unit.
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CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This application claims the benefit of the German patent application No. 102012210900.5 filed on Jun. 26, 2012, the entire disclosures of which are incorporated herein by way of reference.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to a liquid filter, in particular an oil filter of an internal combustion engine, having a filter housing having a removable screw cover and having a raw liquid inlet and a clean liquid outlet, having a filter insert that is situated exchangeably in the filter housing and that separates a raw side and a clean side of the liquid filter from one another, the filter housing further having a central discharge duct for emptying the filter housing when the filter insert is removed, a closing pin that is fixed to the housing in the installed state and that has at least one radially sealing seal in a sealing seat in the discharge duct being capable of being axially displaced between a lower, closed position, assumed when the filter insert is installed and the screw cover is closed, and an upper, open position, assumed when the screw cover is removed and the filter insert is removed, and mechanical, releasable coupling elements being provided between the screw cover or filter insert on the one hand and the closing pin on the other hand. Moreover, the present invention relates to a filter insert for a liquid filter.
[0003] EP 1 307 274 B1 indicates a liquid filter for cleaning liquids such as lubricant oil, water, or fuel. The liquid filter has a filter housing, a filter element, a supporting body, and a slide valve. In the closed state, the slide valve prevents liquid from being able to flow from the raw side or from the clean side into a liquid discharge duct. As soon as the filter housing is open, the slide valve is moved axially, releasing the liquid discharge duct and making it possible for the filter housing to empty. In this liquid filter, the slide valve is releasably snap-connected to a supporting body that is connected to a housing cover. In this way, the slide valve can be separated from the supporting body. This is advantageous because the separation of the components from one another reduces the level of maintenance required for the liquid filter.
[0004] However, in the known liquid filter it has turned out to be disadvantageous that the connecting means by which the slide valve is snap-connected to the supporting body tends to become damaged, in particular to break, during operation. In this way, parts of the connecting means can move to the clean liquid side of the filter, and from there to downstream components, such as, in the case of an oil filter, an internal combustion engine having points that have to be supplied with lubricant, where damage can occur as a consequence. Moreover, during a filter maintenance the connecting means must be separated from one another manually, in particular by exerting adequate tensile force.
SUMMARY OF THE INVENTION
[0005] Therefore, an object of the present invention is to create a liquid filter of the type named above, as well as a filter insert, in which a secure operation is ensured without the risk of damage to downstream components, and simple handling is ensured during filter maintenance.
[0006] The first part of said object, relating to the liquid filter, is achieved according to the present invention by a liquid filter that is characterized in that
through rotation of the screw cover or filter insert in the fastening direction of rotation of the screw cover, the coupling elements enter into an engagement that transmits a torque and a thrust force, through rotation of the screw cover or filter insert in the release direction of rotation of the screw cover, the coupling elements enter into an engagement that transmits a torque and a tensile force, as least as long as the seal is situated in the sealing seat so as to exert a braking moment on the closing pin, and the coupling elements automatically move out of engagement when the seal moves out of the sealing seat, and as a result the closing pin is freely capable of rotation about its longitudinal axis.
[0010] The present invention advantageously brings it about that the risks of mechanical damage that go along with a snap connection, in particular the breakage of parts of the connecting means, are reliably avoided, because according to the present invention the coupling elements are brought into and out of engagement relative to one another solely through rotation. Mechanical bending stresses of the individual parts of the coupling elements do not occur. In this way, a reliable operation of the liquid filter, safe against damage, is ensured. In addition, a particularly simple handling is achieved, because the coupling elements automatically separate from one another when the screw cover is screwed off and the filter insert is pulled out, as soon as the closing pin has reached its open position. Advantageously, a laborious manual separation of the coupling elements is no longer required.
[0011] In a development of the present invention, it is preferably provided that the coupling elements form a toothing, the teeth of the respective coupling elements pointing in opposite directions in the circumferential direction, and, seen in the circumferential direction, the tooth spacing being in each case greater than the tooth length. The teeth form coupling elements that are on the one hand simple and on the other hand are capable of being loaded. Through the indicated ratio of tooth spacing to tooth length, the teeth on the one side can in each case be axially guided between the teeth of the other side, practically free of forces, and can then be brought into engagement by rotation relative to one another. Conversely, the engagement of the coupling elements can be very easily released by rotation in the opposite direction and axial pulling apart.
[0012] In a further specification of the present invention, it is proposed that, regarded in the radial direction, the teeth each have asymmetrical tooth edges, the respectively cooperating tooth edges running at a first angle oblique to the circumferential direction, and the respective other tooth edges running at a second, smaller angle to the circumferential direction, and the backs of the teeth running in the axial direction. Due to the fact that the cooperating tooth edges run at an angle oblique to the circumferential direction, it is achieved that for the one direction of rotation the coupling elements move into engagement as long as a braking moment is exerted on the closing pin, and the coupling elements automatically move out of engagement as soon as the closing pin is capable of rotating freely, because then, as a result of the action of gravity, the teeth of the closing pin automatically slide over the obliquely running contact surfaces along the other teeth cooperating therewith.
[0013] In order to ensure the mentioned sliding of the teeth of the cooperating coupling elements, it is preferably provided that the first angle is between 30° and 60°.
[0014] The second, smaller angle is preferably equal to or greater than the thread pitch of the screw cover. In this way, it is ensured that when the liquid filter is assembled, an axial twisting and seizing is avoided, which otherwise could occur if the edges of the first teeth, pointing in the axial direction, were to impinge on the edges, pointing in the opposite axial direction, of the other teeth.
[0015] In a further embodiment, it is preferably provided that the teeth of the toothings each protrude to diameters that are identical at least in some regions, on the one hand axially downward or radially outward or inward from the screw cover or from the filter insert, and on the other hand correspondingly protrude axially upward or radially inward or outward from the closing pin. The concrete choice of the configuration of the teeth will be made in particular according to the particular space conditions, according to which one configuration or another may be more advantageous.
[0016] In a preferred development of the present invention, it is provided that the closing pin is equipped with flexible holding elements that, in the open position of the closing pin, are expanded and hold the closing pin in the discharge duct in the axial direction, and that, when the closing pin goes from its open position into its closed position and vice versa, are capable of being temporarily compressed, then entering into a frictional fit with the filter housing and, in the closing position of the closing pin, again expanding. The flexible holding elements perform two advantageous functions. The one function is to hold the closing pin axially in its opening position, in which its coupling elements are separated from the coupling elements of the filter insert or screw cover, and to ensure an unhindered discharge of liquid. The second function is to exert a braking moment on the closing pin, also after its seal or seals have been removed from their associated seal seats, in order to bring about a further lifting of the closing pin when the screw cover is screwed off from the housing, and to bring the closing pin to a height relative to the filter housing such that the seal or seals of the closing pin have an axial distance from the associated sealing seat or seats that is adequate and that ensures a disturbance-free flow of liquid. The closing pin becomes capable of rotating freely about its longitudinal axis, and can thus automatically be separated from the screw cover or filter insert, only when the flexible holding elements lose their frictional fit to the filter housing in the fully open position of the closing pin.
[0017] In order to achieve a compact construction with as few components as possible, it is preferably provided that the filter insert has a central supporting body, and that the coupling elements at the filter insert side are situated at the lower end of the supporting body. In this embodiment, the supporting body is part of the filter insert, and is exchanged along with the filter insert during filter maintenance.
[0018] In an alternative embodiment of the liquid filter, it is provided that the closing pin is permanently connected to, or made in one piece with, a supporting body for the filter material body of the filter insert, and that the coupling elements are situated on the one side on the screw cover and on the other side at the top of the supporting body. In this embodiment, the supporting body is a component that remains permanently in the filter housing.
[0019] A further embodiment of the liquid filter according to the present invention provides that a filter bypass valve is situated in the screw cover, connected fixedly thereto, and that second mechanical releasable coupling elements are provided between the filter bypass valve or screw cover on the one hand and the filter insert, in particular a support body situated therein, on the other hand. Thus, here a double configuration of cooperating coupling elements is provided in order on the one hand to connect the screw cover and the filter insert to one another and to separate them from one another, and on the other hand to connect the filter insert and the connecting pin to one another and to separate them from one another, in a simple manner as needed in each case.
[0020] According to the present invention, it is preferably provided that through rotation of the screw cover in its fastening direction of rotation, the second coupling elements enter into an engagement that transmits a torque and a thrust force, and through rotation of the screw cover in its release direction of rotation, the second coupling elements enter into an engagement that transmits a torque and a tensile force. Thus, the connection and separation of the second coupling elements as well is also kept very simple.
[0021] In a further embodiment, it is proposed that the second coupling elements form a toothing, the teeth of the respective coupling elements pointing in opposite directions in the circumferential direction, and, seen in the circumferential direction, the tooth spacing being greater in each case than the tooth length. Through the indicated ratio of tooth spacing to tooth length, in the second coupling elements as well the teeth of the one side can be respectively introduced between the teeth of the other side axially, practically without forces, and then brought into engagement through rotation relative to one another. Conversely, the engagement of the second coupling elements can likewise be separated very easily through rotation in the opposite direction and axial pulling apart.
[0022] Differing from the first coupling elements, in the operation of the liquid filter during a maintenance it is advantageous that the filter insert and the screw cover do not automatically detach from one another. For this purpose, the present invention proposes that, seen in the radial direction, the teeth of the second coupling elements each have asymmetrical tooth edges, the respectively cooperating tooth edges running essentially in the circumferential direction, and the respectively other tooth edges running at an angle to the circumferential direction, and the backs of the teeth running in the axial direction. The orientation of the respectively cooperating tooth edges essentially in the circumferential direction excludes a sliding of the teeth of the one side on the teeth of the other side, so that here an undesirable automatic separation of the coupling elements when the screw cover is screwed off is avoided.
[0023] Here as well, the angle of the respectively other tooth edges is equal to or greater than the thread pitch of the screw cover, in order to avoid axial twisting or seizing if, when the filter insert and screw cover are brought together, the end surfaces of the teeth pointing toward one another in the axial direction accidentally move into a position opposite one another.
[0024] In order to prevent the above-mentioned undesired automatic separation of the screw cover and filter insert even more reliably, the second coupling elements are usefully simultaneously fashioned as snap elements acting in the circumferential direction, whose snap moment is less than a braking moment of the closing pin situated in the closing position. When the screw cover is screwed tight, the first and second coupling elements move out of engagement with regard to the transmission of axial tensile force. When the direction of rotation of the screw cover is reversed, i.e. it is unscrewed, first the second coupling elements, and only after this the first coupling elements, move out of engagement, whereby the above-described desired functional sequence in the maintenance of the filter is ensured.
[0025] In order on the one hand to securely accept the forces that are to be transmitted, in particular the axial tensile forces, and to be able to distribute them advantageously, and on the other hand to keep the shaping and production of the parts of the filter insert simple, it is preferably provided that the toothings of the coupling elements each have from two to six, preferably in each case four, teeth distributed around the circumference.
[0026] In addition, the present invention relates to a filter insert for a liquid filter, in particular for an oil filter of an internal combustion engine, the filter insert being capable of being installed exchangeably in a filter housing having a removable screw cover and having a raw liquid inlet and a clean liquid outlet, and in the installed state the filter insert separating a raw side and a clean side of the liquid filter from one another, and there being provided on the filter insert mechanical, releasable coupling elements for connecting to coupling elements on a closing pin that is fixed to the filter housing in the installed state, the closing pin being situated in a central discharge duct of the filter housing and being provided with at least one radially sealing seal in a sealing seat in the discharge duct, and the closing pin being capable of axial displacement between a lower closing position, assumed when the filter insert is installed and the screw cover is closed, and an upper position, assumed when the screw cover is removed and the filter insert is removed, for emptying the filter housing when the filter insert is removed.
[0027] In order to achieve the second part of the object, relating to the filter insert, a filter insert is proposed that is characterized in that
through rotation of the screw cover and/or filter insert in the fastening direction of rotation of the screw cover, the coupling elements of the filter insert can be brought into an engagement with the coupling elements of the closing pin that transmits a torque and a thrust force, through rotation of the screw cover or filter insert in the release direction of rotation of the screw cover, the coupling elements of the filter insert can be brought into an engagement with the coupling elements of the closing pin that transmits a torque and a tensile force, as long as the seal is situated in the sealing seat so as to exert a braking moment on the closing pin, and the coupling elements can be automatically brought out of engagement with the coupling elements of the closing pin when the seal moves out of the sealing seat, and as a result the closing pin is freely capable of rotation about its longitudinal axis.
[0031] The filter insert according to the present invention achieves the advantage is already described above in connection with the liquid filter.
[0032] Advantageous embodiments and developments of the filter insert according to the present invention are indicated in claims 18 through 30 . With regard to the advantages that can be achieved with these embodiments of the filter insert, reference is made to the corresponding parts of the description of the liquid filter.
BRIEF DESCRIPTION OF THE DRAWINGS
[0033] In the following, exemplary embodiments of the present invention are explained on the basis of a drawing.
[0034] FIGS. 1 through 23 show a first exemplary embodiment of a liquid filter in various representations and in various operating states, and
[0035] FIGS. 24 through 32 show a second exemplary embodiment of the liquid filter, also in various representations and in various operating states.
[0036] In the following description of the Figures, identical parts are always designated by the same reference characters in the various Figures, so that it is not necessary to explain each reference character anew in each Figure. The signification of the individual reference characters is also indicated in the list of reference characters provided below.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0037] FIG. 1 shows, in longitudinal section, a liquid filter 1 having a filter housing 10 , a filter insert 2 situated exchangeably therein, and a screw cover 11 . In filter housing 10 there runs a central discharge duct 13 that is used to empty filter housing 10 when there is a change of filter insert 2 . In normal operation, discharge duct 13 is closed by a closing pin 3 having two seals 33 . 1 and 33 . 2 situated at the lower end of the pin, the seals being situated axially at a distance from one another and having different diameters, and the seals each cooperating in radially sealing fashion with a duct segment 13 . 1 and 13 . 2 . To open discharge duct 13 , closing pin 3 is capable of being moved upward in its axial direction when filter insert 2 is exchanged.
[0038] Filter insert 2 is made up of a filter material body 20 enclosed at its lower side by an end disk 21 and at its upper side by an end disc 22 . A supporting body 23 in the form of a lattice is situated inside filter insert 2 .
[0039] At the upper end of closing pin 3 , first coupling elements 34 are integrally formed on, which cooperate with first coupling elements 24 on the lower end of supporting body 23 , and can enter into and out of engagement therewith.
[0040] Further, second coupling elements are provided further above in liquid filter 1 , namely second coupling elements 25 at the upper end of supporting body 23 , and associated second coupling elements 45 on a valve housing 40 of a filter bypass valve 4 that is fixed to the cover. Inside valve housing 40 , a valve body 41 , pre-loaded by a spring 42 , is guided so as to be capable of axial displacement relative to a valve seat.
[0041] In the assembled state of liquid filter 1 shown in FIG. 1 , filter insert 2 is placed from above, with its lower end disk 21 and central mounting opening 21 ′ provided therein at the front, onto an upper part of closing pin 3 , which there forms a guide segment 30 . On its inner circumference, lower end disk 21 is placed in sealing fashion onto a central pipe support that forms a part of filter housing 10 .
[0042] FIG. 2 shows the upper part of liquid filter 1 according to FIG. 1 in an enlarged longitudinal section. On the upper end of support body 23 , second coupling elements 25 thereof are integrally formed on, as teeth 6 pointing in the circumferential direction. On valve housing 40 , teeth 6 ′ are integrally formed on as second coupling elements 45 oriented in the opposite direction. Teeth 6 and 6 ′ cooperate with one another in the manner of a bayonet closure. Respectively cooperating tooth edges 61 and 61 ′ run essentially in the circumferential direction. The respectively other tooth edges 62 and 62 ′ run at an angle oblique to the circumferential direction, the angle being equal to or greater than the pitch of the screw threading 12 between cover 11 and filter housing 10 . In this way, a seizing of coupling elements 25 and 45 is avoided. Tooth backs 63 and 63 ′ each run in the axial direction, and lie against one another in the state shown in FIG. 2 . This state results when screw cover 11 is rotated in its fastening direction of rotation. In this state, a torque can be transmitted by screw cover 11 to supporting body 23 , but not an axial tensile force.
[0043] FIG. 3 shows an enlarged sectional view of a region of liquid filter 1 , in which first coupling elements 24 and 34 are situated. First coupling elements 24 and 34 are realized in the form of teeth 5 , 5 ′ having asymmetrical tooth edges. Upper tooth edges 51 of teeth 5 , which form first coupling elements 24 , run at an angle of approximately 45° to the circumferential direction. Correspondingly, lower tooth edges 50 ′, of teeth 5 ′ forming coupling elements 34 , run at the same angle oblique to the circumferential direction. Lower tooth edges 52 of teeth 5 , and upper tooth edges 52 ′ of teeth 5 ′, run at a slightly oblique angle to the circumferential direction, this angle being equal to or greater than the pitch angle of screw threading 12 . In the state shown in FIG. 3 , which results when screw cover 11 is rotated in the fastening direction of rotation, tooth backs 53 and 53 ′ of teeth 5 and 5 ′ lie against one another, whereby a torque can be transmitted in the fastening direction of rotation of screw cover 11 and an axial thrust force can be transmitted, but not an axial tensile force.
[0044] FIG. 4 shows liquid filter 1 in a state that results when screw cover 11 is rotated by a certain angle in the release direction of rotation. In this way, both first coupling elements 24 and 34 and also second coupling elements 25 and 45 enter into an engagement with one another that transmits an axial tensile force.
[0045] For second coupling elements 25 and 45 , this state of engagement, in which axial tensile forces can be transmitted, is shown in FIG. 5 .
[0046] FIG. 6 shows how first coupling elements 24 and 34 enter into their engagement that transmits an axial tensile force.
[0047] FIG. 7 shows detail V1 from FIG. 4 . Here, it can be seen clearly that in this state holding elements 31 on guide segment 30 of closing pin 3 are situated in a circumferential groove of filter housing 10 , whereby guide segment 30 is relieved of stress.
[0048] FIG. 8 shows the state of liquid filter 1 after a further releasing rotation of screw cover 11 . During the movement of screw cover 11 upward, both supporting body 23 and closing pin 3 are carried along upward by first coupling elements 24 and 34 and second coupling elements 25 and 45 , which are engaged with one another. Here, holding elements 31 move into a region of filter housing 10 that does not have a groove, whereby guide segment 30 is placed under tension by holding elements 31 , and experiences a braking moment relative to filter housing 10 .
[0049] FIG. 9 shows an enlarged view of detail Z1 from FIG. 8 . Here, the warping of guide segment 30 can be seen, because holding element 31 is situated above the groove of filter housing 10 that first receives this element, resulting in friction.
[0050] FIG. 10 shows the position of the lower end of closing pin 3 in discharge duct 13 . Seals 33 . 1 and 33 . 2 are just leaving their sealing seat, so that a friction previously produced by seals 33 . 1 and 33 . 2 is ceasing. In the present example, this friction is replaced by the friction of holding elements 31 on filter housing 10 .
[0051] FIG. 11 shows liquid filter 1 after still further rotation of screw cover 11 out of filter housing 10 . In this way, closing pin 3 is lifted far enough that its holding elements 31 have now moved into a second, upper groove in filter housing 10 , so that now guide segment 30 of closing pin 3 is again relieved of stress, and no braking moment is exerted on closing pin 3 . Thus, closing pin 3 is now capable of rotating freely about its longitudinal center axis.
[0052] FIG. 12 shows detail X1 from FIG. 11 , in an enlarged view. Here, it can be seen how holding element 31 of guide segment 30 is situated free of tension in the upper groove of filter housing 10 .
[0053] Because closing pin 3 is now capable of rotating freely in the circumferential direction, gravity causes coupling elements 24 and 34 to automatically detach from one another, because automatic sliding over oblique tooth edges 51 and 51 ′ takes place. Thus, the unit made up of screw cover 11 , filter insert 2 , and supporting body 23 on the one hand is then separated from the rest of the liquid filter on the other hand.
[0054] After removing screw cover 11 and filter insert 2 , the state shown in FIG. 13 results. Closing pin 3 is held axially in its raised position by its holding elements 31 , so that discharge duct 13 now remains open.
[0055] FIG. 14 shows detail W1 from FIG. 13 , again in an enlarged view.
[0056] FIGS. 15 through 17 illustrate the assembly of liquid filter 1 after a maintenance session, second coupling elements 25 and 45 according to FIG. 15 and first coupling elements 24 and 34 according to FIGS. 16 and 17 gradually moving into an engagement that transmits a torque and an axial thrust force, but that does not transmit an axial tensile force.
[0057] FIG. 18 shows a unit made up of screw cover 11 and filter insert 2 with support body 23 . Support body 23 is brought, by second coupling elements 21 , into an engagement with second coupling elements 45 on valve housing 40 that transmits a torque and an axial thrust force, this engagement resulting when screw cover 11 is rotated in its fastening direction of rotation. First coupling elements 24 are visible at the lower end of support body 23 .
[0058] FIG. 19 shows screw cover 11 with filter bypass valve 4 fixed thereon on the one hand, and filter insert 2 with support body 23 situated therein on the other hand, as separated individual parts. Second coupling elements 45 are situated on the outer circumference of valve housing 40 . On the upper end of support body 23 second coupling elements 25 are visible, and on the lower end of support body 23 first coupling elements 24 are visible.
[0059] In FIG. 20 , filter insert 2 , together with support body 23 , is placed into screw cover 11 , and via second coupling elements 25 and 45 the two parts are now connected to one another for common attachment to filter housing 10 .
[0060] FIG. 21 shows a view of closing pin 3 as an individual part, on which first coupling elements 34 are visible at the top. In a lower region of guide segment 30 , lug-shaped holding elements 31 are situated. At the bottom, closing pin 3 is realized having two grooves at an axial distance from one another, for accommodating the sealing rings (not shown here).
[0061] FIG. 22 shows a view of supporting body 23 as an individual part, having first coupling elements 24 at the bottom and having second coupling elements 25 at the top.
[0062] FIG. 23 shows valve housing 40 on which second coupling elements 45 are situated.
[0063] FIGS. 24 through 32 show a second exemplary embodiment of liquid filter 1 according to the present invention. The second exemplary embodiment differs from the first exemplary embodiment in that now closing pin 3 is realized in one piece with supporting body 23 , whereby supporting body 23 becomes a component permanently remaining in filter housing 10 , and is no longer part of exchangeable filter insert 2 .
[0064] Due to the uniting of closing pin 3 and support body 23 to form a one-piece component, now only one pair of cooperating coupling elements 24 and 44 is further required, which here are situated on the one hand on the upper end of support body 23 and on the other hand on valve housing 40 .
[0065] In the rest of its construction and in its further functions, liquid filter 1 agrees with the exemplary embodiment already explained above, to whose description reference is made.
[0066] According to FIGS. 25 and 26 , in the second exemplary embodiment it is also the case that coupling elements 24 can be integrally formed on the underside of upper end disk 22 of filter insert 2 , and coupling elements 34 can be integrally formed on the upper end of support body 23 . Upper end disk 23 of filter insert 2 is here connected with a clamping seating to valve housing 40 , by being inserted on. Coupling elements 24 and 34 correspond, in their design and function, to first coupling elements explained in relation to the first exemplary embodiment; therefore, when screw cover 11 is screwed tight, these coupling elements enter into an engagement that transmits a torque and an axial thrust force, and when screw cover 11 is unscrewed, they enter into an engagement that transmits a torque and an axial tensile force, as long as a braking moment is exerted on closing pin 3 by its seals 33 . 1 and 33 . 2 in discharge duct 13 , and/or by holding elements 31 in filter housing 10 ; as soon as the brake moment acting on closing pin 3 ceases, because closing pin 3 has reached its maximum height upward in the direction in which it is pulled, coupling elements 24 and 34 automatically separate from one another as described above.
[0067] These functions, and the cooperation of the various coupling elements 24 , 34 , and 44 in the second exemplary embodiment, are further illustrated in the further FIGS. 28 through 32 , in various operating states in further sectional representations, and, in FIG. 32 , in a view of closing pin 3 and upper end disk 22 .
[0068] As is apparent from the foregoing specification, the invention is susceptible of being embodied with various alterations and modifications which may differ particularly from those that have been described in the preceding specification and description. It should be understood that I wish to embody within the scope of the patent warranted hereon all such modifications as reasonably and properly come within the scope of my contribution to the art.
LIST OF REFERENCE CHARACTERS
[0000]
1 liquid filter overall
10 filter housing
11 screw cover
12 screw threading
13 discharge duct
13 . 1 , 13 . 2 segments of 13
2 filter insert
20 filter material body
21 lower end disk
21 ′ central mounting opening in 21
22 upper end disk
23 support body in 20
24 first coupling elements on 2
25 second coupling elements on 2
3 connecting pin
30 guide segment in 13
31 holding elements
33 . 1 , 33 . 2 seal(s) on 3
34 first coupling elements on 3
4 filter bypass valve
40 valve housing
41 valve body
42 valve spring
44 first coupling elements on 4
45 second coupling elements on 4
5 , 5 ′ teeth of 24 , 34
51 , 51 ′ oblique tooth edges
52 , 52 ′ tooth edges in the circumferential direction
53 , 53 ′ tooth backs
6 teeth of 25 , 45
61 , 61 ′ first tooth edges in circumferential direction
62 , 62 ′ second tooth edges in circumferential direction
63 , 63 ′ tooth backs
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A liquid filter having a housing with a removable screw lid and an interchangeable filter unit, the housing having a discharge channel, wherein a closure valve which when installed is fixed to the housing, is axially adjustable between a closed position when the filter unit is installed and the lid is closed, and an open position when the lid is detached and the filter unit is removed, and wherein releasable coupling elements are provided between the lid or filter unit and the valve. The coupling elements engage to transmit torque and tensile forces, by rotation in the loosening direction of the lid, for as long as a seal of the valve which exerts a braking moment on the valve is located in the sealing seat. The coupling elements disengage when the seal has departed from the sealing seat and the valve is thereby freely rotatable about its longitudinal axis.
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TECHNICAL FIELD
[0001] The present invention relates to an absorbent article including a nonwoven fabric sheet for an absorbent body, and to a method for producing a nonwoven fabric sheet to be used in the absorbent article.
BACKGROUND ART
[0002] Absorbent articles, such as disposable diapers, sanitary napkins and panty liners, are generally composed of a liquid-permeable front sheet, a liquid-impermeable back sheet and an absorbent body situated between the front sheet and the back sheet, and in particular, a core wrap covering super-absorbent polymer particles inside the absorbent body must have functions of reliably hold the super-absorbent polymer particles both when dry and when wet, and of rapidly diffusing body fluids such as urine or blood that have reached the absorbent article, over a wide area of the absorbent body, and rapidly absorbing the body fluids into the super-absorbent polymer particles.
[0003] For example, PTL 1 discloses an essentially longitudinal absorbent article having a liquid-permeable surface, a liquid-retaining absorbent body and a liquid-impermeable leak-resistant, the absorbent body having a diffusible absorption sheet and an absorption retaining sheet situated more to the back side than the diffusible absorption sheet, wherein (a) the diffusible absorption sheet comprises a sheet having a hydrophilicity (cos θ) of 0.5 to 1 and a Klemm water absorption rate of 40 [mm/min]or greater in the lengthwise direction, and (b) the absorption retaining sheet comprises a sheet made of fiber aggregates with a capillary osmotic pressure of 4000 to 15,000 [dyn/cm 2 ], which is a laminated sheet obtained by using a super-absorbent polymer having an absorption of 40 to 70 [g/g] for physiological saline and an absorption rate of 2 [ml/(0.3 g polymer·min)] or greater for the same, to sandwich the fiber aggregates at 10 to 100 wt % (see claim 1 , etc.).
CITATION LIST
Patent Literature
[0004] [PTL 1] Japanese Unexamined Patent Publication No. 4-89053
SUMMARY OF THE INVENTION
Technical Problem
[0005] In the absorbent article disclosed in PTL 1, in order to maintain its strength, the diffusible absorption sheet of the absorbent body is formed by either bonding the fibers using polyvinyl alcohol or the like as the binder, or by fusing the fibers together by a spunbond method, and therefore the fluid diffusibility is sometimes impeded by the bonded sections or fused sections.
[0006] It is therefore an object of the present invention to provide an absorbent article including a nonwoven fabric sheet for an absorbent body having excellent fluid diffusibility, without using strengthening means by post-coating of an adhesive which can impede fluid diffusibility, as well as a method for producing a nonwoven fabric sheet for an absorbent body to be used in the absorbent article.
Solution to Problem
[0007] The absorbent article of the present invention is an absorbent article including a liquid-permeable front sheet, a liquid-impermeable back sheet, an absorbent body situated between the front sheet and the back sheet, and a nonwoven fabric sheet for the absorbent body, wherein the nonwoven fabric sheet includes a pulp fiber layer that includes pulp and has a first surface and a second surface, a first surface side fiber layer situated on the first surface side of the pulp fiber layer and including mainly hydrophilic fibers with a mean fiber length of 25 mm to 64 mm, and a second surface side fiber layer situated on the second surface side of the pulp fiber layer and including mainly hydrophilic fibers with a mean fiber length of 25 mm to 64 mm.
[0008] According to the absorbent article of the present invention, the nonwoven fabric sheet for the absorbent body comprising 3 or more layers including a pulp fiber layer, a first surface side fiber layer and a second surface side fiber layer is formed by tangling the fibers together by a high-pressure stream jet without using strengthening means by post-coating of an adhesive or the like, which can impede fluid diffusibility, and therefore fluids such as body fluids can be widely and rapidly diffused in an in-plane direction of the nonwoven fabric sheet by utilizing capillary action of the fiber aggregates forming the first surface side fiber layer and the second surface side fiber layer. In addition, since the first surface side fiber layer and second surface side fiber layer are situated on both surface sides of the pulp fiber layer, fluid that has diffused in the in-plane direction of the first surface side fiber layer and second surface side fiber layer can be absorbed from both sides of the pulp fiber layer, allowing the water capacity of the nonwoven fabric sheet to be drastically increased while also allowing long-lasting fluid diffusion to be achieved in the in-plane direction of the nonwoven fabric sheet.
Advantageous Effects of Invention
[0009] According to the present invention it is possible to provide an absorbent article including a nonwoven fabric sheet for an absorbent body having excellent fluid diffusibility, and a method for producing a nonwoven fabric sheet for an absorbent body to be used in the absorbent article.
BRIEF DESCRIPTION OF DRAWINGS
[0010] FIG. 1 is a perspective view (schematic view) of a disposable diaper as an embodiment of the absorbent article of the present invention.
[0011] FIG. 2 is a plan view of the disposable diaper of FIG. 1 in the deployed state.
[0012] FIG. 3 is a cross-sectional view in the widthwise direction along line III-III′ of FIG. 2 .
[0013] FIG. 4 is a cross-sectional view (schematic view) of a nonwoven fabric sheet according to an embodiment of the present invention.
DESCRIPTION OF EMBODIMENTS
[0014] Preferred embodiments of the absorbent article of the present invention will now be described in detail with reference to the accompanying drawings.
[0015] FIG. 1 is a perspective view (schematic view) of a disposable diaper as an embodiment of the absorbent article of the present invention, and FIG. 2 is a plan view of the disposable diaper of FIG. 1 in the deployed state. As shown in FIG. 1 and FIG. 2 , the disposable diaper 1 as an embodiment of the present invention has a front section 11 which is contacted with the abdominal region of the wearer, a middle section 12 which is contacted with the crotch region of the wearer, and a back section 13 which is contacted with the gluteal region and/or back region of the wearer. As shown in FIG. 1 , both edges 111 a , 111 b of the front section 11 and both edges 131 a , 131 b of the back section 13 are joined together at the joining sections 14 a , 14 b , whereby a waist opening is formed by the edge 112 of the front section 11 and the edge 132 of the back section 13 and leg openings are formed by both edges 121 a , 121 b of the middle section 12 , the disposable diaper 1 having a pants-type shape.
[0016] As shown in FIG. 1 and FIG. 2 , the disposable diaper 1 comprises a front sheet 2 made of a liquid-permeable nonwoven fabric sheet, plastic film or the like, a back sheet 3 made of a liquid-impermeable polyethylene film or the like, an absorbent body 4 provided between the front sheet 2 and the back sheet 3 , a liquid-impermeable cover sheet 5 , and elastic members 61 , 62 , 63 , 64 . The cover sheet 5 provided on the skin side surface of the front sheet 2 has an opening 51 formed at approximately the center, a portion of the front sheet 2 (the portion of the region where the absorbent body 4 is situated) being exposed from the opening 51 of the cover sheet 5 and, together with the cover sheet 5 , forming the skin side surface of the disposable diaper 1 .
[0017] Also, as shown in FIG. 1 and FIG. 2 , elastic members 61 , 62 , 63 , 64 are provided between the back sheet 3 and the cover sheet 5 , which have hourglass shapes of approximately equal dimensions. Elastic contractive force of the elastic members 61 , 62 causes formation of waist gathers at the waist opening, and elastic contractive force of the elastic members 63 , 64 causes formation of leg gathers (leg side cuffs) at the leg openings. The leg gathers can prevent leakage of excreta from the leg openings. Throughout the present description, the widthwise direction X is the widthwise direction of the disposable diaper 1 (absorbent article) in the deployed state in a plane view (the short direction), and the lengthwise direction Y is the lengthwise direction of the disposable diaper 1 (absorbent article) in the deployed state in a plane view (the front-back direction of the wearer), the widthwise direction X and lengthwise direction Y being mutually orthogonal in a plane view.
[0018] An absorbent body to be used in a disposable diaper (absorbent article) according to an embodiment of the present invention, and a nonwoven fabric sheet for the absorbent body, will now be described in detail. FIG. 3 is a cross-sectional view in the widthwise direction along line III-III′ of FIG. 2 . As shown in FIG. 3 , the absorbent body 4 of this embodiment includes an absorbent core 7 made of a water-absorbing material, a nonwoven fabric sheet 8 for an absorbent body situated on the back sheet 3 side of the absorbent core 7 , and a core wrap (not shown) that encloses the absorbent core 7 and the nonwoven fabric sheet 8 . According to the present invention, the nonwoven fabric sheet may be situated in the sheet of the core wrap enclosing the absorbent core, or it may be situated in contact with the core wrap on the outer side of the core wrap; however, situating the nonwoven fabric sheet in the sheet of the core wrap enclosing the absorbent core is advantageous for absorption and diffusion of fluids such as body fluids, and therefore the nonwoven fabric sheet is preferably situated in the sheet of the core wrap enclosing the absorbent core. Throughout the present description, “for the absorbent body” means, in an absorbent body including an absorbent core and a core wrap enclosing the absorbent core, for placement in contact with the absorbent core, or for placement in contact with the core wrap on the outer side of the core wrap. Also according to the present invention, in order to further improve the diffusibility of fluids such as body fluids passing through the front sheet, the nonwoven fabric sheet or a fluid diffusing sheet different from the nonwoven fabric sheet may also be situated on the front sheet side of the absorbent core.
[0019] The absorbent core is not particularly restricted, and for example, one may be used that has a super-absorbent polymer dispersed and held in fiber aggregates of fluff pulp or a nonwoven fabric. The super-absorbent polymer has a three-dimensional network structure with appropriate crosslinking of a water-soluble polymer, and it can absorb water at up to 20 or more times its own weight. Examples of such super-absorbent polymers include starch-based polymers, crosslinked carboxymethylated cellulose, acrylic acid-based polymers including polymers or copolymers of acrylic acid or alkali metal salt acrylates, and amino acid-based polymers.
[0020] According to the present invention, the nonwoven fabric sheet for an absorbent body is constructed with 3 or more layers including a pulp fiber layer that includes pulp and has a first surface and a second surface, a first surface side fiber layer situated on the first surface side of the pulp fiber layer and including mainly hydrophilic fibers with a mean fiber length of 25 mm to 64 mm, and a second surface side fiber layer situated on the second surface side of the pulp fiber layer and including mainly hydrophilic fibers with a mean fiber length of 25 mm to 64 mm.
[0021] According to the present invention, the phrase “including mainly hydrophilic fibers” means including hydrophilic fibers at greater than 50 mass % with respect to the total mass. The phrase may therefore be reworded to mean including hydrophilic fibers at greater than 50 mass % and up to 100 mass %, while including other components (hydrophobic fibers, for example) at from 0 mass % to less than 50 mass %.
[0022] FIG. 4 is a cross-sectional view (schematic view) of a nonwoven fabric sheet according to an embodiment of the present invention. The nonwoven fabric sheet 8 of this embodiment is formed of a layered body having a three-layer structure, including a pulp fiber layer 81 with a first surface and a second surface, a first surface side fiber layer 82 situated on the first surface side of the pulp fiber layer 81 , and a second surface side fiber layer 83 situated on the second surface side of the pulp fiber layer.
[0023] The pulp fiber layer of the present invention includes mainly pulp which is generally cellulosic fibers with fiber lengths of 1 to 10 mm (i.e., it includes it in a proportion of greater than 50 mass %), and is preferably formed of 100 mass % pulp. The type of pulp is not particularly restricted, and any desired pulp such as wood pulp, nonwood pulp or recycled pulp may be used; however, fluff pulp is most preferably used from the viewpoint of high ability to draw out fluids such as body fluids that are diffused in the first surface side fiber layer and second surface side fiber layer, from the first surface side fiber layer and second surface side fiber layer.
[0024] The pulp preferably includes pulp with a Kajaani mean fiber length of 2 to 3 mm, from the viewpoint of water absorbing property, water retention, flexibility and handleability. The “Kajaani mean fiber length” is the length-weighted average fiber length measured with a Kajaani fiber length analyzer by Kajaani Automation Co., according to JAPAN TAPPI wood pulp test method No. 52:2000. Also, the basis weight of the pulp is not particularly restricted but is preferably about 5 to 60 g/m 2 and more preferably about 15 to 40 g/m 2 , from the viewpoint of water retention, flexibility and bulk.
[0025] The first surface side fiber layer and second surface side fiber layer of the present invention includes mainly hydrophilic fibers with a mean fiber length of 25 mm to 64 mm (i.e., it includes them at greater than 50 mass %), and it preferably includes them at 70 mass % or greater. There are no particular restrictions on the hydrophilic fibers, but from the viewpoint of fluid diffusibility, strength, flexibility and general utility, examples include cellulosic fibers, and more specifically, natural fibers such as cotton and regenerated fibers such as rayon and cupra. Synthetic fibers (such as rayon fibers) that have been hydrophilically treated on the surfaces may also be used. Of these, rayon fibers are especially preferred for use from the viewpoint of fluid diffusibility, strength after tangling, handleability, and general utility.
[0026] According to the present invention, the hydrophilic fibers preferably have a mean fiber length in the range of 25 mm to 64 mm. If the mean fiber length is within this range, fluids such as body fluids that have been discharged can be widely and rapidly diffused in the in-plane direction of the nonwoven fabric sheet utilizing capillary action of the fiber aggregates forming the first surface side fiber layer and the second surface side fiber layer, and diffused fluids can be easily delivered to the pulp fiber layer situated between the first surface side fiber layer and the second surface side fiber layer. The “mean fiber length” is the mean fiber length measured according to “A7.1.1, Method A (Standard method) Method for measuring lengths of individual fibers on graduated glass plate”, under “A7.1 Fiber length measurement” in appendix A of JIS L 1015:2010. This method is the test method corresponding to ISO 6989 published in 1981.
[0027] The forms of the hydrophilic fibers are not particularly restricted, and they may have ordinary circular cross-sections, or irregular cross-sections that are Y-shaped, cross-shaped, hollow or the like, or combinations of these forms. When the hydrophilic fibers include fibers with irregular cross-sections, the fibers with irregular cross-sections will have large surface areas and excellent liquid absorption, thereby allowing the fluid diffusibility of the fiber aggregates forming the first surface side fiber layer and second surface side fiber layer to be further increased.
[0028] According to the present invention, the first surface side fiber layer and second surface side fiber layer may include components other than the hydrophilic fibers in proportions lower than that of the hydrophilic fiber in terms of mass ratio (i.e., proportions of less than 50 mass %), and they are preferably proportions of no greater than 30 mass %. Such other components include hydrophobic fibers, heat-sealable fibers, various treatment agents and fillers, used appropriately either alone or in combinations depending on the desired fluid diffusibility, strength, flexibility, water retention, production cost, etc.
[0029] As hydrophobic fibers there may be used, for example, thermoplastic fibers such as polyethylene, polypropylene, nylon and polyester, or composite fibers with combinations of these thermoplastic fibers; however, polyester-based fibers such as polyethylene terephthalate are preferably used from the viewpoint of strength when wet, and bulk, flexibility and the like.
[0030] Also, from the viewpoint of fluid diffusibility, the hydrophobic fibers used are preferably fibers subjected to hydrophilic treatment on the surfaces with a hydrophilic lubricant or the like, and more preferably polyester-based fibers subjected to hydrophilic treatment. The hydrophilic lubricant to be used for the hydrophilic treatment is not particularly restricted, and examples include alkyl phosphate ester salts and alkyl phosphate metal salts. Moreover, according to the present invention, the first surface side fiber layer, pulp fiber layer and second surface side fiber layer are integrated by a high-pressure stream jet such as a water jet as described below, and therefore the surfaces of the hydrophobic fibers are most preferably subjected to hydrophilic treatment using a hydrophilic lubricant having durability of a level such that it is not flushed off by the high-pressure stream jet (a resistant hydrophilic lubricant). Such a resistant hydrophilic lubricant is not particularly restricted, and for example, it may be a polyether ester, ether nonion, polyether-modified silicone, sulfosuccinate, polyoxyethyleneamide ether, alkylimidazoline-type cation, polyglycerin polyester, a C10-30 betaine compound or sulfuric acid ester salt or sulfonate salt mixed with a C10-30 alkyl phosphate ester salt, of a mixed lubricant such as a mixture of an alkyl phosphate ester salt and a polyether-modified silicone.
[0031] Also, the heat-sealable fibers may be ones including a low-melting-point thermoplastic resin such as a polyethylene resin or low melting point polypropylene at least on their surfaces, examples including polyethylene resin single component fibers; polypropylene resin single component fibers; core-sheath composite synthetic fibers with a polyethylene terephthalate resin core and a polyethylene resin sheath; core-sheath composite synthetic fibers with a polypropylene resin core and a polyethylene resin sheath; core-sheath composite synthetic fibers with a high melting point polypropylene resin core and a low melting point polypropylene resin sheath; side-by-side composite synthetic fibers composed of a polyethylene terephthalate resin and a polyethylene resin; and side-by-side composite synthetic fibers composed of a polypropylene resin and a polyethylene resin.
[0032] When the first surface side fiber layer and the second surface side fiber layer include heat-sealable fibers, the first surface side fiber layer, pulp fiber layer and second surface side fiber layer are integrated by a high-pressure stream jet such as a water jet as described below to obtain a nonwoven fabric sheet, after which the nonwoven fabric sheet is heat set to melt the low melting point resin of the heat-sealable fibers and fuse them with the other fibers, thereby allowing the strength, and especially the wet strength, of the nonwoven fabric sheet to be increased. Since the heat-sealable fibers are included in a lower proportion than the hydrophilic fibers based on mass ratio, even when fused sections are formed by the heat-sealable fibers, the fluid diffusibility of the nonwoven fabric sheet is not impeded and the strength of the nonwoven fabric sheet can be reinforced in an auxiliary manner.
[0033] The first surface side fiber layer and second surface side fiber layer may employ a fiber web formed by a method such as an airlaid method; however, the fiber layer of at least the first surface side fiber layer or the second surface side fiber layer is preferably a carded web formed using a carding machine. By using a carded web it is possible to adequately tangle together the fibers of each fiber layer and the fibers within each fiber layer, when the first surface side fiber layer, pulp fiber layer and second surface side fiber layer are integrated by a high-pressure stream jet such as a water jet as described below, even when the fiber lengths of the constituent fibers are long. The form of the carded web is not particularly restricted and may be any form such as a parallel web, cross web, random web or the like.
[0034] The first surface side fiber layer and second surface side fiber layer of the present invention may be fiber layers having the same construction (i.e., fiber layers having the same fiber type, content and layer structure), or fiber layers with different constructions (i.e., fiber layers differing in at least one aspect from among fiber type, content and layer structure).
[0035] A method for producing a nonwoven fabric sheet for an absorbent body to be used in an absorbent article of the present invention will now be described. The nonwoven fabric sheet can be obtained by a production method that includes at least the following steps; a step of supplying a fiber web for the second surface side fiber layer including hydrophilic fibers, a step of supplying pulp for the pulp fiber layer including hydrophilic fibers onto the fiber web, a step of supplying a fiber web for the first surface side fiber layer including hydrophilic fibers onto the pulp, to obtain a layered body, and a step of high-pressure stream jet treatment from both surface sides of the layered body to tangle together the fibers of each of the fiber layers. More specifically, the constituent fibers such as hydrophilic fibers may be treated with a carding machine or the like either directly or after being blended in a prescribed mixing proportion, to prepare a fiber web for the second surface side fiber layer, such as a carded web, and then the prepared fiber web conveyed while supplying pulp for the pulp fiber layer, including hydrophilic fibers such as fluff pulp, onto the fiber web by airlaying or the like, and further supplying a fiber web for the first surface side fiber layer including hydrophilic fibers such as carded web, onto the pulp to obtain a layered body, and then tangling together at least the fibers of each fiber layer by high-pressure stream jet treatment such as a water jet from both surface sides of the layered body, to obtain a nonwoven fabric sheet in which the first surface side fiber layer, the pulp fiber layer and the second surface side fiber layer are integrated. Also, when the first surface side fiber layer and the second surface side fiber layer include heat-sealable fibers, the nonwoven fabric sheet obtained in this manner may be further heat set to obtain a nonwoven fabric sheet with reinforced sheet strength.
[0036] The nonwoven fabric sheet obtained in this manner has a structure in which the fibers in each fiber layer and the fibers between each fiber layer are tangled by a high-pressure stream jet such as a water jet, and therefore it is possible to impart excellent sheet strength and fluid diffusibility, while also promoting delivery to the pulp fiber layer of the fluids diffused in the in-plane direction of the nonwoven fabric sheets of the first surface side fiber layer and second surface side fiber layer. Furthermore, since the first surface side fiber layer and the second surface side fiber layer can reabsorb fluids and diffuse them in the in-plane direction after having delivered the fluids to the pulp fiber layer, the cycle of absorption of fluids, diffusion in the in-plane direction and delivery to the pulp fiber layer can be carried out repeatedly in the nonwoven fabric sheet, and long-lasting diffusion of the fluids allows the fluid diffusion region and the amount of fluids held in the nonwoven fabric sheet to be markedly increased.
[0037] Moreover, if the structure is such that some of the constituent fibers in the fiber layer of either or both the first surface side fiber layer and second surface side fiber layer are incorporated in the interior of the pulp fiber layer by the high-pressure stream jet such as a water jet, then fluids that have diffused in the in-plane direction of the nonwoven fabric sheets of the first surface side fiber layer and second surface side fiber layer can be more easily delivered to the pulp fiber layer, and thus the cycle of absorption of fluids, diffusion in the in-plane direction and delivery to the pulp fiber layer in the nonwoven fabric sheet can be accomplished more rapidly, as a result allowing the diffusion rate and diffusion region (diffusion area) of fluids in the nonwoven fabric sheet to be further increased.
[0038] According to the present invention, the nonwoven fabric sheet for an absorbent body has a fluid absorption height of preferably 110 mm or greater, more preferably 120 mm or greater and even more preferably 130 mm or greater, in a water absorption test based on the Klemm method described below. Moreover, the nonwoven fabric sheet has a water absorption factor of preferably 2.0 times or greater, more preferably 2.4 times or greater and even more preferably 3.0 times or greater, in the water absorption test. If the fluid absorption height and water absorption factor are within these ranges, fluids such as body fluids can be widely and rapidly diffused in the in-plane direction of the nonwoven fabric sheet, while fluids can also rapidly close up the pulp fiber layer interior to match the height of the liquid permeability.
[0039] Furthermore, according to the present invention, the nonwoven fabric sheet preferably has a fluid absorption height in the fiber layer of either or both the first surface side fiber layer and second surface side fiber layer, that is higher than the fluid absorption height of the pulp fiber layer. If the fluid absorption heights of each of the fiber layers have this relationship, then in the aforementioned cycle, the first surface side fiber layer or the second surface side fiber layer will more easily deliver fluids to the regions of the pulp fiber layer where fluids have not yet been absorbed or retained, and therefore diffusion of fluids can be accomplished in a more long-lasting and rapid manner, and the fluid diffusion regions and water retention capacity of the nonwoven fabric sheet can be further increased.
[0040] The water absorption test based on the Klemm method allows measurement based on the water absorption test method of JIS P 8141:2004, and the specific procedure is explained in the examples provided below.
[0041] According to the present invention, from the viewpoint of fluid diffusibility, sheet strength, liquid permeability, etc., the basis weight of the nonwoven fabric sheet is preferably a basis weight of 15 to 100 g/m 2 , more preferably a basis weight of 20 to 80 g/m 2 , and even more preferably a basis weight of 30 to 60 g/m 2 . Also, from the viewpoint of the state of tangling between the fibers, the fluid diffusibility, the sheet strength, the liquid permeability, etc., the basis weight of each fiber layer composing the nonwoven fabric sheet is preferably in the range of about 10 to 60 g/m 2 for the pulp fiber layer, and preferably in the range of about 5 to 50 g/m 2 for each of the first surface side fiber layer and the second surface side fiber layer.
[0042] Also, the density of the nonwoven fabric sheet is preferably 50 to 300 mg/cm 3 , more preferably 50 to 200 mg/cm 3 and even more preferably 60 to 150 mg/cm 3 , in consideration of the state of capillary formation necessary for diffusion of fluids, the sheet strength, etc.
[0043] According to the present invention, the nonwoven fabric sheet may be used as a member that can contact with the absorbent body of the absorbent article, and for example, it may be used in the absorbent body as a diffusing sheet to be situated on the front sheet side and/or back sheet side of the absorbent core, or as a core wrap to cover the absorbent core. When the nonwoven fabric sheet is used as such a member, fluids such as body fluids that have been discharged are diffused in a wide range throughout the nonwoven fabric sheet, and it can therefore absorb fluids in a wide region of the absorbent core that is adjacent to the nonwoven fabric sheet, and furthermore when the nonwoven fabric sheet is situated on the back sheet side of the absorbent core, it can notably reduce the rewetting amount in the absorbent article (for example, a reduction of 20% or more).
[0044] The present invention can be applied not only to a disposable diaper as with this embodiment, but also to various types of absorbent articles, such as incontinence pads, sanitary napkins and panty liners. Moreover, the absorbent article of the present invention is not restricted to the embodiment described above or the examples described below, and can be appropriately modified within a range that is not outside of the object and gist of the present invention.
EXAMPLES
[0045] The present invention will now be explained in more detail based on examples, with the understanding that the present invention is not limited to the examples.
Example 1
[0046] There were provided rayon fibers (product of Daiwabo Rayon Co., Ltd.) as hydrophilic fibers and polyethylene terephthalate (PET) fibers (product of Toyobo, Ltd.) having the surfaces hydrophilically treated with a resistant hydrophilic lubricant, as hydrophobic fibers, and the rayon fibers and PET fibers were blended to rayon fiber/PET fibers=70 mass %/30 mass %, after which a carding machine was used to fabricate a carded web with a basis weight of 12.0 g/m 2 , for use as the second surface side fiber layer. The fabricated carded web was conveyed while continuously supplying fluff pulp (NB416 by Weyerhaeuser Co., Ltd) for the pulp fiber layer onto the carded web to a basis weight of 21.0 g/m 2 , forming a pulp fiber layer on the second surface side fiber layer. Next, a carded web fabricated in the same manner as the second surface side fiber layer was supplied onto the pulp fiber layer to form the first surface side fiber layer, thus obtaining a layered body comprising the first surface side fiber layer, pulp fiber layer and second surface side fiber layer. The layered body obtained in this manner was conveyed at a transport speed of 10 m/min, while both surface sides of the layered body were subjected to high-pressure stream jet treatment with a water jet (first surface side fiber layer side water pressure: 2 to 5 MPa, second surface side fiber layer side water pressure: 3 MPa, nozzle orifice diameter: 92 μm, nozzle pitch: 0.5 mm, 2 rows) to tangle the constituent fibers in each fiber layer and between each fiber layer, thereby obtaining a three-layer structure nonwoven fabric sheet in which the first surface side fiber layer, pulp fiber layer and second surface side fiber layer were integrated.
Example 2
[0047] A three-layer structure nonwoven fabric sheet was obtained by production in the same manner as Example 1, except that the fluff pulp for the pulp fiber layer was supplied onto the carded web to a basis weight of 26.0 g/m 2 .
Example 3
[0048] A three-layer structure nonwoven fabric sheet was obtained by production in the same manner as Example 2, except that each carded web forming the first surface side fiber layer and the second surface side fiber layer was fabricated without using hydrophobic fibers (PET fibers).
Comparative Example 1
[0049] There were provided rayon fibers (product of Daiwabo Rayon Co., Ltd.) as hydrophilic fibers and polyethylene terephthalate (PET) fibers (product of Toyobo, Ltd.) having the surfaces hydrophilically treated with a hydrophilic lubricant, as hydrophobic fibers, and the rayon fibers and PET fibers were blended to rayon fiber/PET fibers=30 mass %/70 mass %, after which a carding machine was used to fabricate a carded web with a basis weight of 22.5 g/m 2 , for use as a fiber layer corresponding to the second surface side fiber layer of the present invention. The fabricated carded web was conveyed while supplying a carded web fabricated in the same manner as the fiber layer corresponding to the second surface side fiber layer, onto the carded web, forming a fiber layer corresponding to the first surface side fiber layer of the present invention, to obtain a layered body comprising two fiber layers. The layered body obtained in this manner was conveyed at a transport speed of 10 m/min, while both surface sides of the layered body were subjected to high-pressure stream jet treatment with a water jet in the same manner as Example 1 to tangle the constituent fibers in each fiber layer and between each fiber layer, thereby obtaining a two-layer structure nonwoven fabric sheet in which the fiber layer corresponding to the first surface side fiber layer and the fiber layer corresponding to the second surface side fiber layer were integrated.
Comparative Example 2
[0050] A two-layer structure nonwoven fabric sheet was obtained in the same manner as Comparative Example 1, except that the carded web forming each fiber layer was fabricated by blending with rayon fiber/PET fibers=50 mass %/50 mass %.
Comparative Example 3
[0051] A two-layer structure nonwoven fabric sheet was obtained in the same manner as Comparative Example 1, except that the carded web forming each fiber layer was fabricated by blending with rayon fiber/PET fibers=70 mass %/30 mass %.
[0052] For each of the nonwoven fabric sheets of Examples 1 to 3 and Comparative Examples 1 to 3 obtained as described above, the basis weight (g/m 2 ), thickness (mm), density (g/cm 3 ), fluid absorption height (mm) after 5 minutes in the Klemm method and transported amount per unit mass (g/g) were measured by the following measuring methods. Also, the mixing ratio of rayon fibers and PET fibers in the first surface side fiber layer and second surface side fiber layer was measured by the measuring method described below, using each carded web fabricated in the nonwoven fabric sheet production process described above. The measurement results are shown in Table 1.
[Table 1]
[0053]
[0000]
TABLE 1
Comparative
Comparative
Comparative
Example 1
Example 2
Example 3
Example 1
Example 2
Example 3
Starting material
First
Rayon/PET
Rayon/PET
Rayon
Rayon/PET
Rayon/PET
Rayon/PET
composition of
surface side
70%/30%
70%/30%
100%
30%/70%
50%/50%
70%/30%
nonwoven fabric
fiber layer
(Set basis weight
(Set basis weight
(Set basis weight
(Set basis weight
(Set basis weight
(Set basis weight
sheet
12.0 g/m 2 )
12.0 g/m 2 )
12.0 g/m 2 )
22.5 g/m 2 )
22.5 g/m 2 )
22.5 g/m 2 )
Pulp fiber
Pulp
Pulp
Pulp
—
—
—
layer
100%
100%
100%
(Set basis weight
(Set basis weight
(Set basis weight
21.0 g/m 2 )
26.0 g/m 2 )
26.0 g/m 2 )
Second
Rayon/PET
Rayon/PET
Rayon
Rayon/PET
Rayon/PET
Rayon/PET
surface side
70%/30%
70%/30%
100%
30%/70%
50%/50%
70%/30%
fiber layer
(Set basis weight
(Set basis weight
(Set basis weight
(Set basis weight
(Set basis weight
(Set basis weight
12.0 g/m 2 )
12.0 g/m 2 )
12.0 g/m 2 )
22.5 g/m 2 )
22.5 g/m 2 )
22.5 g/m 2 )
Basis weight (g/m 2 )
44.2
51.3
50.9
45.8
46.1
45.1
Thickness (mm)
0.57
0.57
0.48
0.62
0.57
0.53
Density (mg/cm 3 )
78
90
106
74
81
85
Fluid absorption height (mm)
123
135
157
8
37
69
Transported amount (g/g)
3.38
4.11
4.59
0.22
1.19
1.91
[0054] As shown in Table 1, the nonwoven fabric sheets of Examples 1 to 3 all had fluid absorption heights of 120 mm or greater and transport amounts of 3 g/g or greater, exhibiting higher fluid absorption heights and transported amounts than the nonwoven fabric sheets of Comparative Examples 1 to 3, and having excellent fluid diffusibility. Also, based on comparison of Examples 1 to 3, it was demonstrated that a higher rayon fiber mixing ratio in the first surface side fiber layer and second surface side fiber layer results in a higher fluid absorption height and transported amount being exhibited, and increased fluid diffusibility of the nonwoven fabric sheet corresponding to the rayon fiber mixing ratio.
[0055] The methods for measuring the properties were as follows.
[Basis Weight]
[0056] Ten samples of size of 100 mm×100 mm are taken and the mass of each sample is measured. Next, the mass (g) of each sample is divided by the area (m 2 ) of each sample to calculate the basis weight (g/m 2 ) of each sample. The mean value for the basis weights of the 10 samples is calculated, and the mean value is used as the basis weight.
[Thickness]
[0057] The thickness of the nonwoven fabric is measured using a THICKNESS GAUGE UF-60 by Daiei Kagaku Seiki Mfg. Co., Ltd. Measurement of the thickness with the UF-60 is carried out with a 44 mm diameter measuring surface, and application of 0.3 kPa pressure on the nonwoven fabric.
[Density]
[0058] The density of the nonwoven fabric is calculated by dividing the basis weight of the nonwoven fabric by the thickness.
[Fluid Absorption Height and Transported Amount]
[0059] The fluid absorption height and transported amount after 5 minutes in the Klemm method are measured according to the water absorption test method of JIS P 8141:2004, in the following manner.
[0060] (1) The sample is cut to a size of 230 mm×25 mm (length×width), a line is drawn 30 mm from the edge in the lengthwise direction, and the initial mass (W 0 ) of the test strip is measured.
[0061] (2) A cuboid dipping container with dimensions 170 mm×90 mm×40 mm (length×width×depth) is filled with artificial urine to a height of 35 mm. The artificial urine is prepared by dissolving 200 g of urea, 80 g of sodium chloride, 8 g of magnesium sulfate, 3 g of calcium chloride and approximately 1 g of dye: Blue #1 in 10 L of ion-exchanged water.
[0062] (3) The test strip is fixed to a suspending member with the drawn line at the lower end and dipped in the artificial urine up to the drawn line, and allowed to stand for 5 minutes.
[0063] (4) After standing for 5 minutes, the height increase of the artificial urine from the drawn line is measured as the fluid absorption height (mm).
[0064] (5) Next, the test strip is removed from the suspending member, the section with a length of 30 mm (the section below the drawn line) that was dipped in the artificial urine is cut out, and the mass (W 1 ) of the remaining section with a length of 200 mm is measured.
[0065] (6) The transported amount (X) (g/g) is calculated by the following formula.
[0000] X ={( W× 230/200)− W 0 }/W 0
[0066] (7) The above test is repeated 5 times, and the mean value is used.
[Mixing Ratio of Rayon Fibers and PET Fibers]
[0067] The mixing ratio of rayon fibers and PET fibers in the carded web is determined by measuring the mixing ratio of rayon fibers by the following procedure.
[0068] (1) A fiber web including rayon fibers and PET fibers is prepared as a measuring sample.
[0069] (2) An approximately 0.2 g portion of the fiber web is cut to a size fitting in a 100 mL beaker, and the mass (g) of the cut fiber web (sample initial mass W A ) is measured.
[0070] (3) The cut fiber web and 30 g of hexafluoroisopropanol are placed in a 100 mL beaker, and stirred for 1 hour at a rotational speed of 300 rpm.
[0071] (4) The contents of the beaker are filtered using filter paper with a pre-measured mass (g) (filter paper initial mass W F ).
[0072] (5) The residue on the filter paper is allowed to stand in a draft chamber for each filter paper, and dried for 1 hour.
[0073] (6) The masses (g) of the residue and filter paper after drying are measured.
[0074] (7) The mass (g) of the rayon fibers in the fiber web (rayon fiber mass W P ) is calculated by subtracting the masses of the residue and filter paper after drying from the total of the sample initial mass W A and the filter paper initial mass W F .
[0075] (8) The rayon fiber mixing ratio F A (mass %) is calculated from the calculated rayon fiber mass and sample initial mass W A , using the following formula.
[0000] F A =( W P /W A )×100
[0076] Exemplary aspects of the present invention will now be described.
[0077] One aspect of the present invention (aspect 1) is an absorbent article including a liquid-permeable front sheet, a liquid-impermeable back sheet, an absorbent body situated between the front sheet and the back sheet, and a nonwoven fabric sheet for an absorbent body, wherein the nonwoven fabric sheet includes a pulp fiber layer that includes pulp and has a first surface and a second surface, a first surface side fiber layer situated on the first surface side of the pulp fiber layer and including mainly hydrophilic fibers with a mean fiber length of 25 mm to 64 mm, and a second surface side fiber layer situated on the second surface side of the pulp fiber layer and including mainly hydrophilic fibers with a mean fiber length of 25 mm to 64 mm.
[0078] According to another aspect of the present invention (aspect 2), in the absorbent article of aspect 1, the fiber layer of either or both the first surface side fiber layer and second surface side fiber layer further includes hydrophobic fibers in a smaller amount than the hydrophilic fibers, as the mass ratio.
[0079] According to yet another aspect of the present invention (aspect 3), in the absorbent article of aspect 2, the hydrophobic fibers include thermoplastic fibers.
[0080] According to yet another aspect of the present invention (aspect 4), in the absorbent article of aspect 3, the thermoplastic fibers are hydrophilically treated polyester-based fibers.
[0081] According to yet another aspect of the present invention (aspect 5), in the absorbent article of any one of aspects 1 to 4, the hydrophilic fibers in the fiber layer of either or both the first surface side fiber layer and second surface side fiber layer have irregular cross-sections.
[0082] According to yet another aspect of the present invention (aspect 6), in the absorbent article of any one of aspects 1 to 5, the hydrophilic fibers in the fiber layer of either or both the first surface side fiber layer and second surface side fiber layer include cellulosic fibers.
[0083] According to yet another aspect of the present invention (aspect 7), in the absorbent article of any one of aspects 1 to 6, the pulp in the pulp fiber layer includes fluff pulp.
[0084] According to yet another aspect of the present invention (aspect 8), in the absorbent article of any one of aspects 1 to 7, the pulp in the pulp fiber layer includes pulp with a Kajaani mean fiber length of 2 to 3 mm.
[0085] According to yet another aspect of the present invention (aspect 9), in the absorbent article according to any one of aspects 1 to 8, there is included a structure in which the fibers of each of the fiber layers are tangled together by the action of a water stream.
[0086] According to yet another aspect of the present invention (aspect 10), in the absorbent article of any one of aspects 1 to 9, the fiber layer of either or both the first surface side fiber layer and second surface side fiber layer includes a carded web.
[0087] According to yet another aspect of the present invention (aspect 11), in the absorbent article of any one of aspects 1 to 10, there is included a structure in which a portion of the fibers in the fiber layer of either or both the first surface side fiber layer and second surface side fiber layer are incorporated inside the pulp fiber layer.
[0088] According to yet another aspect of the present invention (aspect 12), in the absorbent article according to any one of aspects 1 to 11, the fluid absorption height of the fiber layer of either or both the first surface side fiber layer and the second surface side fiber layer is higher than the fluid absorption height of the pulp fiber layer, in a water absorption test by the Klemm method.
[0089] According to yet another aspect of the present invention (aspect 13), in the absorbent article according to any one of aspects 1 to 12, the absorbent body includes an absorbent core, and the nonwoven fabric sheet is situated at least between the back sheet and the absorbent core.
[0090] Yet another aspect of the present invention (aspect 14) is a method for producing a nonwoven fabric sheet for an absorbent body to be used in an absorbent article according to any one of aspects 1 to 13, the method including a step of supplying a fiber web for the second surface side fiber layer including hydrophilic fibers, a step of supplying pulp for the pulp fiber layer including hydrophilic fibers onto the fiber web, a step of supplying a fiber web for the first surface side fiber layer including hydrophilic fibers onto the pulp, to obtain a layered body, and a step of high-pressure stream jet treatment from both surface sides of the layered body to tangle together at least the fibers of each of the fiber layers.
REFERENCE SIGN LIST
[0000]
1 Disposable diaper
2 Front sheet
3 Back sheet
4 Absorbent body
5 Cover sheet
61 - 64 Elastic members
7 Absorbent core
8 Nonwoven fabric sheet
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An absorbent article contains a non-woven fabric sheet for an absorbent. The non-woven fabric sheet is produced without employing a strength-imparting means such as post-coating of an adhesive agent that can deteriorate a liquid diffusion property of the non-woven fabric sheet. The absorbent article includes a liquid-permeable surface sheet, a liquid-impermeable back sheet, an absorbent arranged therebetween, and the non-woven fabric sheet for the absorbent. The non-woven fabric sheet contains pulp, a pulp fiber layer, a first-surface-side fiber layer arranged on a first surface of the pulp fiber layer and mainly composed of hydrophilic fibers having an average fiber length of 25 to 64 mm, and a second-surface-side fiber layer arranged on a second surface of the pulp fiber layer and mainly composed of hydrophilic fibers having an average fiber length of 25 to 64 mm.
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BACKGROUND OF THE INVENTION
The present invention relates to transport apparatus for transporting flexible sheet-like articles, for example, sheets of paper, cards and envelopes.
Known machines for bundling letter or dispatch envelopes comprise intake equipment for inducting envelopes disposed in a stack. Such intake equipment includes a cylinder, which rotates in operation and which has suction openings for applying suction to successive envelopes, drawing individual envelopes from the base of the stack and, for example, transferring the envelopes to downstream transport equipment. At the point of each transfer, the suction openings are ventilated so that the envelope is released from the cylinder.
A known form of intake equipment has a cylinder with a shaft and two cylinder body portions, which are mounted on the shaft to be rotatable therewith and the circumferential surfaces of which incorporate a series of suction openings, which open into a suction channel extending along the rotational axis. The shaft is hollow and its interior connects the suction channels of the two cylinder body portions to a suction device via a control coupling. The control coupling comprises a first part fastened to a frame of the equipment to be non-rotatable relative thereto and a second part connected to the shaft to be rotatable therewith. The two parts have air passages with openings which, in a certain rotational position of the cylinder, face each other. In this rotational position, the cylinder applies suction to successive envelopes and entrains the envelopes in succession. The control coupling is also provided with a ventilation channel in order to ventilate the suction openings in another rotational position of the cylinder.
Present between the two cylinder body portions is a groove in which is arranged a separating device. The separating device is mounted on the frame to be non-rotatable relative thereto and is provided with a suction opening, which is located in the interior of the groove below the envelope stack. The suction opening of the separating device is connected via a duct with separate suction control couplings, which in turn are connected with the suction device. Each of these control couplings comprises a first part fastened to the frame to be non-rotatable relative thereto and a second part which is mounted on a separate shaft and which is rotated synchronously with the cylinder by a gear. This separate control coupling is constructed in such a manner that the suction opening of the separating device, in a particular rotational position of the cylinder, supplies suction to suck the lowermost envelope of the stack partially into the groove. Subsequently, this envelope is released by ventilation of the suction opening of the separating device so that it can be entrained by the cylinder. The separating device ensures that only one envelope is drawn away from the stack at a time.
In the known equipment, relatively long air paths are present between the two control couplings and the suction openings of the cylinder and separating device. In operation of the equipment, these air paths must be alternately partially evacuated and then ventilated. For this purpose, a relatively large quantity of air must be sucked away or let in. This entails the disadvantages that the maximum possible operating speed is relatively limited and a considerable amount of noise is generated. The noise is to a large extent caused by the substantial quantities of air which must be sucked away from or let into the air paths. In particular, ventilation generates noise like a report on the sudden inflow of air. Furthermore, the known intake equipment has the disadvantage that the control couplings require a considerable amount of space and thereby increase the overall size of the equipment.
Transport cylinders with suction openings are used not only for intake equipment, but also for other transport and deflection purposes. For example, in the specification of Swiss Patent Application No. 1 0847/78, there is described a cylinder, which serves to provide a deflector and which has a number of suction channels each provided with a plurality of suction openings opening at the circumferential surface of the cylinder. The suction channels open at one of the end faces of the cylinder. The cylinder is associated with a suction control coupling comprising a ring which is nonrotatably fastened to the frame and is co-axial with the cylinder. The end face of the ring facing the cylinder end face in which the suction channels open is provided with grooves extending along a circular arc and with a radial ventilation groove. In certain rotational positions of the cylinder, the suction channel openings in the end face of the cylinder communicate with the grooves in the ring of the control coupling, so that air is either sucked out of the suction channels or else the suction channels are ventilated.
This deflector is also only capable of operation at relatively low speeds. The grooves in the stationary ring of the control coupling and the openings of the suction channels at the end face of the cylinder extend for only a relatively short distance in radial direction because only a small space is available between the shaft and the outer rim of the cylinder. Accordingly, the flow cross-sectional area for air transition from the stationary ring of the control coupling to the cylinder is relatively small, with the result that the operating speed of the deflector is correspondingly limited to a relatively low value. This is particularly so because at least a part of the air in the cylinder itself must traverse a relatively long path due to the fact that all the air is sucked away or flows in at one end face of the cylinder and thus in part must flow through almost the entire length of the cylinder.
SUMMARY OF THE PRESENT INVENTION
The invention has as its object the provision of transport apparatus for transporting sheets of paper, cards, letter or dispatch envelopes and other such flexible sheet-like articles with the maximum possible operating speed and with minimum generation of noise.
In accordance with one aspect of the present invention, there is provided transport apparatus for transporting flexible sheet-like articles, comprising a frame in which is mounted a transport cylinder to be rotatable about an axis. The cylinder comprises a cylindrical inner surface defining a bore co-axial with said axis and means defining at least one suction transfer duct, a first passage extending through said cylindrical inner surface and connecting said bore to said at least one duct, and at least one second passage connected to said at least one duct and opening at the circumference of the cylinder for supplying suction to attract individual such articles to said circumference for transport by the cylinder. Drive means are provided to rotate the cylinder about said axis and a suction device for providing suction. A connecting means serves to alternately connect said at least one duct to the suction device in one rotational orientation of the cylinder and to ventilate said at least one duct in another rotational orientation of the cylinder. The connecting means comprises a body which is mounted to the frame to be secure against rotation and which projects into said bore. The body comprises a cylindrical outer surface disposed so as to face said cylindrical inner surface of the cylinder and means which define suction transfer passage means connected to the suction device and opening at said cylindrical outer surface so as to be connected to said at least one duct via said first passage in said one rotational orientation of the cylinder.
In another aspect of the invention there is provided transport apparatus for transporting flexible sheet-like articles, the apparatus similarly comprising a frame in which a transport cylinder is mounted to be rotatable about an axis. The cylinder comprises means defining at least two suction transfer ducts, passage means connected to said ducts and opening at the circumference of the cylinder for supplying suction to attract individual such articles to said circumference for transport by said cylinder, and a groove extending circumferentially of said cylinder and between said ducts, the base of said groove being in the form of an annular surface which is co-axial with said axis and which includes a recess. A suction device is present for providing suction and transfer means are provided for drawing individual such articles partly into said groove in a predetermined rotational orientation of said cylinder to facilitate transfer of the articles thereto. The transfer means comprises a member which is mounted on the frame to be secure against rotation and which projects into said groove. The member comprises an inner surface facing said annular surface and extending concentrically therewith, and means defining a first passage connected to the suction device and opening at said inner surface of the member and a second passage, which extends between and opens at said inner surface of the member and an outer surface of the member in said groove and which is connected to said first passage by said recess when the cylinder is in said predetermined rotational orientation for supplying suction to attract individual ones of the articles to said outer surface.
BRIEF DESCRIPTION OF THE DRAWINGS
An embodiment of the present invention will now be more particularly described by way of example with reference to the accompanying drawings in which:
FIG. 1 is a longitudinal sectional view of transport apparatus according to the said embodiment, the view being taken along the axis of a cylinder of the apparatus with parts of the apparatus being drawn displaced relative to each other to improve clarity,
FIG. 2 is a cross-section along the line II--II of FIG. 1, with the cylinder drawn in another rotational position, and
FIG. 3 is a cross-section along the line III--III of FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, there is shown transport apparatus which can, for example, form a part of a machine for bundling letter or dispatch envelopes. The apparatus comprises a frame 1 which is fastened to a frame of the machine or is formed by parts of the latter frame. Fastened to the frame 1 is a stack holder 3, which amongst other things comprises an inclined support 5 and strippers 7 and 9 and holds a stack of envelopes 11.
A cylinder, indicated generally by 21, is mounted in the frame 1 to be rotatable about a horizontal axis 23. The cylinder 21 comprises a shaft 25 on which are mounted two substantially cylindrical body portions 27 each having a continuous through bore 27a co-axial with the axis 23. The body portions 27 are mounted on the shaft, to be rotatable therewith, by means of screws 29, shown only in part (FIG. 1). The bores 27a each include a section 27b of a greater diameter than that of the shaft 25. These sections 27b are externally bounded by cylindrical inner surfaces 27c and are open at the mutually remote ends of the two body portions 27.
Two bushes 31 and 33 are arranged at the two ends, respectively, of the shaft 25. The bushes are provided at their mutually remote ends with flanges and are connected by screws to the frame 1 to be secure against rotation. The bushes 31 and 33 have continuous through bores 31a and 33a, respectively, co-axial with the axis 23. The bore 31a is provided at the lefthand end of the respective bush with an enlargement, in which a ballbearing 35 is located. To the right of this, the bore 31a has a section of reduced diameter, the diameter of this section being slightly greater than the diameter of the shaft so that the shaft can rotate freely but is to some extent sealed off at this point. Immediately to the right of the reduced diameter section is an enlargement which, together with the shaft 25, defines an annular chamber 31b. The righthand end of the bore 31a again has a section of reduced diameter in which is located a bearing ring 37, which serves for the journalling of the shaft 25 and which at the same time seals off the chamber 31b to some extent at the righthand end of the bush 31.
The bush 33 is by and large constructed identically to the bush 31 and its bore 33a also has, in the interior part of the bush, an enlargement which together with the shaft 25 defines a chamber 33b, the chamber being sealed off outwardly to some extent. The only difference between the two bushes 31 and 33 is that at its outer end the bush 33 is provided with a bearing ring 39 rather than a ballbearing for the journalling of the shaft. At the inner end of the bush opening 33a, a bearing ring 41 is present as in the case of the bush 31.
The chambers 31b and 33b are connected by radial openings 31c and 33c, respectively, and by stub pipes 43 and 45, respectively, with the interior of a suction duct 47. The duct 47 in turn is connected with a suction device 49, which comprises a pump and preferably also a storage means.
The two bushes 31 and 33 have portions 31d and 33d, respectively, which face each other and which project into the bore sections 27b of the cylinder body portions 27. A sufficient amount of play is present between cylindrical outer surfaces 31e and 33e of, respectively, the portions 31d and 33d and the inner surfaces 27c of the body portions 27 to on the one hand permit body portions to rotate with minimal friction and on the other hand to close off the bore sections 27b relatively tightly.
The two body portions 27 each have a respective suction channel 27d, which extends parallel to the axis 23 and is bounded by a milled recess and by a cover element 51 secured in place by screws. The cover element 51 is provided with a series of suction openings 51a which extend in the direction of the axis 23 and communicate with the atmosphere. Each channel 27d is connected with a radial passage 27e, which opens at the inner surface 27c. In addition, three further suction channels 27f, extending parallel to the axis 23, are provided in each body portion 27, each of the channels 27f being formed by a blind bore tightly closed at its open end by a screw 53. A series of suction openings 27i extend from each of the channels 27f to the circumferential surface of the respective body portion 27, and, each of the channels 27f is connected with a radial passage 27g, which opens at the inner surface 27c.
The portions 31d and 33d of the bushes 31 and 33 are each provided with a radial passage 31f or 33f. Each of these passages 31f and 33f extends over a circular sector of about 130° with respect to the axis 23, as can be seen from the boundary lines of the opening 33f drawn in dashed lines in FIG. 2. The passages 31f and 33f extend from the chambers 31b and 33b, respectively, to the outer surfaces 31e and 33e, respectively, so that in certain rotational positions of the cylinder they connect the channels 27d and 27f thereof with the chambers 31b and 33b. Each of the two bushes 31 and 33 thus comprises a passage means which is designated as an entity by 31g or 33g, is tightly closed off outwardly to some extent, and which in certain rotational positions of the cylinder connects the suction channels 27d of the cylinder body portions with the suction device 49.
The bush portions 31d and 33d are also provided at their circumferential surfaces 31e and 33e with ventilation channels 31h and 33h, respectively, which extend parallel to the axis 23 and which are each disposed partly within and partly externally of the respective body portion 27. In a certain rotational position of the cylinder, the ventilation channels 31h and 33h overlap the radial passages 27e leading to the suction channels 27d of the body portions 27.
At this juncture, it is again pointed out that the bushes 31 and 33 and the body portions 27 in FIG. 1 are partially sectioned along planes which do not extend vertically, as a comparison with FIG. 2 will show. In addition, the illustrated position of the stub pipes 43 and 45 in FIG. 1 does not correspond to a vertical section.
A groove 61 is provided between the two cylinder body portions 27. Arranged in the groove 61 is a separating device, indicated generally by 63, comprising a ring 67 connected to the shaft 25 by means of a screw 65 to be rotatable with the shaft. The ring 67 is provided with a recess 67b in its circumferential surface 67a, this surface being co-axial with the axis 23. The separating device 61 further comprises a body 69 which is rigidly fastened to the frame 1 and which is of generally C-shaped cross-section. The body 69 extends around about half the circumference of the ring 67 and has an inner surface 69a which is concentric with the axis 23 and which is provided with transition means extending closely adjacent to the surface 67a. The body 69 is provided with passage 69b, which extends from the suction duct 47 to an opening 69c at the inner surface 69a. The body 69 is also provided with an approximately radially extending passage 69d, which comprises a relatively wide opening at the inner surface 69a and a plurality of narrow openings at an outer surface portion of the body 69. This outer surface portion is disposed just inside the groove 61, in the proximity of the upper rim of the lowermost one of the envelopes 11. In a certain rotational position of the cylinder 21, the recess 67b connects the opening 69c with the passage 69d.
The shaft 25 is connected through an articulated coupling 71 and transmission means (not shown) with a drive motor 73.
In operation of the transport apparatus hereinbefore described, the drive motor 73 drives the cylinder 21 so that it rotates in a clockwise direction with respect to FIGS. 2 and 3. Air is constantly sucked away by the suction device 49 so that an underpressure is always present in the duct 47 and in the passages 31g and 33g of the bushes 31 and 33. In addition, an underpressure is of course constantly present in the passages 69b of the body 69 of the separating device.
During each revolution of the cylinder 21, the ring 67 of the separating device 63 is positioned so that the recess 67b connects the passage 69b with the passage 69d. As a result, the lowermost envelope of the stack is slightly deformed and a portion thereof is sucked into the groove 61. The lowermost envelope is thus separated at one edge thereof from the remaining envelopes. Approximately at that moment, the mutually aligned suction channels 27d of the two cylinder body portions 27 are connected by the passages 27e with the passage 31g and 33g so that suction is supplied through the opening 51a to suck the lowermost envelope away from the stack, while the remaining envelopes in the stack are held back by the strippers 7 and 9. Shortly after the start of this process, the recess 67b reaches a position in which it connects the passage 69d with the atmosphere and ventilates this passage.
The cylinder 21 then transports the lowermost envelope away from the stack through a certain rotational angle, the envelope being additionally attracted to the cylinder by suction supplied from successive suction openings 27i of the suction channels 27f.
When the passage 27e are aligned with the ventilation channels 31h and 33h, the suction channels 27d are ventilated. Subsequently, the suction channels 27f are ventilated in succession. The envelope can then detach from the cylinder and be taken over by another transport or processing device (not shown) of the machine.
The two bushes 31 and 33 thus each form a stator of a suction control coupling, the rotor of which is formed by a respective one of the cylinder body portions 27. During ventilation of the suction channels 27d and 27f, air is supplied to relieve just these channels while the passages 31g and 33g of the bushes 31 or 33 remain subject to underpressure. During the transition from ventilating to sucking and vice versa, only relatively small quantities of air have to be sucked away or let in. Moreover, each of the passages 27e can connect the respective suction channel 27 with the associated passage 31g or 33g over a relatively large part of the length of the channel measured along the axis 23.
In the separating device 63, the body 69 forms the stator and the ring 67 the rotor of a suction control coupling. On changing from suction to ventilation and vice versa, again only relatively small quantities of air have to be let in or sucked away.
The apparatus can therefore operate at high speed, for example, it may be readily possible to draw about 100 envelopes per minute from the stack into the machine for further processing. In operating at that speed, the apparatus generates a relatively small amount of noise.
The apparatus illustrated in the drawings serves to induct letter or dispatch envelopes. It is, of course feasible to adapt the apparatus to induct postcards consisting of thin flexible cardboard.
Moreover, the apparatus can not only be employed for the intake of envelopes or cards, but can also be used at other points in a machine at which paper sheets, cards, letter or dispatch envelopes and the like, have to be transported.
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There is disclosed transport apparatus for transporting flexible sheet-like articles, especially envelopes. The apparatus comprises a transport cylinder, which is mounted on a shaft rotatably journalled in a frame and which comprises two cylindrical body portions. The body portions are each provided with axial suction ducts with outlet openings communicating with the circumferential surfaces of the body portions. The body portions are provided at their mutually remote ends with bores into which project bushes, which are mounted to the frame to be secure against rotation. A suction device is connected in a certain rotational position of the cylinder, through passages which are provided in the bushes and open at the circumferential surfaces of the bushes, with the suction ducts of the cylinder body portions. In another rotational position of the cylinder, the suction ducts of the body portions are ventilated by the bushes. The apparatus is capable of high operating speeds with minimum noise production.
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FIELD OF THE INVENTION
The present invention generally relates to apparatus and methods for extruding thermoplastic filaments and, more particularly, apparatus for melt blowing multi-component or single component filaments.
BACKGROUND OF THE INVENTION
Melt spinning techniques, such as spunbonding or meltblowing techniques, for extruding fine diameter filaments find many different applications in various industries including, for example, in nonwoven material manufacturing. This technology generally involves extruding a thermoplastic material from multiple rows of discharge outlets extending along the lower surface of an elongate spinneret. Spunbonded and/or meltblown materials are used in such products as diapers, surgical gowns, carpet backings, filters and many other consumer and industrial products. The machines for meltspinning such materials can be very large and include numerous filament discharge outlets.
For certain applications, it is desirable to utilize two or more types of thermoplastic liquid materials to form individual cross-sectional portions of each filament. Often, these multi-component filaments comprise two components and, therefore, are referred to as bicomponent filaments. For example, when manufacturing nonwoven materials for use in the garment industry, it may be desirable to produce bicomponent filaments having a sheath-core construction. The outer sheath may be formed from a softer material which is comfortable to the skin of an individual and the inner core may be formed from a stronger, but perhaps less comfortable material having greater tensile strength to provide durability to the garment. Another important consideration involves cost of the material. For example, a core of inexpensive material may be combined with a sheath of more expensive material. For example, the core may be formed from polypropylene or nylon and the sheath may be formed from a polyester or co-polyester. Many other multi-component fiber configurations exist, including side-by-side, tipped, and microdenier configurations, each having its own special applications. Various material properties can be controlled using one or more of the component liquids. These include, as examples, thermal, chemical, electrical, optical, fragrance, and anti-microbial properties. Likewise, many types of die tips exist for combining the multiple liquid components just prior to discharge or extrusion to produce filaments of the desired cross-sectional configuration.
One problem associated with multi-component extrusion apparatus involves the cost and complexity of the manifolds used to transmit liquid(s) to the spinneret or extrusion die. Typical manifolds are typically machined with many different passages to ensure that the proper flow of each component liquid reaches the die under the proper pressure and temperature conditions. These manifolds are therefore relatively complex and expensive components of the melt spinning apparatus.
For these reasons, it would be desirable to provide a meltblowing apparatus having a manifold system which may be easily manufactured while still achieving the goal of effectively transmitting the heated liquid or liquids to the die tip.
SUMMARY OF THE INVENTION
The invention generally provides a lamellar meltblowing die apparatus for extruding a heated liquid into filaments and directing air at the filaments. The apparatus is constructed with a plurality of plates each having opposite side faces. At least two of the side faces confront each other and have a liquid passage positioned therebetween for transferring the heated liquid. At least two of the side faces confront each other and have an air passage positioned therebetween for transferring the air. At least two of the side faces confront each other and have a heating element passage therebetween. A heating element is positioned within the heating element passage for heating at least one of the liquid and the air. An extrusion die is coupled with the plurality of plates and communicates with the liquid passage and the air passage for discharging the heated liquid as multiple filaments and for discharging the air at the filaments. The air may, for example, be heated or unheated process air with or without quench air.
The liquid passage is preferably formed by respective first and second recesses on adjacent plates that abut one another. Likewise, the air passage is formed by respective third and fourth recesses on adjacent plates that abut one another, and the heating element passage is formed by respective fifth and sixth recesses on adjacent plates that abut one another. Recesses from different ones of these pairs of recesses may, for example, be located on opposite sides of the same plate. In the preferred embodiment, multiple heating element passages are positioned between two of the plates and multiple heating elements are respectively contained in the heating element passages. The heating element passage or passages are preferably located between the liquid passage and the air passage.
The liquid passage and the air passage each include an inlet portion and an outlet portion with the outlet portion being wider than the inlet portion. The outlet portion of the liquid passage forms an elongate liquid outlet slot. A plurality of distribution passages communicate with an elongate air outlet slot in one of the plates and the distribution passages further communicate with the air passage. The extrusion die includes an elongate liquid inlet slot and an elongate air inlet slot respectively aligned in communication with the elongate liquid outlet slot and the elongate air outlet slot.
The invention further contemplates methods of meltblowing liquid filaments, such as single or multiple component thermoplastic polymeric filaments, in general accordance with the use of the apparatus described above.
Various advantages, objectives, and features of the invention will become more readily apparent to those of ordinary skill in the art upon review of the following detailed description of the preferred embodiments, taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a multi-component meltblowing apparatus constructed in accordance with a preferred embodiment of the invention.
FIG. 1A is an exploded perspective view of the apparatus shown in FIG. 1 .
FIG. 2 is a cross sectional view taken along line 2 — 2 of FIG. 1 .
FIG. 3 is a fragmented view of the assembled apparatus taken generally along line 3 — 3 of FIG. 2 .
FIG. 4 is a cross sectional view similar to FIG. 2 , but illustrating an alternative embodiment of the apparatus.
FIG. 5 is a cross sectional view taken along line 5 — 5 of FIG. 4 .
FIG. 6 is a cross sectional view similar to FIG. 2 , but illustrating another alternative embodiment of the apparatus.
FIG. 7 is a cross sectional view similar to FIG. 4 , but illustrating another alternative embodiment of the apparatus.
DETAILED DESCRIPTION
FIGS. 1 , 1 A, 2 and 3 illustrate a die apparatus 10 constructed in accordance with a first embodiment. Apparatus 10 is comprised of a manifold structure 12 coupled for fluid communication with an extrusion die 14 . Manifold structure 12 is a lamellar construction or plate assembly comprised of multiple plates 16 a–c , 18 a–c and 20 . These plates are securely fastened together in side-by-side relation using appropriate fasteners 22 (only one shown in FIG. 1 ) extending through holes 24 in each of the plates. As best shown in FIG. 2 , respective outside pairs of plates 16 a , 16 b and 18 a , 18 b form process air manifold sections and include respective air input ports 26 , 28 . Plates 16 a , 16 b and 18 a , 18 b respectively abut each other and contain air passages 27 , 29 therebetween. Air passages 27 , 29 are respectively formed by pairs of recesses 30 , 32 and 34 , 36 that align with each other in abutting faces of the plates 16 a , 16 b and 18 a , 18 b.
As shown best in FIG. 1A , these recesses 30 , 32 and 34 , 36 take the form of so-called coat hangar recesses which become wider in dimension from the inlet portion 40 located proximate input ports 26 , 28 to an outlet portion 42 located proximate respective distribution passages 44 . Distribution passages 44 extend respectively through plates 16 b and 18 b and lead to similar distribution passages 46 , 48 in plates 16 c and 18 c and, finally, into elongate air outlet slots 50 , 52 which extend lengthwise along the undersides of plates 16 c , 18 c and communicate with coextensive elongate inlet slots 53 , 55 in the top of the extrusion die 14 . Plates 16 c and 18 c respectively abut central plate 20 .
Respective liquid passages 54 , 56 are formed between plates 16 c , 20 and 18 c , 20 and, again, are formed by respective pairs of coat hangar recesses 58 , 60 and 62 , 64 that align with each other in abutting surfaces of these plates 16 c , 20 and 18 c , 20 . As shown in FIG. 1A , these recesses 58 , 60 and 62 , 64 are also formed with a coat hangar configuration between inlet portions adjacent respective liquid input ports 66 , 68 and outlet portions which form elongate liquid outlet slots 70 , 72 for abutting the top surface of the extrusion die 14 and aligning with coextensive liquid inlet slots 73 , 75 . In this embodiment, the two liquid input ports 66 , 68 and coat hangar passages 54 , 56 are provided for producing bicomponent filaments from extrusion die 14 . Extrusion die 14 may be any suitable extrusion die having, for example, a laminated plate construction with appropriate porting and passages to combine and extrude filaments from the outlet orifices extending along the underside of the extrusion die 14 and to attenuate or otherwise affect those filaments with process air. Representative dies are, for example, disclosed in U.S. Pat. Nos. 5,562,930; 5,551,588; and 5,344,297, however, such dies would require modification with suitable passages (not shown) to transfer and discharge process air received from air outlet slots 50 , 52 .
Also in accordance with the invention, heating elements 74 , 76 are respectively contained in passages 80 , 82 between plates 16 b , 16 c and 18 b , 18 c . Each passage is again preferably formed by respective pairs of aligned and abutting recesses 84 , 86 and 88 , 90 in plates 16 b , 16 c and 18 b , 18 c . These heating elements 74 , 76 , which are preferably electrically operated heating elements, may be advantageously situated between the respective air and liquid passages 27 , 54 and 29 , 56 so as to heat both the liquid and the air traveling to extrusion die 14 . Sufficient heat may also be supplied to heat the extrusion die 14 itself to the appropriate operating temperature.
FIGS. 4 and 5 illustrate another apparatus 100 constructed in accordance with the invention. In this embodiment, apparatus 100 again comprises a multiple plate assembly or manifold structure 102 coupled with an extrusion die 104 . Manifold structure 102 is similar to that described with respect to the first embodiment in that a seven plate construction 106 a–c , 108 a–c , 110 is used for providing both process air and two component liquids, such as polymers, to the extrusion die 104 . However, in this embodiment, two additional plates 112 , 114 have been added to the outside of the manifold structure 102 to supply quenching air through respective input ports 116 , 118 and air passages 120 , 122 in the form of coat hangar passages as described above, and respective transfer passages 124 , 126 and 128 , 130 respectively extending through plates 106 a , 106 b and 108 a , 108 b and communicating with appropriate passages (not shown) in the extrusion die 104 . This quenching air functions to cool the filaments after they have been discharged.
As further shown in FIGS. 4 and 5 , input ports 140 , 142 are provided for introducing two different component liquids, such as two different types of polymer materials, into apparatus 100 . In addition, input ports 144 , 146 are provided for process air. Liquid input ports 140 , 142 communicate with respective pairs of abutting and aligned recesses 148 , 150 and 152 , 154 which form coat hangar passages and communicate directly with elongate slots (not shown) in the top of extrusion die 104 . Input ports 144 , 146 communicate with respective pairs of abutting recesses 156 , 158 and 160 , 162 in plates 106 a , 106 b and 108 a , 108 b . These recess 156 , 158 and 160 , 162 also form coat hanger air passages which communicate with respective elongate slots 164 , 166 in plates 106 c , 108 c through respective transfer passages 168 , 170 and 172 , 174 in plates 106 b , 106 c and 108 b , 108 c to provide process or attenuating air to die 104 . Passages 120 , 122 are likewise formed as coat hangar passages formed by abutting recesses 176 , 178 and 180 , 182 having narrower portions adjacent input ports 116 and 118 and wider portions adjacent respective transfer passages 124 and 128 . Electric heaters 184 , 186 are provided as in the first embodiment.
FIG. 6 illustrates another alternative die apparatus 200 having a laminated plate construction. This apparatus 200 is similar to that described above with respect to the first embodiment ( FIGS. 1 , 1 A, 2 , 3 ), but is configured to discharge single component filaments or monofilaments rather than a bicomponent filament. Thus, the central plate 20 used in the first embodiment has been eliminated thereby resulting in a six plate construction rather than a seven plate construction for manifold structure 202 . As with the previous embodiments, an extrusion die 204 is coupled to manifold structure 202 for discharging one or more filaments and, optionally, discharging air to facilitate a meltblowing operation. However, for spunbond apparatus, it will be appreciated that the process air passages and structure associated therewith may be eliminated. A single liquid input port 206 and coat hanger passage 208 receive the liquid, such as a thermoplastic polymer. Coat hanger passage 208 is formed by aligned recesses 210 , 212 in abutting faces of plates 16 c ′ and 18 c ′. Plates 16 c ′ and 18 c ′ are designated with prime marks (′) to denote that they are slightly modified, as illustrated, from plates 16 c , 18 c . All other aspects of apparatus 200 are as described above with respect to the first embodiment and, therefore, identical reference numerals have been used and no further description is necessary.
FIG. 7 illustrates another alternative apparatus 220 similar to that described above with respect to FIGS. 4 and 5 but, like the embodiment of FIG. 6 , apparatus 220 is configured to discharge single component filaments or monofilaments rather than bicomponent filaments. Again, the central plate 110 of the embodiment illustrated in FIGS. 4 and 5 has been eliminated and an eight plate manifold structure 222 results. Manifold structure 222 is configured to deliver liquid, process air and quench air to an extrusion die 224 . A single liquid input port 206 and a coat hanger passage 208 is formed between abutting plates 106 c ′, 108 c ′ to communicate with an appropriate elongate inlet slot (not shown) in the top of the extrusion die 224 . Plates 106 c ′ and 108 c ′ are designated with prime marks (′) to denote that they are slightly modified, as illustrated, from plates 106 c , 108 c . All other aspects of the embodiment shown in FIG. 7 are described with respect to the embodiment of FIGS. 4 and 5 and, therefore, identical reference numerals have been used and no further description is necessary.
While the present invention has been illustrated by a description of various preferred embodiments and while these embodiments has been described in some detail, it is not the intention of the Applicant to restrict or in any way limit the scope of the appended claims to such detail. Additional advantages and modifications will readily appear to those skilled in the art. The various features of the invention may be used alone or in numerous combinations depending on the needs and preferences of the user. This has been a description of the present invention, along with the preferred methods of practicing the present invention as currently known. However, the invention itself should only be defined by the appended claims, wherein we claim:
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A lamellar die apparatus for extruding a heated liquid into filaments and directing air at the filaments. The apparatus includes a plurality of plates each having opposite side faces. At least two of the side faces confront each other and have a liquid passage positioned therebetween for transferring the heated liquid. At least two of the side faces confront each other and have an air passage positioned therebetween for transferring the air. At least two of the side faces confront each other and have a heating element passage therebetween. A heating element is positioned within the heating element passage for heating at least two of the plates. An extrusion die is coupled with the plurality of plates and communicates with the liquid passage and the air passage for discharging the heated liquid as multiple filaments and for discharging the air at the filaments.
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BACKGROUND OF THE INVENTION
1. Field Of The Invention
The present invention relates to washing machines. More particularly, though not exclusively, the present invention relates to a method and apparatus for mounting a pump to a washing machine.
2. Problems In The Art
In a typical washing machine, the washing machine pump is one of the areas requiring service compared to other areas. As a result service technicians must remove and replace washing machine pumps regularly.
In a traditional prior art washing machine, the pump is fastened to the base frame of the washing machine with screws or similar fasteners. Therefore, in order to install or remove a pump from a washing machine, the washing machine has to be tipped so that access to the screws or fasteners from underneath of the washing machine base is gained.
Another problem with prior art washing machines is that the pump will vibrate and cause noise. As a result, the pump must be dampened by some means.
FEATURES OF THE INVENTION
A general feature of the present invention is the provision of a method and apparatus for mounting a pump to a washing machine which overcomes problems found in the prior art.
A further feature of the present invention is the provision of a method and apparatus for mounting a pump to a washing machine which uses a twist lock which is held in place by the hoses of the washing machine.
Further features, objects, and advantages of the present invention include:
A method and apparatus for mounting a pump to a washing machine which includes a pair of mounting feet coupled to the pump adapted to lock into the base of the washing machine.
A method and apparatus for mounting a pump to a washing machine which includes a pair of holes and grooves formed in the base of the washing machine to accommodate a twist lock configuration with the pump.
A method and apparatus for mounting a pump to a washing machine which includes a mounting base coupled to the pump which allows the pump to flex.
A method and apparatus for mounting a pump to a washing machine which uses a flexible mount which matches the natural frequency of the mount with the operating frequency of the pump.
A method and apparatus for mounting a pump to a washing machine which uses a flexible mounting member which reduces the strength necessary to pass shipping and installation impacts.
A method and apparatus that allows the pump mounting to remain flexible yet limits the motion of the pump to prevent breaking of the mount during installation and shipping.
A method and apparatus for mounting a pump to a washing machine which allows a user to gain access to the pump from the front of the washing machine.
A method and apparatus for mounting a pump to various locations on a washing machine including the outer tub.
These as well as other features, objects, and advantages of the present invention will become apparent from the following specification and claims.
SUMMARY OF THE INVENTION
The method and apparatus for mounting a component to a washing machine allows the component to be secured using a twist-type fastener to removably secure the component to the appliance. The invention includes a twist lock and one or more hoses coupled to the component and the appliance to secure the component in the locked position. In the preferred embodiment, a washing machine pump is secured to a washing machine by inserting a pair of feet formed on the pump into a corresponding pair of apertures in the base which secure the pump to the base of the appliance after the pump is twisted to a locked position. One or more hoses are then attached to the pump to secure the pump in place.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a washing machine of the present invention.
FIG. 2 is a side view of a pump used with the present invention.
FIG. 3 is a top view of the pump shown in FIG. 2.
FIG. 4 is a partial plan view of the base of the washing machine shown in FIG. 1.
FIG. 5 is a top view of the pump shown in FIGS. 2 and 3 in the locked (dashed lines) and unlocked (solid lines) positions.
FIG. 6 is a bottom view of the base of the washing machine showing the pump in the locked position.
FIG. 7 is a side view of the pump of the present invention illustrating the flexible mount.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention will be described as it applies to its preferred embodiment. It is not intended that the present invention be limited to the described embodiment. It is intended that the invention cover all alternatives, modifications, and equivalencies which may be included within the spirit and scope of the invention.
FIG. 1 is a perspective view of a washing machine 10 of the present invention. The washing machine 10 shown in FIG. 1 is a horizontal axis washing machine. As shown, the washing machine 10 includes a door 12 which provides access to the interior of the washing machine 10 from the front. Disposed within the washing machine 10 is a wash tub 14 which surrounds a perforated wash basket 16. The components of the washing machine 10 described above are not a part of the present invention. FIG. 1 also shows a pump 18 mounted to the base 20 of the washing machine 10. The pump 18 shown in FIG. 1 is shown diagramatically in order to show its position relative to the remainder of the washing machine 10. The pump 18 is connected to the tub 14 via a tub outlet hose and to a drain via a drain hose. Of course, the pump 18 could be located elsewhere. In addition, the present invention could apply to other types of washing machines and other types of appliances.
FIGS. 2 and 3 show side and top views, respectively, of the washing machine pump 18. The pump 18 is comprised of a motor 22 which is operatively connected to an impeller 24. The impeller 24 is housed within the pump housing 26. When the motor 22 is activated, water is pumped from an input port 28, through the pump housing 26, and out through the output port 30. In this way, water is drawn out of the wash tub 14, through the pump 18, and is drained via the output port 30.
The pump 18 also includes a pump mount 32. The pump mount 32 further comprises a pair of mounting feet 34 which each include a flange 35 and a slot 36 formed between the feet 34 and the flange 35. The mounting feet 34 are each coupled to an arm 38 which extends outward from the mount 32. The arms 38 are generally C-shaped as shown in FIG. 2. Also extending from the pump mount 32 are a pair of secondary arms 40 which each include a stop 42 which is comprised of an upward facing protrusion. The purpose of the arms 38 and 40 are discussed below. Preferably, the pump mount 32 is made of resilient material such as plastic so that the arms 38 will be flexible.
FIG. 4 is a top view of a portion of the base 20 of the washing machine 10. The base 20 is preferably comprised of sheet metal being approximately 0.045 inches thick. Formed in the base 20 are two mounting apertures 46 which are positioned at the location in which the pump 18 is mounted. The apertures 46 each include a first end 48 having a first diameter and a second end 50 having a second diameter. The first diameter is larger than the diameter of the feet 34, but smaller than the diameter of the flanges 35. The second diameters are smaller than the diameters of both the feet 34 and flanges 35. In this way, the pump 18 can be positioned over the holes 46 such that the feet 34 extend through the first end 48 of the holes 46 such that the feet 34 extend below the base 20, while the flanges 35 rest upon the top of the base 20. Once the pump 18 is set into place as described above, it can be rotated counterclockwise until the feet 34 line up with the second ends 50 of the holes 46. In this position, the pump 18 cannot be lifted from the base 20 without rotating the pump 18 clockwise to where the feet 34 are lined up with the first ends 48 of the holes 46.
FIG. 5 is a top view of the pump 18 and the base 20 of the washing machine 10. FIG. 5 shows the pump 18 in a first position (solid lines) in which the feet 34 are aligned with the first ends 48 of the holes 46. FIG. 5 also shows the pump 18 rotated counterclockwise (dashed lines) showing the feet 34 aligned with the second ends 50 of the holes 46. When the pump 18 is in the position shown by dashed lines, it cannot be removed from the base 20 without rotating the pump 18 clockwise to the position shown by solid lines. Once the pump 18 is rotated counterclockwise to the position shown by dashed lines, the wash tub outlet hose 52 is connected to the input port 28 and the drain hose 54 is connected to the output port 30 as shown. The hoses 52 and 54 hold the pump 18 in the locked position so that the pump 18 cannot rotate clockwise to the position shown in solid lines. In this way, the hoses 52 and 54 lock the pump 18 in place eliminating the need for a detent or screw or some other device for preventing rotation of the pump 18. The hoses 52 and 54 are carefully positioned and selected so that they serve this function. In addition, the hoses 52 and 54 are installed with the proper amount (or lack of) slack in order to inhibit the rotation of the pump 18.
FIG. 6 is a view taken from below the base 20 showing the mounting apertures 46 and the feet 34 of the pump mount 32. For purposes of clarity, only the feet 34 of the pump 18 are shown in FIG. 6. FIG. 6 also shows arrows 56 and 58. Arrow 56 shows the direction of rotation for removing or unsecuring the pump 18 while arrow 58 shows the direction of rotation for locking the pump 18 into place.
FIG. 7 is a side view of the pump 18 shown mounted to the base 20. As mentioned above, the arms 38 are made flexible in order to isolate the pump vibration from the rest of the machine. In addition, while making the mount flexible, it is possible to make the natural frequency of the pump mount 32 match the operating frequency of the pump. If this is done properly, the pump mass will act as part of a tuned mass vibration absorber which will contribute additional vibration isolation from the base 20. One skilled in the art can design the mount in this way simply by carefully selecting the dimensions and configuration of the mount while taking account of such variables as the mass of the pump, the operating speed of the pump, the angular momentum of the pump, etc.
FIG. 7 also illustrates the operation of the flexible pump mount 32. FIG. 7 shows the normal position of the pump 18 in solid lines. In broken lines, FIG. 7 shows the pump 18 in a moved or flexed position. As shown, because of the flexibility of the arms 38, the pump is allowed to move slightly in either direction. The pump 18 is prevented from moving too far by the stops 42 which will come into contact with the upper portion of the arms 38 when the pump 18 is flexed a certain amount. In the preferred embodiment, if the pump deflects more that 0.150 inches, there is an interference between one of the arms 38 and the corresponding stop 42. In this way, the mount 32 allows the pump to be flexible, but at the same time restricts the motion of the pump 18.
In an alternative embodiment, the pump 18 has two feet each with a rubberized slider slid into place. The pump and rubberized sliders are set into the mounting apertures 46 as described above and rotated into position as described above. In this embodiment, the rubber isolators absorb the high frequency vibrations generated by the pump. In another embodiment, components other than hoses, such as wiring harness, could be used to hold the pump in the locked position. Note that other alternatives are also possible within the scope of the present invention. In addition, the present invention may apply to a variety of appliances including clothes washing machines, dish washing machines, dryers, refrigerators, etc.
The present invention operates as follows. The operation of the present invention will be described from the standpoint of the installation of the pump 18, or the service and maintenance of the pump 18. When the pump 18 is initially installed into the washing machine 10, the pump 18 is positioned above the base 20 with the feet 34 aligned with the first ends 48 of the mounting apertures 46 (shown by solid lines in FIG. 5). With the feet 34 inserted through the holes 46, the pump 18 is rotated counterclockwise to the position shown by dashed lines in FIG. 5. To lock the pump 18 into place, the hoses 52 and 54 are connected to the input and output ports 28 and 30, respectively.
When the pump needs replacing or servicing, a technician simply detaches hoses 52 and 54 and rotates the pump 18 clockwise to the position shown by solid lines in FIG. 5. The pump 18 can then be removed from the base 20. At no time does a technician need access to the bottom side of the base 20. In addition, the technician does not need to remove any screws or other fasteners.
If pressure is applied to the pump 18 during shipping or during use, the flexible pump mount 32 will allow the pump 18 to flex, reducing the chance of breakage. However, the pump mount 32 will prevent the pump 18 from moving too far by means of the arms 38 and stops 42.
The preferred embodiment of the present invention has been set forth in the drawings and specification, and although specific terms are employed, these are used in a generic or descriptive sense only and are not used for purposes of limitation. Changes in the form and proportion of parts as well as in the substitution of equivalents are contemplated as circumstances may suggest or render expedient without departing from the spirit and scope of the invention as further defined in the following claims.
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A pump mount of the present invention is adapted to removably mount a pump to a washing machine without requiring access to the bottom of the washing machine. The pump includes a mount having a pair of feet which are adapted to be secured to the base of the washing machine using a twist lock. The feet can be inserted into holes formed in the washing machine base and the pump twisted to lock the pump in place. The wash tub outlet hose and drain hose are then attached to the pump. The hoses attached to the pump secure the pump in the locked position preventing the pump from twisting to the unlocked position.
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TECHNICAL FIELD
[0001] This invention relates to grinding machines and, more particularly, to methods of determining the condition of an electroplated grinding wheel to indicate when a grinding wheel is near the end of its life cycle.
BACKGROUND OF THE INVENTION
[0002] Grinding machines for grinding camshafts and crankshafts are known in the art. For rough grinding, such a machine may use a grinding wheel spindle having a steel hub, onto which a single layer of cubic boron nitride (CBN) grains are held by an electroplated layer of material such as nickel to provide a grinding wheel with a grinding surface around the circumference of the wheel.
[0003] Over the life of the wheel, the grains are worn down and the nickel layer is eroded. This is a gentle and slowly-evolving condition during the life of the wheel. However, at some point, damage to the bonding layer becomes catastrophic, resulting in grain loss. This then transfers more of the cutting load to the remaining active grains. Rapidly, grains are stripped, causing failure of the grinding surface and rubbing between the metal wheel hub and workpieces takes place producing extremely high forces on the grinding spindle bearing system. If continued, the additional grinding may overload the grinding motor and/or damage the grinding wheel spindle. In order to avoid spindle damage and motor overload, grinding wheels are prematurely replaced after a set number of grinds. Consequently, grinding wheels which may still be usable are prematurely replaced, resulting in increased manufacturing costs.
[0004] A method of determining when a grinding wheel is near the end of its life cycle is desired to prevent excessive grinding machine wear or damage while avoiding premature replacement of usable grinding wheels.
SUMMARY OF THE INVENTION
[0005] The present invention provides a method of determining the condition of a grinding wheel during grinder operation to avoid over use or premature replacement of the grinding wheel.
[0006] A grinding machine designed for grinding of camshafts, crankshafts or other workpieces may include an electric motor, which drives a rough grinding spindle having a steel hub. The hub periphery preferably carries a single layer of cubic boron nitride (CBN) grains held in place by an electroplated material such as nickel. The grinding machine is adapted to rotate a workpiece, such as a camshaft or crankshaft, adjacent the grinding wheel.
[0007] Sensors positioned within the grinding machine monitor motor torque, spindle speed, grinding force and grinding position. The sensors relay information to a controller, which controls movement of the grinding wheel and records periodic readings of the grinding force applied during grinding of a workpiece into a desired shape.
[0008] The controller calculates and records an average of the grinding force readings during a selected portion of the grind of each workpiece to determine an average of the recorded grinding force for each part. The controller may also monitor the motor torque applied during grinding and determine an average of recorded motor torque for a selected portion of the grind of each workpiece.
[0009] If the average of recorded grinding force or the average of recorded motor torque exceeds a predetermined grinding force or motor torque limit, the controller actuates a fault signal to stop the grinding machine, indicating the grinding wheel is near the end of its life cycle. The worn grinding wheel can then be replaced.
[0010] When the averages of recorded grinding force readings or the average of recorded motor torque readings do not exceed the predetermined grinding force or motor torque limits, the controller will allow the grinding machine to perform subsequent grinds, until the controller determines the grinding wheel is near the end of its life cycle.
[0011] During successive grinds, the controller continues to calculate the average of recorded grinding force readings and the average of recorded motor torque readings for the selected portions of each grind. The average of recorded grinding force readings and average of recorded motor torque readings from the current grind is compared to the average of these readings of the previous grind to quantify an incremental increase in average grinding force readings and average motor torque readings from one grind to the next. The level of increase is then compared to a predetermined limit of grinding force increase and a predetermined limit of motor torque increase. If the increase exceeds either limit, the controller will actuate a fault signal and stop the grinding machine and allow the spent grinding wheel to be replaced. This prevents damage caused by continued operation. If the increase does not exceed the limits, the controller will allow the grinding machine to continue the current operations.
[0012] These and other features and advantages of the invention will be more fully understood from the following description of certain specific embodiments of the invention taken together with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a simplified view of an exemplary grinding machine for use in camshaft rough grinding;
[0014] FIG. 2 is a graph of drive force readings versus time intervals for the last plunge of a rough grinding process on a machine similar to FIG. 1 ; and
[0015] FIG. 3 is a graph of grinding motor torque versus time intervals for the last plunge of a rough grinding process similar to FIG. 2 .
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0016] Referring now to FIG. 1 of the drawings in detail, numeral 10 generally indicates a grinding machine for use in camshaft rough grinding, as well as other grinding functions. The grinding machine 10 has a motor 12 , which drives a grinding spindle 14 carrying a hub 15 . An outer periphery of the hub is covered by a single layer 18 of cubic boron nitride (CBN) grains which are held to the periphery of the hub 15 by electroplating thereon a material such as nickel, thus forming a grinding wheel 16 . The single layer of CBN provides grinding or cutting edges which enable the grinding wheel 16 to grind steel, cast iron, or other hard substances.
[0017] The grinding machine 10 is adapted to rotate a workpiece 20 , such as a camshaft or crankshaft, in a rotatable chuck 22 adjacent the grinding wheel 16 . If desired, multiple grinding wheels similar to grinding wheel 16 may be carried by the grinding spindle 14 to enable the grinding machine 10 to simultaneously grind multiple surfaces of a workpiece. Coolant nozzles, not shown, may direct coolant against the grinding interface to carry away heat and grinding particles from the grinding interface.
[0018] Sensors, not shown, within the grinding machine 10 monitor motor torque, spindle speed, grinding force and grinding position and relay the information to a controller 24 . The controller 24 controls the movement of the grinding wheel 16 and monitors the condition of the grinding wheel 16 using information relayed from the sensors.
[0019] According to the present invention, the controller 24 determines the condition of the grinding wheel 16 using the level of grinding force between the wheel 16 and a workpiece during grinding of a workpiece into a desired shape. If desired, the controller 24 may also use the level of motor torque reached. When either the level of grinding force or the level of motor torque exceeds predetermined limits, specific to the grinding machine 10 , the controller actuates a fault signal to stop the grinding machine, to allow the worn grinding wheel 16 to be replaced.
[0020] Referring now to the operation of the controller 24 in further detail, the controller 24 operates by first monitoring and recording the level of grinding force applied by the grinding wheel 16 at a series of time intervals during a selected portion of a workpiece grind, such as a final plunge cut during one rotation of the workpiece. The recorded grinding forces are then averaged to create an average of recorded grinding forces, which is then compared to a grinding force limit.
[0021] The grinding force limit is predetermined and established by engineers based on the type of grinding machine, the type of grinding wheel and the material of the workpiece. Using grinding machine 10 as an example, the grinding force limit is established to be around 16 percent of the maximum force capability of the grinding machine 10 . The force limit is calculated by adding 10 percent of the force capability of the grinding machine to the average level of grinding force of a typical workpiece with an unused grinding wheel. If the average of recorded grinding force exceeds the force limit, the controller 24 will actuate a fault signal to stop the grinding machine 10 , to allow the worn grinding wheel 16 to be replaced.
[0022] If desired, the controller 24 may use motor torque to provide a second method of monitoring the condition of the wheel 16 . The controller 24 monitors and records periodic readings of motor torque exerted by the wheel drive motor 12 over a period of time, such as a final plunge cut during one rotation of the workpiece 20 . The readings of recorded motor torque are then averaged to create an average of recorded motor torque, which is then compared to a motor torque limit. The motor torque limit is predetermined and established by engineers based on the type of grinding machine, the type of grinding wheel and the material of the workpiece.
[0023] Using grinding machine 10 as an example, the motor torque limit is established to be around 40 percent of the maximum torque capacity of the grinding wheel drive motor 12 . The motor torque limit is calculated by adding 10 percent of the drive motor torque capability to the average motor torque exerted when a typical workpiece is ground with an unused grinding wheel. If the average motor torque exceeds the torque limit, the controller 24 actuates a fault signal to stop the grinding machine, to allow the worn grinding wheel 16 to be replaced.
[0024] The controller 24 continues to determine the average of recorded grinding force during subsequent grinds of subsequent workpieces to create an average of recorded grinding force for each grind or workpiece. The average of recorded grinding force from a current grind is then compared to the previous average of recorded grinding force from a previous grind or a previous workpiece to quantify an incremental increase in the average of recorded grinding force from one grind or workpiece to the next. The increase is then compared to a predetermined grind force increase limit, which is predetermined and established by engineers based on the type of grinding machine, the type of grinding wheel and the material of the workpiece.
[0025] Using grinding machine 10 as an example, the force increase limit is established to be 40 percent greater than the average of recorded grinding force of the previous grind or workpiece. Therefore, if the previous average or recorded grinding force is 5% of the force capacity of the grinding machine, an increase of up to 2% would be allowable (40% of 5%=2%). If the level of increase exceeds 2%, then the controller 24 actuates a fault signal to stop the grinding machine 10 , to allow the worn grinding wheel 16 to be replaced.
[0026] If the increase is below 2%, the controller proceeds to compare the average of recorded grinding force of the current grind to the grinding force limit. If the average or recorded grinding force exceeds the grinding force limit, the controller actuates a fault signal to stop the machine to allow the worn grinding wheel to be replaced.
[0027] The controller 24 may also record and average the level of motor torque during subsequent grinds or subsequent workpieces to create an average of recorded motor torque for each grind or workpiece. The average or recorded motor torque from the current grind is then compared to the previous average of recorded motor torque to quantify an incremental increase in the average of recorded motor torque from one grind or workpiece to the next. The level of increase is then compared to a motor torque increase limit, which is predetermined and established by the type of grinding machine, the type of grinding wheel and the material of the workpiece.
[0028] Using grinding machine 10 as an example, the torque increase limit between the successive grinds or workpieces is established to be 40% greater than the average of recorded grinding force of the previous grind or workpiece. Therefore, if the previous average of recorded motor torque value is approximately 30% of the capacity of the grinding machine, a change of up to 12% would be allowable (40% of 30%=12%). If the level of increase exceeds 12%, then the controller 24 actuates a fault signal to stop the grinding machine 10 to allow the worn grinding wheel 16 to be replaced.
[0029] If the increase is below 12%, the controller proceeds to compare the average of recorded motor torque, from the current grind, to the motor torque limit to see if the current motor torque average exceeds the torque limit, indicating a failed grinding wheel. If the average of recorded motor torque exceeds the motor torque limit, the controller actuates a fault signal to stop the grinding machine to allow the worn grinding wheel to be replaced.
[0030] In operation, an unfinished cast workpiece 20 , such as a camshaft, is rotated by the grinding machine 10 adjacent the grinding wheel 16 . Once the workpiece 20 is securely retained within the chuck 22 of the grinding machine 10 , the grinding wheel 16 is brought up to optimal grinding speed. The grinding wheel 16 is then advanced toward the workpiece 20 . As the grinding wheel makes contact with the workpiece, the workpiece is rotated to allow the wheel to grind away any imperfections on the surface of the workpiece. During this time, cooling solution is sprayed on the grinding interface to carry away heat from the grinding process. Depending on the workpiece and the type of grinding wheel, it may require multiple plunge cuts, at multiple depths, to grind the workpiece into a desired shape and to provide a machined surface.
[0031] As the grinding wheel 16 grinds the surface of the workpiece 20 , motor torque and grinding force information are relayed to the controller 24 . The information is then averaged and compared to motor torque and grind force limits stored within the controller 24 , as previously described, to determine the condition of the wheel 16 . As subsequent workpieces 20 are ground in the same manner as described above, the motor torque and grind force information from the subsequent grind are averaged and recorded. The recorded grind force and motor torque are then compared to the previous grind to quantify the increase as previously described. The increase of grinding force and motor torque are then compared to increase limits, to determine the condition of the wheel 16 , as previously described.
[0032] FIG. 2 is a graph comparing wheelhead forces of three normal wheels and two failed wheels operating in the grinding machine 10 . The results show that failed grinding wheels, represented by lines 30 , 32 utilized an average of about 28% of the grinding force capacity of the grinding machine. The good grinding wheels represented by lines 34 , 36 , 38 utilized an average of only about 5.5% of the grinding force capacity of the grinding machine. This shows that as the grinding wheel 16 nears the end of its useful life, prior to failure, the amount of grinding force begins to increase substantially. Accordingly, the controller 24 monitors the status of the grinding wheel 16 using grinding force loads in a manner to predict when a grinding wheel 16 is near the end of its life cycle, before the grinding wheel fails as illustrated by lines 30 , 32 .
[0033] FIG. 3 of the drawings is a graph comparing motor torque for three normal wheels and two failed wheels operating in grinding machine 10 . The results show that failed grinding wheels, represented by lines 40 , 42 , utilized an average of about 43% of the motor torque capacity of the grinding machine 10 . The good grinding wheels, represented by lines 44 , 46 , 48 , utilized an average of about 29% of the motor torque capacity of the grinding machine 10 . Accordingly, the controller 24 monitors the status of a grinding wheel using motor torque to predict when the grinding wheel is near the end of its life cycle, before the grinding wheel 16 fails as illustrated by lines 40 , 42 .
[0034] It should be understood that by comparing the average of recorded grinding forces and the average of recorded motor torque from grind to grind or workpiece to workpiece, the controller 24 is able to detect a failed or near failed grinding wheel before the operating limits of the grinding machine 10 are reached.
[0035] In order to insure the most accurate results, the average recorded grinding force and average recorded motor torque should be compared at the same cycle or position for each workpiece 20 to ensure consistent results. Otherwise, the changes from cycle to cycle may cause the controller 24 to err and falsely stop the grinding machine 10 . Preferably, the averaged grinding force and motor torque should be compared at the same plunge depth each time so that variations of the workpiece and other factors such as the aim of coolant nozzles and the level of coolant flow directed over the grinding wheel are consistent. At present, the last or second to last grind cycle or workpiece revolution has been found to be the most consistent from workpiece to workpiece. Therefore, the average grinding force and motor torque from these cycles provide the most accurate indices for control.
[0036] While the invention has been described by reference to certain preferred embodiments, it should be understood that numerous changes could be made within the spirit and scope of the inventive concepts described. Accordingly, it is intended that the invention not be limited to the disclosed embodiments, but that it have the full scope permitted by the language of the following claims.
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A method of determining the condition of a grinding wheel is provided to avoid over use or premature changing of the grinding wheel in a grinding machine, such as for crankshaft or camshaft grinding. The grinding machine has a motor which drives a grinding spindle carrying an abrasive coated hub acting as a grinding wheel. Sensors detect the level of grinding force and motor torque required to grind a workpiece into a desired shape. The information is relayed to a controller, which averages and compares the grinding force and torque information to force and torque limits to determine the condition of the wheel. In addition, the controller compares grinding force and motor torque over a series of grinds to determine the level of increase between grinds to further determine the condition of the grinding wheel. If the level of increase exceeds an increase limit, the controller actuates a fault signal to stop the grinding machine indicating that the wheel is near the end of its life cycle.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] The present application claims the benefit of U.S. patent application Ser. No. 60/980,703, filed Oct. 17, 2007, which is hereby incorporated by reference in its entirety.
TECHNICAL FIELD
[0002] The present invention relates generally to a board game and in particular, relates to a board game that assists the player in learning to eat a balanced meal by linking the eating of different foods of the meal to game play and otherwise turning the entire eating experience into fun.
BACKGROUND
[0003] The use of board games as a means of entertainment is well known in the prior art and despite the increased popularity of electronic video and computer games, board games remain a popular form of competitive amusement for both children and adults. Today's board games may be generally classified into several broad categories. Games such as chess and checkers are of a type that generally divide the game board into a series of squares, and game pieces are moved from square to square as dictated by the rules of the game without necessarily having to follow a particular pathway or route. There are also a wide variety of “pathway-type” board games wherein the game pieces are moved sequentially along a standardized play path, usually consisting of a sequence of blocks or spaces having at least a beginning space and an ending space, as in monopoly. Finally, there are board games which attempt to simulate or mimic a particular sport or activity, such as baseball and football. Countless variations and combinations of such types of board games are known in the prior art, many of which employ some form of chance-determining means, such as one or more die, a spinner having numerals thereon, or “chance” cards, for determining the movement of the game pieces.
[0004] In addition to amusing and entertaining the players, many board games also employ some type of teaching device, sequence, or materials in an attempt to add an educational aspect or means for increasing the knowledge or skill of the players concerning a particular subject or subjects to the game.
[0005] While there are a vast number of games that provide educational information in different fields, there is a need for providing an educational game that assists in teaching children that eating a nutritional meal can be a “fun” experience and that dinner time does not always have to be mundane, fussy time of the day as it is for many younger children.
SUMMARY
[0006] A method of playing a board game that assists a child to eat a healthy, balanced meal includes the steps of: (a) providing a set of food holders that hold a plurality of food items in separate locations; (b) identifying the individual food holders with different visual indicia; (c) providing a spinner device that includes a substrate with a surface that includes a plurality of playing spots that include visual indicia that corresponds to the food holders; (d) spinning a spinner that is above the substrate surface, the spinner having a first end that randomly points to one of the playing spots; (e) directing the player to consume food in one or more food holders in accordance with instructions that are present as part of the playing spot that is pointed to by the first end of the spinner; and (f) repeating the spinning and directing steps.
[0007] A board game that assists and encourages a child to eat a healthy, balanced meal includes a food tray that includes a plurality of food holders that hold a plurality of food items in separate locations. The food holders are identified with different visual indicia that serve to uniquely identify each food holder. The board game further includes a spinner device that includes a substrate with a surface that includes a plurality of playing spots that include visual indicia that corresponds to the visual indicia that uniquely identifies the food holders. The spinner device has an arm that is rotatably coupled to the substrate and having a first end that randomly points to one of the playing spots after the arm comes to rest after being spun. Each playing spot has instructions displayed thereon that require the child to take one bite from food that is contained in at least one of the food holders.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
[0008] The foregoing and other features of the present invention will be more readily apparent from the following detailed description and drawings figures of illustrative embodiments of the invention in which:
[0009] FIG. 1 is a top plan view of a food holder that is part of a board game and a cup that is optionally part of the board game according to one exemplary embodiment of the present invention;
[0010] FIG. 2 is a top plan view of the food holder; and
[0011] FIG. 3 is a top plan view of a spinner that is part of the board game.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0012] Referring to FIGS. 1-3 , a board game 100 according to one exemplary embodiment is illustrated and is intended to assist children in eating their entire meals. It is common for children to not like to eat their entire meal in a timely manner. For example, some children take a relatively lengthy amount of time to finish their meal based on the meal containing one or more food items that the user is not particularly fond of eating. For example, many children do not like to eat vegetables and consequently, the child will slowly eat the vegetables thinking that after a while, the parent will become tired and will remove the meal from the child resulting in the child not having to eat the entire meal and more specifically, resulting in the child not having to eat healthy vegetables.
[0013] Other children do not like a particular food type, such as vegetables, and will refuse to eat this food type or will orally protest by crying or otherwise fussing or playing with the food when the parents request that the child eat the food type. This makes dinner time a difficult time for the parents and frankly, many parents do not look forward to dinner time and feeding their children.
[0014] The board game 100 is constructed to change how a child views the entire dinner experience and in particular, the board game 100 links the eating of a complete, balanced meal with the playing of the board game 100 and therefore makes the entire eating experience more enjoyable for the child.
[0015] The board game 100 includes a food holder member 110 which holds the meal to be eaten and in particular, is designed to segregate and hold the different food items that make up the meal. The illustrated food holder member 110 is in the form of a tray that has a number of recessed compartments for individually holding the different food items of the meal. For example, the food holder member 110 has a first recessed compartment 120 for holding a first food item or type, a second recessed compartment 130 for holding a second food item or type, a third recessed compartment 140 for holding a third food item or type, and a fourth recessed compartment 150 for holding a fourth food item or type. It will be appreciated that while the illustrated food holder type has four different recessed compartments, the food holder type is not limited to have four recessed compartments and instead can include less than four (e.g., two) or more than four (e.g., five) recessed compartments.
[0016] It is intended that the four recessed compartments 120 , 130 , 140 , 150 hold the different food and prevent mixing or commingling of the food.
[0017] It will also be appreciated that the sizes of the four recessed compartments 120 , 130 , 140 , 150 can be the same or more likely at least one of the recessed compartments will have a larger size than the others since one of the recessed compartments holds the main portion of the meal. For example, the first recessed compartment 120 can be designated as the compartment that holds the main meal component or food type and the other recessed compartments hold the side dishes, such as vegetables and fruit and dessert.
[0018] For example, a traditional child's meal will include a main food component (the first food item), vegetables (the second food item), fruit (the third food item), and a dessert (the fourth food item). Accordingly, in the illustrated embodiment, the main food component is contained in the first recessed compartment 120 , vegetables are contained in the second recessed compartment 130 , fruits are contained in the third recessed compartment 140 and the dessert is contained in the fourth recessed compartment 150 .
[0019] The relative sizes of the recessed compartments can be selected in view of food that is intended to be placed in the respective recessed compartment. For example, the fourth recessed compartment 150 can be intended to hold the dessert of the meal and therefore, this compartment can have an area that is less than the other recessed compartments since it is not desirable for the child to eat too much dessert for any given meal. Since the consumption of vegetables and fruits is encouraged as being part of a healthy lifestyle and promotes healthy child growth. Thus, the second and third recessed compartments 130 , 140 can be about the same size.
[0020] Some typical main food components include spaghetti, macaroni and cheese, chicken, pizza, hamburger, peanut butter and jelly sandwich, etc. Vegetables include the standard wide assortment of vegetables including green beans, carrots, broccoli, coin, etc. Fruits can include apples, bananas, strawberries, oranges, etc. Desserts can include cookies, brownie, ice cream, cake, etc.
[0021] In the illustrated embodiment, the depths of the recessed compartments 120 , 130 , 140 , 150 can be the same or they can be different.
[0022] In accordance with the present invention, each of the recessed compartments includes an identifying indicia that identifies and distinguishes each of the recessed compartments from the other recessed compartments. For example, the first recessed compartment 120 includes first identifying indicia 122 , the second recessed compartment 130 includes second identifying indicia 132 , the third recessed compartment 140 includes third identifying indicia 142 and the fourth recessed compartment 150 includes fourth identifying indicia 152 . The identifying indicia is different from one another since it serves to visually distinguish one compartment from another.
[0023] In contrast to having mundane indicia, such as different letters or different numerals, the identifying indicia 122 , 132 , 142 , 152 is geared more to children and therefore has a children's theme. For example, the identifying indicia 122 , 132 , 142 , 152 can have an animal theme, a transportation theme, a sports theme, a toy theme, etc.
[0024] FIGS. 1 and 2 illustrate identifying indicia 122 , 132 , 142 , 152 that has an transportation theme. The identifying indicia 122 , 132 , 142 , 152 can include not only graphic representations but also text. For example, when the indicia has a transportation theme, the first identifying indicia 122 has a graphic representation of an automobile and includes the text “Car”; the second identifying indicia 132 has a graphic representation of a plane and includes the text “Plane”, the third identifying indicia 142 has a graphic representation of a bus and includes the text “Bus”, and the fourth identifying indicia 152 has a graphic representation of a train and includes the text “Train”. When the identifying indicia takes the form of animals, the first identifying indicia 122 has a graphic representation of a cow and includes the text “Cow”; the second identifying indicia 132 has a graphic representation of a dog and includes the text “Dog”, the third identifying indicia 142 has a graphic representation of a horse and includes the text “Horse”, and the fourth identifying indicia 152 has a graphic representation of a cat and includes the text “Cat”.
[0025] As shown in FIG. 3 , the board game 100 includes a random number or space generator 200 that complements the food holder member 110 and provides instructions to the player. In one embodiment, the random number or space generator is in the form of a spinner wheel 200 . The spinner 200 is of the type commonly found in board games being essentially circular with a finger-activated spinning arrow pivotally attached at the center. More specifically, the spinner wheel 200 has a substrate 210 that has a front face or surface 212 that faces the player as the game is played. The spinner wheel 200 also includes a finger-activated spinner or spinning arrow 220 that is rotatably coupled to the substrate 210 and includes a first end 222 that is the end which the player contacts to spin the spinner 220 and an opposite second pointed end 224 (arrow end) that provides instructions to the player.
[0026] The front face 212 includes a number of playing spaces that are arranged as pie-wedge segments of the circular playing surface of the spinner wheel 200 . In accordance with the present invention, the arrow 224 is capable of landing on any of the pie-wedge segments specifying which food compartment is to be eaten from. In other words, when the player spins the spinner 220 , the player is instructed or is given a choice as to where the next bite of the meal is to be taken from the food holder member 110 . In one embodiment, there are eight (8) pie-wedge segments 230 , 232 , 234 , 236 , 238 , 240 , 242 , 244 that contain indicia and/or text that instructs the player.
[0027] In the illustrated embodiment, the pie-wedge segment 230 has an illustration of the plane that is also formed on the second recessed compartment 130 and has the text “Take 1 Bite”, and therefore, if the user lands on this space during play, the player must take 1 Bite from the food item that is present in the second recessed compartment 130 . The pie-wedge segment 232 has illustrations of the car, plane, bus and train that are also formed on the recessed compartment 120 , 130 , 140 , 150 , respectively, and has the text “Choose 1 Bite”, and therefore, if the user lands on this space during play, the player must take 1 Bite from any of the food items that are present in the recessed compartment 120 , 130 , 140 , 150 . This permits the child to take a bite from a favorite food that may be present. The pie-wedge segment 234 has an illustration of the car that is also formed on the first recessed compartment 120 and has the text “Take 1 Bite”, and therefore, if the user lands on this space during play, the player must take 1 Bite from the food item that is present in the first recessed compartment 120 . The pie-wedge segment 236 has illustrations of the plane and train that are also formed on the second and fourth recessed compartment 130 , 150 and has the text “1 Bite Each”, and therefore, if the user lands on this space during play, the player must take 1 Bite from the food items that are present in both the second and fourth recessed compartment 130 , 150 .
[0028] The pie-wedge segment 238 has an illustration of the bus that is also formed on the third recessed compartment 140 and has the text “Take 1 Bite”, and therefore, if the user lands on this space during play, the player must take 1 Bite from the food item that is present in the third recessed compartment 140 . The pie-wedge segment 240 has illustrations of the car, plane, bus and train that are also formed on the recessed compartment 120 , 130 , 140 , 150 , respectively, and has the text “1 Bite Each”, and therefore, if the user lands on this space during play, the player must take 1 Bite from each of the food items that are present in the recessed compartment 120 , 130 , 140 , 150 . The pie-wedge segment 242 has an illustration of the train that is also formed on the fourth recessed compartment 150 and has the text “Take 1 Bite”, and therefore, if the user lands on this space during play, the player must take 1 Bite from the food item that is present in the fourth recessed compartment 150 . The pie-wedge segment 244 has illustrations of the car and bus that are also formed on the first and third recessed compartments 120 , 140 and has the text “Choose 1 Bite”, and therefore, if the user lands on this space during play, the player can choose to take 1 Bite from the food items that are present in the first and third recessed compartments 120 , 140 .
[0029] The child spins the spinner 220 and eats food from wherever the spinner 220 lands as a result of the pie-wedge segments providing eating instructions to the player. In this manner, eating is turned into child's play and once engaged in an entertaining meal, children won't notice that they are actually eating very healthy food.
[0030] Of course, the above eating instructions that are provided on the pie-wedge segments are merely exemplary and it will be understood that the pie-wedge segments can include other eating instructions other than the ones described above. In any event, the board game 100 is designed to enhance and encourage a child to eat a healthy, balanced meal.
[0031] The front face 212 of the substrate 210 of the spinner wheel 200 is preferably formed of a washable surface and includes some protective coating, like a plastic coating, so that in the event that food or drink is accidentally dropped on the spinner wheel 200 , it can be easily removed by wiping it off.
[0032] Optionally and as shown in FIG. 1 , the board game 100 includes a cup 300 that has the graphic representations that form a part of the board game 100 . In other words, the cup has the graphic representations that are found in the recessed compartments and on the playing surface of the spinner wheel 200 .
[0033] It will also be understood that the food holder can include different graphics than those represented herein and can otherwise be identified so long as there is a coordination between the playing spots on the spinner wheel and the compartments of the food holder. For example, the compartments of the food holder can be identified with different colors and the spinner wheel can have corresponding color blocks and instructions that dictate which food compartments are to be eaten from. In addition, the number of pie-segments can be varied and the instructions on the spinner wheel also can be varied and be different from the ones illustrated herein so long as the spinner wheel includes instructions that result in eating from each of the food compartments.
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A method of playing a board game that assists a child to eat a healthy, balanced meal includes the steps of: (a) providing a set of food holders that hold a plurality of food items in separate locations; (b) identifying the individual food holders with different visual indicia; (c) providing a spinner device that includes a substrate with a surface that includes a plurality of playing spots that include visual indicia that corresponds to the food holders; (d) spinning a spinner that is above the substrate surface, the spinner having a first end that randomly points to one of the playing spots; (e) directing the player to consume food in one or more food holders in accordance with instructions that are present as part of the playing spot that is pointed to by the first end of the spinner; and (f) repeating the spinning and directing steps.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to high speed digital integrated circuits, and in particular, to low voltage differential swing (LVDS) signal drivers for uses in and with high speed digital integrated circuits.
2. Description of the Related Art
With the tremendous growth of the Internet, data transfers, in terms of both volume and speed, are increasing dramatically in all areas of communications. For example, data streams for digitized video signals, high definition television (HDTV) and color graphics data require increasing amounts of bandwidth. As a result, increasingly higher speed interconnects between integrated circuits (chips), functional boards and systems become increasingly critical. While virtually all such data is digital in form, it is a high speed analog circuit technique that has become increasingly prevalent in meeting such data transfer needs. This circuitry, i.e., LVDS, provides for multigigabit data transfers on copper interconnects and high speed transmission lines, including fiber optic applications. These LVDS circuits have proven speed, low power, noise control and cost advantages important in point-to-point applications for telecommunications, data communications and video displays.
However, while LVDS circuits continue to provide significant advantages in applications requiring high data transfer rates, such circuits are not immune from three major parameters that influence the operation of virtually any circuit or system: circuit fabrication (or manufacture) process variations (“P”); power supply voltage variations (“V”); and operating temperature variations (“T”); often referred to collectively as PVT.
With respect to fabrication process variations, it is well known that notwithstanding the stringent quality control measures typically used to fabricate integrated circuits, fabrication processes nonetheless suffer some variations among the various processing parameters.
With respect to power supply variations, it is well known that notwithstanding the use of various filters or shielding techniques, noise and especially low frequency noise can be present or induced in the power supply line (e.g., switching noise, electromagnetic interference, etc.). Power supply noise can cause jitter on the rising and falling edges of the signal being processed, as well as frequency skew within the output signal.
With respect to operating temperature variations, such variations will virtually never be avoidable, as operating temperatures can vary due to a number of causes, including variations in data transfer rates, ambient temperature, variations in power supply voltage, among others. As operating temperatures vary, so can the amplitude, phase and frequency of some of the signals being processed.
Further, conventional LVDS circuits are sensitive to circuit load conditions. Variations in the load impedance will induce variations in the output differential voltage or output offset voltage or both.
SUMMARY OF THE INVENTION
A low voltage differential swing (LVDS) signal driver having a substantially constant output differential voltage (Vod) and a substantially constant output offset voltage (Vos) irrespective of variations in circuit fabrication processes, power supply voltages and operating temperatures (PVT), as well as circuit load conditions. A driver replica circuit which replicates a portion of the actual LVDS driver circuit conducts a driver replica operating current that is a scaled replica of the LVDS driver operating current. Operating voltages within the LVDS driver and driver replica circuits are monitored and controlled by bias voltages provided by the driver replica circuit. The desired scaling factor for the operating currents is ensured by appropriate scaling of the sizes of the circuit devices within the LVDS driver and driver replica circuits.
In accordance with one embodiment of the presently claimed invention, a low voltage differential swing (LVDS) signal driver includes differential signal driver circuitry and signal replication circuitry. The differential signal driver circuitry receives upper and lower biasing signals and in response thereto conducts a driver operating current, provides a driver monitor signal and receives and converts a differential input signal to a LVDS signal. The signal replication circuitry, coupled to the differential signal driver circuitry, receives upper and lower reference signals and the driver monitor signal and in response thereto provides the upper and lower biasing signals and conducts a replica operating current which is maintained as a predetermined replica of the driver operating current.
In accordance with another embodiment of the presently claimed invention, a low voltage differential swing (LVDS) signal driver includes differential signal driver means and signal replicator means. The differential signal driver means is for receiving upper and lower biasing signals and in response thereto conducting a driver operating current, providing a driver monitor signal and converting a differential input signal to a LVDS signal. The signal replicator means is for receiving upper and lower reference signals and the driver monitor signal and in response thereto providing the upper and lower biasing signals and conducting a replica operating current which is maintained as a predetermined replica of the driver operating current.
In accordance with still another embodiment of the presently claimed invention, a method for generating a low voltage differential swing (LVDS) signal driver includes: receiving upper and lower biasing signals and in response thereto conducting a driver operating current, providing a driver monitor signal and converting a differential input signal to a LVDS signal; receiving upper and lower reference signals and the driver monitor signal and in response thereto providing the upper and lower biasing signals and conducting a replica operating current; and maintaining the replica operating current as a predetermined replica of the driver operating current.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a functional block diagram of a LVDS signal driver in accordance with one embodiment of the presently claimed invention.
FIG. 2 is an electrical schematic diagram of an example embodiment of the circuit of FIG. 1 .
FIGS. 3A-3D together are a more detailed electrical schematic diagram of a specific embodiment of the circuit of FIG. 1 in accordance with the circuit topology of FIG. 2 .
DETAILED DESCRIPTION OF THE INVENTION
The following detailed description is of example embodiments of the presently claimed invention with references to the accompanying drawings. Such description is intended to be illustrative and not limiting with respect to the scope of the present invention. Such embodiments are described in sufficient detail to enable one of ordinary skill in the art to practice the subject invention, and it will be understood that other embodiments may be practiced with some variations without departing from the spirit or scope of the subject invention.
Throughout the present disclosure, absent a clear indication to the contrary from the context, it will be understood that individual circuit elements as described may be singular or plural in number. For example, the terms “circuit” and “circuitry” may include either a single component or a plurality of components, which are either active and/or passive and are connected or otherwise coupled together to provide the described function. Additionally, the term “signal” may refer to one or more currents, one or more voltages, or a data signal. Within the drawings, like or related elements will have like or related alpha, numeric or alphanumeric designators.
Referring to FIG. 1, an LVDS signal driver circuit 10 (preferably in integrated circuit form) in accordance with one embodiment of the presently claimed invention includes a differential signal driver circuit 12 and a replica bias circuit 14 which, as discussed in more detail below, provides and replicates a number of bias signals.
In accordance with well known LVDS circuit principles, the driver circuit 12 receives a differential input signal Vin having a primary (“positive”) differential signal phase Vinp and an inverse (“negative”) differential signal phase Vinn. As is well known, the driver circuit 12 converts this signal Vin to a LVDS output signal Vout having a peak-to-peak differential signal amplitude Vod (e.g., approximately 350 millivolts) and an offset voltage Vos (e.g., 1.2 volts). This output signal Vout drives a load resistance Rload located at the receiver circuitry (not shown) external to this circuitry 10 . (As is well known in the art, the differential input signal Vin need not necessarily be a dual differential signal, but can also be a single differential input signal, as discussed in more detail below.)
In accordance with the presently claimed invention, this driver circuitry 12 provides a driver monitor signal Vmondrv and receives two bias signals Vbiasup, Vbiaslw. As discussed in more detail below, this monitor signal Vmondrv is monitored and controlled by way of the incoming bias signals Vbiasup, Vbiaslw with the result being that the driver circuitry 12 has significantly reduced PVT sensitivity.
As discussed in more detail below, the replica bias circuitry 14 generates an upper monitor signal Vmonup and a lower monitor signal Vmonlw, as well as a replica monitor signal Vmonrep. The upper Vmonup and lower Vmonlw signals are compared against corresponding externally generated upper Vrefup and lower Vreflw reference signals, with the resulting difference signals Vbiasup and Vbiaslw, respectively, provided as upper and lower biasing signals to the driver circuitry 12 . The replica monitor signal Vmonrep is similarly compared to the driver monitor signal Vmondrv, with the resulting difference signal Vbiasin used to bias the replica bias circuitry 14 .
Referring to FIG. 2, one example embodiment 10 a of the circuit 10 of FIG. 1 can be implemented as shown. The LVDS driver circuitry 12 a includes P-type metal oxide semiconductor field effect transistors (P-MOSFETs) M 0 , M 3 and M 9 , and N-MOSFETs M 1 , M 2 and M 1 , all interconnected substantially as shown. Transistors M 0 , M 1 , M 2 and M 3 form the output signal “switchbox” with differential pair transistors MO and M 3 receiving the primary differential phase Vinp and differential pair transistors M 1 and M 2 receiving the inverse differential phase Vinn of the input signal Vin. (It should be understood that while this output switchbox has been implemented in a complementary arrangement of P-and N-MOSFETs, a similar switchbox can be implemented using all P-MOSFETs or all N-MOSFETs as desired.). The interconnected drain terminals of transistors of M 0 and M 1 and transistors M 2 and M 3 provide the differential output signal Vout. In accordance with well known LVDS principles, when transistors M 1 and M 3 are turned on, transistors M 0 and M 2 are turned off, while conversely, when transistors M 0 and M 2 are turned on, transistors M 1 and M 3 are turned off. Accordingly, the output current lout is steered through the external load resistor Rload (not shown) to produce the output voltage Vout. (As noted above, the differential input signal Vin need not necessarily be a dual differential signal, but can also be a single differential input signal, in which case for this complementary arrangement of P- and N-MOSFETs, the gate terminals of transistors M 3 and M 2 would be driven together while the gate terminals of transistors M 0 and M 1 would be driven together.)
Transistors M 9 and M 10 serve as a current source and a current sink, respectively, for the output current lout flowing between the positive power supply terminal VDD and the negative power supply terminal VSS (or ground GND). As discussed in more detail below, transistor M 9 is biased by an upper biasing voltage Vbiasup and transistor M 10 is biased by a lower biasing voltage Vbiaslw which maintain the output current lout in such a manner as to establish and maintain the driver monitor voltage Vmondrv at the interconnect between the current source transistor M 9 and output switchbox transistors M 0 and M 3 .
The replica bias circuitry 14 a includes P-MOSFETs M 4 , M 5 and M 6 , and N-MOSFETs M 7 and M 8 interconnected in a telescopic, or totem pole, manner substantially as shown. Transistor M 6 serves as a current source controlled by the upper biasing voltage Vbiasup. Similarly, transistor M 8 serves as a current sink controlled by the lower biasing voltage Vbiaslw. Transistors M 5 and M 7 , with their respective gate terminals biased at power supply rails VSS and VDD, respectively, are biased in their fully on states and provide isolation between the current source M 6 and sink M 8 transistors and transistor M 4 . Transistor M 4 is operated to emulate the load resistor Rload by providing within the replica bias circuitry 14 a a replica resistance corresponding to the load resistor Rload.
A replica current Irep flows through transistors M 6 , M 5 , M 4 , M 7 and M 8 . As per Ohm's Law, the voltage Vrep across transistor M 4 must equal the product of the current Irep through transistor M 4 and the resistance RM 4 of transistor M 4 , or Vrep=Irep*RM 4 .
Similarly, the output current lout in the driver circuitry 12 a flows through the load resistor Rload (not shown). Also as per Ohm's Law, the voltage Vout across the Rload must equal the product of the current lout through the load Rload and the resistance Rload, or Vout=Iout*Rload.
The gate terminal of transistor M 4 is controlled, or modulated, by the intermediate biasing voltage Vbiasin generated by signal comparison circuit OP 3 . This biasing voltage Vbiasin controls, or modulates, the resistance RM 4 of transistor M 4 . In turn, this controls, or modulates the replica current Irep through the replica circuitry 14 a . Further in turn, this controls, or modulates, the replica monitor voltage Vmonrep which is compared by circuit OP 3 against the driver monitor voltage Vmondrv. (It should be understood that, as an alternative, the driver monitor voltage Vmondrv could also be that appearing at the interconnect between the current sink transistor M 10 and output switch box transistors M 1 and M 2 . In a corresponding manner, the replica monitor voltage Vmonrep would then be that appearing at the interconnect of transistors M 7 and M 8 . As discussed above, signal comparison amplifier OP 3 could monitor these voltages and provide the intermediate biasing voltage Vbiasin in an equally effective manner.)
Based upon this comparison of these input signals Vmondrv, Vmonrep, circuit OP 3 will adjust the intermediate biasing voltage Vbiasin as necessary to cause these input signals Vmondrv, Vmonrep to become and remain equal. As a result, the drain-to-source voltages Vds, as well as the gate-to-source voltages Vgs (due to the common gate biasing voltage Vbiasup), of current source transistors M 6 and M 9 equal. Accordingly, the currents Irep and lout sourced by these transistors M 6 and M 9 , respectively, are maintained at respective values that are determined by the relative sizes (e.g., channel widths) of these transistors M 6 , M 9 . For example, if transistors M 6 and M 9 were of equal size, then these currents Irep, lout would be equal, or Irep=lout. However, if transistor M 9 is larger than transistor M 6 by a factor of 20 (in accordance with a preferred embodiment of this circuit 10 a ) then the ratio of the output current lout to the replica current Irep would be Iout:Irep=20:1.
It should be understood that virtually any scaling factor can be selected, depending upon the desired replica Irep and output Iout currents. Depending upon the desired scaling factor, such scaling factor will be common with respect to the ratios of the sizes of the various transistors as follows: transistors M 6 and M 9 ; transistors M 5 , M 0 and M 3 ; transistors M 7 , M 1 and M 2 ; and transistors M 8 and M 10 .
In accordance with this scaling factor, since the transistor stack of the driver circuitry 12 a and the transistor stack of the replica biasing circuitry 14 a are equal in terms of device counts between the power supply rails VDD, VSS, the respective voltages dropped across the corresponding devices will be equal. For example, the drain-to-source voltages across transistors M 6 and M 9 will be equal, as will the drain-to-source voltages across transistors M 8 and M 10 , transistors M 5 , M 0 and M 3 , and transistors M 7 , M 1 and M 2 . Lastly, the replica voltage Vrep across transistor M 4 , as noted above, will be equal to the output voltage Vout. This replica voltage Vrep can be changed by proper selection of the upper Vrefup and lower Vreflw reference voltages.
Signal comparison circuitry OP 1 receives and compares the upper monitor signal Vmonup and the upper reference voltage Vrefup to provide the upper biasing voltage Vbiasup for transistors M 6 and M 9 . Similarly, signal comparison circuit OP 2 receives and compares the lower monitor signal Vmonlw and lower reference voltage Vreflw to provide the lower biasing voltage Vbiaslw to transistors M 8 and M 10 . In accordance with well known voltage comparator circuit principles, if the upper Vmonup or lower Vmonlw monitor signal voltages increase, e.g., due to an increase in the replica current Irep, then the upper Vbiasup and lower Vbiaslw signal voltages, respectively, also increase. Conversely, if these monitor signal voltages Vmonup, Vmonlw decrease, then the corresponding biasing voltages Vbiasup, Vbiaslw also decrease. As a result, the output lout and replica Irep currents are maintained at the values necessary to, in turn, maintain the output signal voltage Vout at the value established by the controlling of transistor M 4 .
Referring to FIGS. 3A and 3B, a more detailed example embodiment 10 b of the circuit 10 a of FIG. 2 can be implemented as shown. The LVDS driver circuitry 12 b includes P-MOSFETs M 206 , M 205 , M 259 , M 263 , M 208 , M 207 and M 35 , and N-MOSFETs, M 186 , M 185 , M 2 , M 1 , M 188 , M 187 and M 30 , all interconnected substantially as shown. Transistors M 206 , M 205 , M 259 , M 263 , M 208 , M 207 , M 186 , M 185 , M 2 , M 1 , M 188 and M 187 form the output signal switchbox with differential pair transistors M 206 , M 205 , M 259 , M 263 , M 208 and M 207 receiving the primary differential phase Vinp and differential pair transistors M 186 , M 185 , M 2 , M 1 , M 188 and M 187 receiving the inverse differential phase Vinn of the input signal Vin. The interconnected drain terminals of these transistors provide the differential output signal Vout. Transistors M 35 and M 30 serve as the current source and current sink, respectively, for the output current Iout.
The replica bias circuitry 14 b includes P-MOSFETs M 165 , M 166 and M 170 , N-MOSFETs M 156 and M 155 , and resistor R 74 , all interconnected substantially as shown. Resistor R 74 is connected across transistor M 170 for the purpose of increasing the resolution of the variable resistance formed by the parallel combination of resistor R 74 and the drain-to-source, or channel, resistance of transistor M 170 . Signal comparison circuit OP 3 , contained within circuit block 20 , receives and compares the driver monitor voltage Vmondrv and replica monitor voltage Vmonrep and provides the intermediate biasing voltage Vbiasin to the gate terminal of transistor M 170 .
Signal comparison circuitry OP 1 receives and compares the upper monitor signal Vmonup and the upper reference voltage Vrefup to provide the upper biasing voltage Vbiasup for transistors M 165 and M 35 . Similarly, signal comparison circuit OP 2 receives and compares the lower monitor signal Vmonlw and lower reference voltage Vreflw to provide the lower biasing voltage Vbiaslw to transistors M 155 and M 30 . In accordance with well known voltage comparator circuit principles, if the upper Vmonup or lower Vmonlw monitor signal voltages increase, e.g., due to an increase in the replica current Irep, then the upper Vbiasup and lower Vbiaslw signal voltages, respectively, also increase. Conversely, if these monitor signal voltages Vmonup, Vmonlw decrease, then the corresponding biasing voltages Vbiasup, Vbiaslw also decrease. As a result, the output lout and replica Irep currents are maintained at the values necessary to, in turn, maintain the output signal voltage Vout at the value established by the controlling of transistor M 170 .
Additional circuitry 22 , including P-MOSFETs M 233 , M 234 , M 209 and M 228 , N-MOSFETs M 189 , M 192 , M 199 and M 198 , resistor R 64 , and circuit blocks 24 a and 24 b , which is not part of the presently claimed invention, provides a power down function such that when output signal terminals OUT and OUTB are connected to a signal bus but are not driving such signal bus and, therefore, are placed in a high impedance mode, any other signal voltage appearing on the bus will not cause any of the parasitic diodes within the output P-MOSFETs to turn on due to the presence of such signal bus voltages.
Other circuitry 26 can also be provided as a pre-driver stage to ensure that, for each phase of the input signal Vin, all of the output current passes to the load with none remaining to be dissipated within the switchbox, thereby ensuring maximum efficiency in terms of transfer of output current to the load. (For example in the circuit of FIG. 2, when transistors M 1 and M 3 are turned on, transistors M 0 and M 2 are turned off completely, and conversely, when transistors M 0 and M 2 are turned on, transistors M 1 and M 3 are turned off completely.) Additionally, a resistor string 28 can be included to provide any necessary reference voltages.
A simulation of the circuitry 10 b as implemented in FIGS. 3A and 3B demonstrated an output voltage Vout having variations in its differential output voltage amplitude Vod and offset voltage Vos of 15 millivolts and 17 millivolts, respectively, across PVT and load resistance variations.
Based upon the foregoing discussion, it can be seen that LVDS signal driver circuitry in accordance with the presently claimed invention advantageously minimizes sensitivity to variations in circuit fabrication processes, power supply voltage and operating temperature. For example, by monitoring and maintaining a constant voltage across the output signal switchbox and maintaining equal biasing voltages across corresponding circuit components within the driver and replica bias circuits while also emulating the load, the differential output Vod and offset Vos voltages will be dependent virtually only on the reference voltages Vrefup, Vreflw. In turn, such reference voltages Vrefup, Vreflw can be generated using PVT-insensitive voltage sources such as bandgap voltage sources, which demonstrate high immunity from PVT variations and are well known in the art.
Various other modifications and alternations in the structure and method of operation of this invention will be apparent to those skilled in the art without departing from the scope and the spirit of the invention. Although the invention has been described in connection with specific preferred embodiments, it should be understood that the invention as claimed should not be unduly limited to such specific embodiments. It is intended that the following claims define the scope of the present invention and that structures and methods within the scope of these claims and their equivalents be covered thereby.
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A low voltage differential swing (LVDS) signal driver having substantially constant output differential voltage (Vod) and substantially constant output offset voltage (Vos) irrespective of variations in circuit fabrication processes, power supply voltages and operating temperatures (PVT), as well as circuit load conditions. A driver replica circuit which replicates a portion of the actual LVDS driver circuit conducts a driver replica operating current that is a scaled replica of the LVDS driver operating current. Operating voltages within the LVDS driver and driver replica circuits are monitored and controlled by bias voltages provided by the driver replica circuit. The desired scaling factor for the operating currents is ensured by appropriate scaling of the sizes of the circuit devices within the LVDS driver and driver replica circuits.
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BACKGROUND OF THE INVENTION
1. Field of the invention
The present invention concerns a method of splicing two optical fiber cables.
It applies particularly, but not exclusively, to two ribbon cables each comprising a plurality of monomode fibers.
Such multifiber cables are intended for use in future multiservice optical networks. The jointing of such cables raises problems of cost, optical quality and ease of execution.
Jointing two optical fibers entails dimensional tolerances in the order of one micrometer because of the high degree of confinement of the optical energy. The simultaneous jointing of several pairs of fibers obviously accentuates the difficulty, all the more so in that economic objectives require a low-cost connection device to be used by relatively unskilled personnel under difficult operating and environmental conditions, in particular in trenches.
2. Description of the prior art
At present an operative places the ends of the fibers of each cable in channels etched into one surface of a silicon primary plate; a complementary plate is used to immobilize the fibers. The correct alignment of the two cables requires the use of complex and costly guide means. Guide means are described, for example, in the Pat. No. US-A-3 864 018 or the article by P. STEINMAN in "Fiber and Integrated Optics" vol. 9 pp. 43-52. The primary plates have projections on their outer surfaces cooperating with etched grooves in silicon secondary plates between which the ends of the two cables are sandwiched. These techniques impose severe tolerances on the thickness of the primary plates, the width and the angle of the secondary plate grooves and the spacing between these grooves The ends of each cable must be optically polished by a time-consuming and delicate operation. All aspects of the method are difficult and costly.
An object of the present invention is to enable the process of jointing two optical fiber cables to be considerably simplified.
SUMMARY OF THE INVENTION
The present invention consists in a method of splicing two optical fiber cables using a glass multi-ferrule having a series of parallel axis internal capillary channels opening onto respective end surfaces of said multi-ferrule and two exterior reference surfaces, in which method:
adhesive is introduced into said channels,
the stripped ends of the fibers of the two cables are inserted into respective channels through said end surfaces until they substantially reach the central part of said multi-ferrule where they are immobilized,
said multi-ferrule and said fibers are cut transversely to said fibers in two areas to either side of said central part to obtain two multi-ferrule sections fastened to respective cables and an intermediate multi-ferrule section which is discarded, and
said two multi-ferrule sections are aligned in a splicing body comprising guide means for their respective common reference surfaces and, before they are brought into contact, a refractive index matching gel is injected into said body at the interfaces of said fibers.
A method in accordance with the invention therefore utilizes two multi-ferrule sections obtained from a common original multi-ferrule and initially situated very close to each other within the original multi-ferrule, at a distance of around 10 mm, for example. Consequently the two sections have intrinsically the same geometrical characteristics in respect of their internal channels and their external reference surfaces; any differences are within tolerances enabling very good optical coupling to be achieved.
In one specific embodiment, the cutting of said multi-ferrule into sections is facilitated by weakened areas transverse to said channels.
Thus when said channels are in a common plane inside the multi-ferrule two parallel grooves orthogonal to said plane open into said channels. It is also possible to provide two further grooves in the opposite surface of said multi-ferrule in line with the previously mentioned grooves. These additional grooves may have an asymmetric V-shape cross-section, for example.
End surfaces of said multi-ferrule advantageously include bearing surfaces for the insulative material jackets of said cables.
Moreover, the ends of said channels are preferably chamfered to facilitate insertion of the fibers.
In one specific embodiment, the cut cross-section of the fibers is oblique to the axis of said channels to reduce retroreflected light.
Other features and advantages of the invention will emerge from the following description of embodiments thereof given by way of non-limiting illustrative example only with reference to the appended highly diagrammatic drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a view in elevation of a multi-ferrule used in a method in accordance with the invention.
FIG. 2 is a view in cross-section on the line II--II in FIG. 1.
FIG. 3 is an end view of the multi-ferrule from FIG. 1.
FIG. 4 .shows the phase of bonding the fibers of two cables info the multi-ferrule from FIG. 1.
FIGS. 5 and 6 how the cutting into sections of the multi-ferrule from FIG. 1.
FIG. 7 shows the two multi-ferrule sections joined to their respective cables and separated from the intermediate section.
FIG. 8 shows the two sections from FIG. 7 brought together splicing body.
FIG. 9 is an end view of the body from FIG. 8.
DETAILED DESCRIPTION OF THE INVENTION
FIGS. 1 through 3 show a silica glass multi-ferrule comprising internally a series of capillary channels 2 with parallel axes which (in this example) are coplanar.
A multi-ferrule of this kind is the subject matter of French Pat. No. FR-A-9013857.
Externally it has a cylindrical surface 3 with an axis 4 and a diameter of 3 mm and a plane surface 5 approximately 2.5 mm wide. The surfaces 3 and 5 will be referred to hereinafter as "reference surfaces". The length of the multi-ferrule is 30 mm.
The plane containing the channels 2 is near the diametral plane of the cylinder and parallel to the surface 5. Assume six equidistant channels 2 with a spacing of 250 μm matching the number and location of the fibers in the cables 21 and 22 to be jointed, which can be seen in FIG. 4.
The end surfaces 6 and 7 are machined to provide bearing surfaces 8, 9 for the cables to be jointed. The surfaces 8, 9 are at a distance of 125 μm (with a tolerance of -0, +25 μm) from the common diametral plane of the channels 2. The entries of the channels 2 are provided with chamfers 10 to facilitate the insertion of the fibers. A machined oblique surface is provided at the entry of the channels 2 for the same reason.
The multi-ferrule 1 also has transversely machined weakened areas to facilitate dividing it into sections at a later stage.
These areas comprise two grooves 11 and 12 each 2 mm wide with a distance between their central axes of 8 mm. These grooves are orthogonal to the plane of the channels 2 and their bottoms intersect the channels 2.
Chamfers 10 are preferably formed at the bottom of the grooves, again to facilitate the entry of the fibers into their channels.
A tolerance with respect to the height of the grooves 11 and 12 of ±25 μm would be acceptable relative to the nominal dimension, which would be that of the common diametral plane of the channels 2. Additional asymmetric V-shape grooves 13 and 14 are machined into the surface 5 in line with the grooves 11 and 12.
A low-viscosity adhesive 25 polymerized by ultraviolet light may be introduced into the channels 2 of the multi-ferrule 1 as just described which can then be packaged in an opaque plastics material tube for subsequent use. The dimensional stability of the component is guaranteed by the fact that the multi-ferrule is made from silica glass which has a very low coefficient of thermal expansion.
The various phases of a splicing method in accordance with the invention will be described hereinafter with reference to the jointing of ribbon cables 21 and 22 of which only a single fiber 23, 24 can be seen in FIG. 4.
The two cables 21 and 22 are first stripped to remove the protective plastics material coating from the fibers 23, 24 over a given length with a wide tolerance of ±1 mm. No conditions are imposed as to the quality of the fiber ends; even jagged ends can be tolerated.
The prepared ends of the fibers 23, 34 are collectively inserted into the channels 2 of the multi-ferrule 1 containing the adhesive 25 which can be polymerized by ultraviolet light. This operation is facilitated by the chamfers 10 and because the spacing of the fibers is the same in the cable and in the channels.
The fibers are inserted until the plastics material coating of the cables 21, 22 bears against the surfaces 8 and 9, the stripped length of the fibers 23, 24 being such that the fiber ends reach the central part of the multi-ferrule 1. A deposit of adhesive on the surfaces 8 and 9 fastens the cables 21 and 22 to the multi-ferrule and exposure to ultraviolet light (schematically represented by the arrows 26) bonds the fibers.
The multi-ferrule 1 and the two cables 21, 22 are immobilized in a jig. Two diamond-coated cutters 31 and 32 with prism-shape cutting edges (with an included angle of 60°, for example) are then used (FIG. 5) to score the surfaces of the fibers 23, 24 in the grooves 11 and 12 to create weakened areas. These cutters are suspended vertically with a return spring and movable transversely.
As shown in FIG. 6, lateral traction means schematically indicated by the arrows 33 and 34 apply tension to the multi-ferrule 1 to initiate rupture at the scored areas 37, 38 associated with the V-shape notches 13, 14.
This produces two multi-ferrule sections 41 and 42 joined to the respective ribbon cables 21, 22 (FIG. 7); the end faces 43, 44 of the fibers 23, 24 are of the optical quality required for optical coupling. Depending on the cutters 31, 32 employed, the faces 43, 44 may be at right angles or oblique to the axes of the channels 2.
According to the invention the two multi-ferrule sections 41, 42 have external reference surfaces 3 and 5 originating in very closely adjacent areas of a common original multi-ferrule 1. Prior art techniques are available which can achieve multi-ferrules whose external dimensions over longitudinal distances of a few centimeters are sufficiently invariant, as is the parallel relationship between the axes of the channels 2 and the axis 4, for satisfactory optical alignment to be achieved, as shown in the FIGS. 8 and 9 diagrams:
The tolerances on the channel diameter are: -0, =1 μm.
The spread of channel axis position relative to the optimum plane passing as close as possible to each axis must be within ±10 μm.
The spread of channel axis spacing in the direction of the aforementioned optimum plane is within ±10 μm.
FIGS. 8 and 9 show a splicing body 50 which aligns and mechanically fixes the two sections 41 and 42.
The reference surfaces 3 and 5 are pressed against surfaces 51 and 52 of the splicing body by an elastically deformable leaf spring 53. Before the sections 41 and 42 are brought into contact a refractive index matching gel is inserted through an orifice 55 into the gap between the interfaces 43, 44.
The invention is of course not limited to the embodiment that has just been described. Any means described herein may be replaced with equivalent means without departing from the scope of the invention.
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A method of splicing two optical fiber cables uses a glass multi-ferrule having a series of parallel axis internal capillary channels opening onto respective end surfaces of the multi-ferrule and two exterior reference surfaces. An adhesive that is polymerized by ultraviolet light is introduced into these channels. The multi-ferrule is cut into three sections. The splicing is achieved by jointing the outermost two sections.
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This is a continuation, of application Ser. No. 269,884, filed June 3, 1981, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a thermal printer, and, more particularly, it is concerned with an improvement in the thermal printer for better print quality.
2. Description of the Prior Art
It is a usual practice in the thermal printer for printing characters and letters that a thermal head having a vertical row of dots is first heated, and then the thermal head is moved sidewise, while printing. In view of such a printing operation under heat by the thermal head, there tend to occur differences in the running of the printed dots depending on heat generating time, temperature characteristic of the thermal head, paper quality, and so forth, hence it is difficult to maintain constant the size and density of the printed dots. Rather, the difference in density is prone to occur due to density of the printed dots. In order to avoid such a disadvantage, there has been made a correction or adjustment among the horizontal rows (cr rank) of dots relative to the lateral movement of the thermal head.
Of recent, the number of dots in a character tend to increase (e.g., 24×24 dots per character) due to printing of complicated character patterns such as chinese characters and so on. With such an increase in the number of dots in one character, the distance among the dots constituting the character becomes shorter. A consequence of which it has become more and more difficult to improve the printed quality of the character without a density adjustment in not only the horizontal row (rank) but also the vertical row (file).
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide a thermal printer free from the above-mentioned disadvantages, which is realized by carrying out adjustment of the dots in the vertical row.
It is another object of the present invention to provide a thermal printer of an improved construction provided with a thermal head having a printing position of at least n numbers of dots in the vertical row, wherein comparison is first made relative to the mutually adjacent dot positions in the vertical row dot pattern data to be printed. Then a heat generating signal for vertical row adjustment is generated at least once for one vertical row dot pattern data to adjust the density difference in the vertical row, and, in addition to an ordinary heat generating signal, the above-mentioned vertical row adjusting heat generating signal is applied to the thermal head at least once, thereby performing the printing of one vertical row for the above-mentioned vertical row dot pattern data.
It is still another object of the present invention to provide a thermal printer, wherein comparison is first made between the above-mentioned vertical row dot pattern data and the preceding dot pattern data relative to the above-mentioned dot pattern data. Then a heat generating signal for horizontal row adjustment is generated at least once relative to the above-mentioned vertical row dot pattern data to adjust the density difference in the horizontal row. In addition to the above-mentioned heat generating signal for the vertical row adjustment, the above-mentioned heat generating signal for the horizontal row adjustment is applied to the thermal head at least once, thereby performing printing of one vertical row for the above-mentioned vertical row dot pattern data.
It is yet another object of the present invention to provide a thermal printer, wherein the above-mentioned ordinary heat generating signal, heat generating signal for the vertical row adjustment, and heat generating signal for the horizontal row adjustment; are applied to the thermal head with a certain time lag or delay.
It is another object of the present invention to provide a thermal printer, wherein one-dot pattern is divided into three patterns of basic, vertical row (file) adjustment, and horizontal row (rank) adjustment patterns, then heat is generated in the thermal head for each pattern, and the three patterns are superposed one after the other for one dot to adjust the printing position, thereby improving the printed quality of a character.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a block diagram showing one embodiment of the thermal printer according to the present invention;
FIG. 2 is a block diagram showing the details of the vertical row adjusting circuit shown in FIG. 1;
FIG. 3 is also a block diagram showing details of the horizontal row adjusting circuit shown in FIG. 1; and
FIG. 4 is diagram showing one example of the dot adjusting pattern according to the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the following, the present invention will be described in detail in reference to the accompanying drawing.
FIGS. 1, 2 and 3 indicate one preferred embodiment of the present invention. In FIG. 1, a reference numeral 1 designates a new pattern register to store therein input dot pattern data DP. A reference numeral 2 designates a preceding pattern register to store therein the dot pattern which was previously introduced as an input into the new pattern register 1. Reference numeral 3 refers to a vertical row (file) adjusting circuit to produce an output vertical row adjusting pattern when the new dot pattern stored in the new pattern register 1 is supplied thereto. Reference numeral 4 refers to a vertical row adjusting pattern latch to store therein the vertical row adjusting pattern. Reference numerical 5 designates a horizontal row (rank) adjusting circuit to produce an output horizontal row adjusting pattern when the new dot pattern and the preceding dot pattern, which have been read out respectively from the new pattern register 1 and the previous pattern resister 2, are supplied thereto. Reference numeral 6 refers to a horizontal row adjusting pattern latch to store therein the horizontal row adjusting pattern. Reference numeral 7 designates a basic pattern latch, in which the content as supplied from the new pattern register 1 is latched.
As soon as the new dot pattern data DP is introduced into the new pattern register 1 as an input, the vertical row adjusting pattern, the horizontal row adjusting pattern, and the basic pattern are latched in the respective latches 4, 6 and 7 through the vertical row adjusting circuit 3, the horizontal row adjusting circuit 5, and the new pattern register 1, afterwards the these patterns are respectively forwarded to corresponding head drivers 9, 10 and 8. Each of the head drivers 8, 9 and 10 heats the thermal head 11 with a predetermined time lag in accordance with the input dot pattern. The sequence of heating is controlled by signal lines l 1 and l 2 , thereby generating heat in the order of the head drivers 8, 9 and 10. The heat generating time for each of the head drivers 8, 9 and 10 is predetermined appropriately in consideration of the characteristics of the thermal head, quality of paper, etc.
The modes of adjustment of the printing position according to the present invention will be described in further details hereinbelow.
In one vertical row of dots in the thermal printer, as the space intervals among the dots arranged in the vertical row are rather short as mentioned in the foregoing, there tends to emerge running of ink among the closely adjacent dots as printed. Considering this point, the vertical row adjustment according to the present invention is performed in such a manner that, when no dot exists in the basic pattern, i.e., when no dot printing is done at the dot position, no adjustment is effected at that dot position, leaving the same blank. While a dot exists in the basic pattern, judgement is made as to whether any dots are present at the adjacent positions above and below the dot, or not. When there is a dot at either the upper or the lower position thereof, the dot printing is effected as the vertical row adjustment, and, when the dots exist at both upper and lower positions, no dot printing for the adjustment is effected to avoid running of the dot due to the superposed printing. In the lateral movement of the vertical row of the dots, the thermal head is heated with respect to the preceding dot pattern, while heating of the head with respect to the current dot pattern is effected before the head heated for the preceding dot pattern is completely cooled. As the result of this, when the superposed printing is effected to carry out the horizontal row adjustment when the dots also exist even in the current pattern, at the place where the dots existed in the preceding pattern, the density of the dots printed at the position becomes excessively high. To avoid this, when the horizontal row adjustment is to be done, the dot patterns in both preceding and current patterns are compared, and, if dots are present in both patterns at the same position, no horizontal adjustment is effected. The dot printing is done at the horizontal row adjustment only when no dot exists in the preceding dot pattern, and even if dots are present in the preceding dot pattern, no horizontal adjustment is conducted at the position where no dot is present in the current pattern, leaving the same blank.
Thus, the present invention contemplates improvement in the quality of the printed characters by first dividing the dot pattern to be printed into the vertical row, horizontal row, and the basic patterns, and then combining the heat generating time with each pattern.
In the following, detailed explanations will be given as the vertical and horizontal row adjusting circuits in reference to FIGS. 2 and 3.
The vertical row adjusting circuit 3 is constructed, for example, with a left shift register 12, a right shift register 13, logic sum gates 14, 15, exclusive logic sum gates 16, 17, and a logic sum gate 18, as shown in FIG. 2. An output from the new pattern register 1 is supplied to the shift registers 12, 13 and the gates 14, 15, 16 and 17. An output from the logic sum gate 18 is supplied to the vertical row adjusting pattern latch 4. It is to be noted here that the gates 14 to 18 as shown in FIG. 2 are disposed for each bit in the registers 1, 12 and 13, although, for the sake of simplicity, only one bit is shown in FIG. 3. When a new dot pattern input is introduced into the new pattern register 1, the new dot pattern is shifted by one bit in the leftward direction by the left shift register 12. A logic product of the result of the left shifting and the content of the new pattern register 1 is taken in the gate 14, and an exclusive logic sum of the result obtained in the gate 14 and the content of the new pattern register 1 is taken in the gate 16, whereby comparison is made between the content of each dot position. Further the content of the dot position one dot above the same, and an output "1" is obtained from the gate 16, only when the content of the dot position in the new dot pattern is "1", and the content of the dot position one dot above the same dot position is "0". In the same manner, the new dot pattern is shifted by one bit in the rightward direction by the right shift register 13, the logic product of the result of the rightward shifting and the content of the new pattern register 1 is taken in the gate 15, and the exclusive logic sum of the result obtained in the gate 15 and the content of the new pattern register 1 is taken in the gate 17. In this manner, comparison is made between the content of each dot position and the content of the dot position one dot below the same, whereby an output "1" is obtained from the gate 17, only when the content of the dot position in the new dot pattern is "1" and the content of the dot position one dot below the same dot position is "0". By taking the logic sum of the outputs from the gates 16 and 17 in the gate 18, an adjusting output "1" is obtained, only when the content of a certain dot position is "1" and a content of the adjacent dot position either above or below thereof is "1", while a vertical row adjusting pattern as an adjusting output "0" is obtained in other state, i.e., when the content of the dot position is "0" and the content of the adjacent dot position either above or below the dot is "1". This vertical row adjusting pattern is stored in the latch 4.
FIG. 3 illustrates a concrete embodiment of the horizontal adjusting circuit 5. The circuit is constructed with a logic product gate 19 and an exclusive logic sum gate 20, provided in each bit of the registers 1 and 2. In other words, when new dot pattern input is introduced into the new pattern register 1, a logic product of the content of the new pattern register 1 and the content of the preceding pattern register 2 are taken in the gate 19, and an exclusive logic sum of the result obtained in the gate 19 and the content of the new pattern register 1 is taken in the gate 20. In this manner, comparison is made between the preceding and current dot patterns, and based on the comparison an adjusting output "1" is produced, only when the content of the dot position in the new dot pattern is "1" and the content of the corresponding dot position in the preceding dot pattern is "0". While an adjusting output "0" is produced in other state, i.e., when the content of the dot position in the new dot pattern is "0" or the content of the corresponding position in the preceding dot pattern is "1", even if the content of the dot position in the new dot pattern is "1". The result obtained from the gate 20 constitutes the horizontal row adjusting pattern which is stored in the latch 6.
FIG. 4 shows one example of the basic pattern, the vertical row adjusting pattern, and the horizontal row adjusting pattern formed in the above-described manner in accordance with the present invention. The three patterns obtained according to the present invention are printed in superposition on one and the same position for three times in the order of the basic pattern, the vertical adjusting pattern, and the horizontal row adjusting pattern.
As stated in the foregoing, the thermal printer according to the present invention performs the density adjustment in both vertical and horizontal rows at the time of the thermal printing, which makes it possible to effect the optimum adjustment in conformity to the head characteristic and the paper quality, hence remarkable improvement can be attained in the quality of the printed character.
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There is disclosed a thermal printer constructed with a thermal head having a plurality of heat generating sections to record a pattern on a recording sheet; a pattern memory to record pattern information for selectively driving said plurality of heat generating sections in said thermal head; an adjusting pattern device connected to the pattern memory to discriminate the pattern informations for selective driving of at least three adjacent heat generating sections out of the plurality of heat generating sections in the thermal head, and to generate adjusting pattern information which drives two heat generating sections out of the three heat generating sections; and a feeding device connected to the pattern memory and the adjusting pattern device, to feed the pattern information stored in the pattern memory and the adjusting pattern information to the thermal head.
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BACKGROUND OF INVENTION
The present invention relates to a new and improved device for transferring a weft or filling thread from the weft thread beat-up position to the path of movement of a weft thread picker or insertion element of a shuttleless loom, particularly a gripper loom.
More specifically, the invention is concerned with a transfer device having a transfer mechanism controllable in synchronism with the movement of the loom sley or batten. The transfer mechanism comprises a transfer lever which executes an oscillatory movement and has a thread clamp at its free end. A fixed clamping surface on the transfer lever cooperates with a movable clamping surface.
In shuttleless power looms, particularly gripper looms, it is necessary according to conventional techniques to fixedly clamp the end of the preceding weft thread in the weft thread beaten-up position and before it is cut-off, in order to then bring the newly formed leading end of the next weft thread into the path of movement of the weft thread gripper.
From Swiss Pat. No. 533,190 one such type of transfer device is already known in which the movable clamping surface is formed by an element which has a clamping jaw and which is displaceable on the transfer lever, which in this case is rotatable, and the entire arrangement being under the influence of a helical spring.
However, with this prior art arrangement, there is achieved a clamping effect which is neiher sufficiently controllable nor secure. The latter is so because there prevail considerable centrifugal forces in the region of the clamping jaw and because of the fact that the rigidity of the clamping member makes it sensitive to vibrations. Moreover, the functional reliability of this arrangement can be quickly lost by the accumulation of fluff at the transfer device. Consequently, this increases the danger that the insufficiently clamped thread will be inserted insufficiently deeply into the clamp or nipper of the weft thread gripper.
In Austrian Pat. No. 258,228 a thread clamp is proposed wherein its movable clamping surface is formed by a suitably shaped leaf spring, but the leaf spring here acts with its longitudinal axis in the picking direction of the thread, which leads to relatively indeterminable clamping conditions. Moreover, the structure is voluminous, resulting in long and thus inexact actuating paths. Likewise, there is the danger of the clamping region being obstructed or clogged by fluff.
SUMMARY OF INVENTION
It is therefore an object of the present invention to provide an improved weft thread transfer device of the character described which, while avoiding the disadvantages of the known arrangements referred to above, is insensitive to machine vibrations, has a clamping action which remains unaffected by the movement of the transfer lever, is of extremely simple conception, and in particular is self-cleaning.
This object and others are achieved in accordance with the present invention by a device for transferring a weft thread from the weft thread beaten-up position to the path of movement of a weft thread picker of a shuttleless loom, particularly a gripper loom, wherein such device comprises a transfer mechanism controllable in synchronism with the movement of the loom sley or batten. The transfer mechanism comprises a transfer lever arranged to execute an oscillatory movement and having a thread clamp at its free end, with a fixed clamping surface on the transfer lever cooperating with a movable clamping surface. According to the invention the movable clamping surface is defined by a leaf spring extending substantially perpendicular to the picking direction. An actuating lever is pivotally mounted on the transfer lever and is operatively connected to a tongue of the leaf spring to effect momentary opening of the two clamping surfaces. An adjustable stop is provided at the region of pivotal movement of the transfer lever and is arranged to cause a relative countermovement of the actuating lever when the actuating lever strikes the stop, to thereby cause said momentary opening of the two clamping surfaces.
By these measures it is now possible to construct a weft thread transfer device of the previously mentioned type which is simple and functionally reliable, having constant clamping pressure for all ranges of different thread quality, and wherein a high degree of self-cleaning of fluff and the like is achieved due to impact of the actuating lever against the stop during the pivotal movement of the transfer lever into its forward end position and by the resultant opening of the thread clamp in a phase of maximum deceleration, causing pieces or particles of dirt and fluff to be thrown out by the centrifugal force.
In order to be able to adjust the clamping pressure between the two clamping surfaces it is preferable to mount the leaf spring to be tiltable on a pin. Setting means, such as a setting or adjustment screw, mounted on the transfer lever are arranged to act on a second tongue projecting from the leaf spring in the region where the pin is mounted, the setting means exerting a torque or rotational moment upon the leaf spring which is effective in the clamping direction.
According to a further preferred feature of the invention, a positioning nose for the weft thread extends upwards from the outside marginal edge of the fixed clamping surface on the transfer lever and determines the depth of insertion of the weft or filling thread between the two clamping surfaces at said outside edge.
By means of this arrangement the thread can adopt a position which extends rearwardly at an inclined angle, so that the thread can be reliably gripped by the weft thread gripper over a long effective clamping tension and can be protectively removed from the clamp.
It is advantageous if there is mounted at the sley or batten of the loom at least one thread pick-up or entrainment member arranged to skirt the outside marginal edge of the fixed clamping surface in order to push the weft thread towards the positioning nose.
A further thread pick-up or entrainment member can be arranged to skirt close to the other, inside marginal edge of the fixed clamping surface and also can be secured to the batten or sley for conjoint movement with the aforementioned first thread pick-up or entrainment member. Preferably, the second thread pick-up is offset relative to the first and is arranged to lead the same in the direction of the beating-up movement of the batten. By virtue of this arrangement the thread can adopt a more accurately defined inclined position between the clamping surfaces.
A notch can serve as a stop for the weft thread drawn into the clamp by the second thread pick-up or entrainment member. This notch can be formed by a partial bevelling of the inside marginal edge of the fixed clamping surface.
From the forward edge of this bevelling backwards towards the positioning nose the free front edge of the fixed clamping surface can be arranged to extend at an inclination so that the aforementioned bevelling extends practically to a projecting or protruding nose of the clamping surface.
When with this arrangement the weft thread gripper grips the thread presented by the transfer device, the thread is very carefully and gently released from the thread clamp, with the thread sliding along the bevelling, so that, as mentioned, the clamping action on the thread is maintained effective right up to the picking movement.
BRIEF DESCRIPTION OF THE DRAWINGS
In order that the invention may be fully understood certain preferred embodiments of device in accordance with the invention will now be described by way of example and with reference to the accompanying drawing, in which:
FIG. 1 is a diagrammatic illustration of the device constructed in accordance with the invention for the transfer of a weft thread in a loom; and
FIG. 2 is a diagrammatic illustration of a modified embodiment of a detail part of the arrangement shown in FIG. 1 and shown on an enlarged scale.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows part of a gripper power loom, the view being taken through a section of a woven fabric piece 20 with the shed formed by the upper set of warp threads 21 and the lower set of warp threads 22. Each of the weft or filling threads 23 is inserted through the shed between the two sets of warp threads 21 and 22 by means of a weft thread gripper, which is not particularly shown. The path of movement of this weft thread gripper is indicated by the broken line 24.
As is known, each inserted weft thread 23 is beaten-up against the fell 27 of the woven material or fabric 20 by means of a reed 26 which is connected to a sley or batten 15 and which is reciprocable back-and-forth together with the batten, as generally indicated by the double-headed arrow 25. Thereafter, each inserted weft thread 23 is cut at the selvedges of the woven fabric 20 by conventional cutting means (not shown).
In order to be able to subsequently bring the end of the previously inserted weft thread 23, after the cutting operation, into the path of movement 24 of the weft thread gripper, so that it can become the beginning of the next weft thread, the device of the present invention incorporates a transfer lever 1 fixedly connected for rotation to a shaft 31 mounted on the machine frame 30. This transfer lever 1 carries at its free end a thread clamp 2 which will be described in greater detail hereinafter.
The aforementioned shaft 31 is driven in any suitable manner in synchronism with the reciprocating movement of the batten 15 of the power loom in alternating directions of rotation. As a result the transfer lever 1 is caused to execute an oscillatory movement, as generally indicated by the double-headed arrow 32.
The aforementioned thread clamp 2 includes a fixed clamping surface 3 formed on the transfer lever 1 and a movable clamping surface 4' defined by part of a leaf spring 4.
The leaf spring 4 or equivalent structure, which is bent upwards from its clamping surface 4', is tiltably mounted on a pin 11. A setting screw 13 which is mounted on the transfer lever 1 acts on a tonque 12 projecting from the leaf spring 4 at the region where the pin 11 is mounted. This setting screw 13 enables an adjustment of the torque acting in the clamping direction and consequently an adjustment of the clamping force exerted by the leaf spring 4.
In order to open the thread clamp 2 by raising the leaf spring 4 from the fixed clamping surface 3, the arrangement includes an actuating lever 7 which is mounted on a pin 8 carried by the transfer lever 1 for pivotal movement relative to such transfer lever 1. The actuating lever 7 is here substantially Z-shaped and sits in a slot 9 in the transfer lever 1. With this arrangement the actuating lever 7 has its lower lever arm arranged to cooperate with a spatially fixed stop 10 which is located within the range of pivotal movement of the transfer lever 1. On the other hand, the upper arm of the actuating lever 7 is connected to a tongue 5 formed on the other end of the leaf spring 4 by means of a tension wire 6 or the like.
When, with this arrangement, the transfer lever 1 is pivoted in the clockwise sense towards the stop 10, the actuating lever 7 is stopped in its movement, and consequently, this causes a relative counter movement to be imparted to the actuating lever which results in raising of the leaf spring 4 and thus opening of the thread clamp 2.
As FIG. 2 shows in greater detail, a positioning nose 14 for the weft thread 23 projects upwardly from the outside marginal edge 40 of the fixed clamping surface 3 on the transfer lever 1. This positioning nose 14 determines the outer insertion position of the weft thread 23 between the two clamping surfaces 3 and 4'.
As FIGS. 1 and 2 further show, a thread pick-up or entrainment member 16 cooperates with the positioning nose 14 for the weft thread 23 at the outside marginal edge 40 of the fixed clamping surface 3. This thread pick-up or entrainment member 16 is arranged fixedly on the batten 15 of the loom so as to be able to skirt close by the outside marginal edge 40. Upon forward movement of the batten 15 during the beating-up phase, the thread pick-up or entrainment member 16 guides the weft thread 23 into contact with the positioning nose 14 and between the two thread clamping surfaces 3 and 4'.
As an alternative to this arrangement it is possible to have, as shown in FIG. 2, a further thread pick-up or entrainment member 116 which is fixed for conjoint movement with the aforementioned first thread pick-up 16 on the batten 15, so as to be able to skirt close to the inside marginal edge 41 of the fixed clamping surface 3. Preferably, the second thread pick-up 116 is offset relative to the first pick-up 16 and is arranged to lead in advance of it in the beating-up direction of the batten 15. Thus, the thread 23 can assume an accurately defined inclined position between the clamping surfaces 3, 4', starting from the positioning nose 14 and extending across the transfer lever 1, as can be seen clearly from FIG. 2.
These measures ensure that the weft thread 23 can be gripped securely by the weft thread gripper over a long effective clamping span and can be inserted deeply into the nipper or clamp of the weft thread gripper.
As a stop for the weft thread entrained by the second or inside thread pick-up or entrainment member 116 there can be provided a notch or groove 44 which is formed by a partial bevelling 43 of the inside marginal edge 41 of the fixed clamping surface 3.
From the forward edge of the bevel 43 rearwards towards the positioning nose 14 the free front face 42 of the fixed clamping surface 3 extends at an angle or inclination, so that the bevel 43 terminates in effect in a projecting nose of the clamping surface 3.
When, with this arrangement, the weft thread gripper grips the weft thread 23 presented by the transfer device, then this weft thread 23 is very carefully and gently released from the thread clamp 2, because the thread 23 can slide along against the inclined front face 42, with the result that the clamping action on the thread is maintained right up to the picking of the thread.
These measures permit the inserted weft thread 23 to be pushed into the momentarily open thread clamp 2, and there held fast, simultaneously with it being beaten-up against the fell or woven edge 27 of the fabric 20. Subsequently, the cutting operation can be carried out with conventional means which therefore are not particularly shown. Thereafter, the thread end, i.e. what is now the beginning of the next weft thread, is brought back by pivotal movement of the transfer lever 1 in the counter-clockwise sense into the path of movement 24 of the weft thread gripper and is there taken-up by the gripper in the manner described above.
It will be clearly apparent that the concept and design of the aforementioned weft thread transfer device is simple and functionally reliable, especially in terms of achieving a constant clamping pressure, even with the most varied types of thread quality, and that also, as described above, there is additionally attained good self-cleaning of the transfer device.
While there are shown and described present preferred embodiments of the invention, it is to be distinctly understood that the invention is not limited thereto, but may be otherwise variously embodied and practiced within the scope of the following claims. Accordingly,
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A transfer device comprises a transfer lever arranged to execute an oscillatory movement and carries a thread clamp at its free end. This thread clamp comprises a leaf spring constituting a movable, controllable clamping element. The leaf spring can be raised by an actuating lever pivotally mounted on the transfer lever and which is movable relative thereto. At least one thread pick-up or entrainment element and preferably two thread pick-ups or entrainment elements, are arranged on the batten of the loom to position the weft or filling thread in the thread clamp in a predetermined position. This arrangement constitutes a relatively very simple, operationally reliable and self-cleaning transfer device.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present disclosure relates to subject matter contained in priority Korean Application No. 10-2012-0132564, filed on Nov. 21, 2012, which is herein expressly incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present disclosure relates to a clothes treating apparatus having a hot air supply device and an operating method thereof.
[0004] 2. Description of the Related Art
[0005] In general, a clothes treating apparatus as a device for supplying hot air generated by a heater into the drum and absorbing the moisture of an object to be dried to perform drying on the object to be dried, and can be largely classified into an exhaust type clothes dryer and a condensation type clothes dryer according to the method of treating humid air that is generated by absorbing moisture to dry the object to be dried.
[0006] Furthermore, the hot air can be heated using any method, and as an example, it may be divided into a gas type dryer for burning fossil fuels such as gas or the like to obtain the amount of heat and an electric type dryer for obtaining the amount of heat using electrical energy. Of them, the gas type dryer has an advantage in that the maintenance cost is relatively low compared to the electric type dryer.
[0007] On the other hand, in order to optimally maintain the dry performance as well as reduce the damage of the object to be dried therein, it may be required to maintain the temperature of hot air within a suitable temperature range. To this end, as disclosed in Korean Patent No. 10-2009-0024163 (Title of Invention: Apparatus and method for controlling ignition of gas dryer), the temperature of supplied hot air is measured using a temperature sensor or the like, and the amount of fuel supplied to the burner is adjusted according to the measured temperature of hot air, thereby allowing hot air to maintain an optimal temperature range.
[0008] However, according to the foregoing related art, the operation of the burner is merely controlled based on only the temperature of supplied hot air, and an environmental change due to the drying process is not properly reflected, and thus there is a limit in reducing the amount of energy consumption.
SUMMARY OF THE INVENTION
[0009] The present disclosure is contrived to overcome the foregoing drawbacks in the related art, and a technical task of the present disclosure is to provide an operating method of a clothes treating apparatus capable of reducing the amount of gas used.
[0010] Furthermore, another technical task of the present disclosure is to provide a clothes treating apparatus capable of reducing the amount of gas used during the drying process using the foregoing operating method.
[0011] In order to accomplish the foregoing technical tasks, according to an aspect of the present disclosure, there is provided a clothes treating apparatus including a drum configured to accommodate an object to be dried; a linear valve configured to linearly adjust the amount of supplied gas; a burner configured to burn gas supplied by the linear valve; a hot air supply device configured to supply hot air heated by the burner into the drum; a temperature sensor configured to measure the temperature of air exhausted from the drum; and a control means configured to adjust the amount of gas supplied to the burner based on a temperature measured by the temperature sensor, wherein the control means partitions a drying process into a plurality of sections based on a temperature change of the exhaust air, and varies a gas supply amount for each section.
[0012] Here, the plurality of sections may be partitioned to include a first heating section located at the beginning of the drying process; an evaporation section located subsequent to the first heating section to activate moisture evaporation from the object to be dried so as to have a relatively low temperature increase rate; and a second heating section located subsequent to the evaporation section to have a relatively high temperature increase rate.
[0013] At this time, the control means may control a gas supply amount during the first heating section to be relatively greater than that during the evaporation section. Furthermore, the control means may control such that the highest amount of gas is supplied during the first heating section.
[0014] On the other hand, the control means may control a gas supply amount during the second heating section to be relatively less than that during the evaporation section. Here, the control means may control such that the lowest amount of gas is supplied during the second heating section.
[0015] Furthermore, the amount of supplied gas may be constantly maintained within each section. In addition, the control means may determine the weight of an object to be dried therein based on a temperature increase rate per hour at the beginning of the first heating section, and determine an initial gas input amount according to the determined weight.
[0016] According to another aspect of the present disclosure, there is provided a clothes treating apparatus including a drum configured to accommodate an object to be dried; a linear valve configured to linearly adjust the amount of supplied gas; a burner configured to burn gas supplied by the linear valve; a hot air supply device configured to supply hot air heated by the burner into the drum; a temperature sensor configured to measure the temperature of air exhausted from the drum; a selection means configured to select one of a plurality of drying courses with variant gas supply modes; and a control means configured to adjust the amount of gas supplied to the burner based on a temperature measured by the temperature sensor and the selected drying course, wherein the control means partitions a drying process into a plurality of sections based on a temperature change of the exhaust air, and varies a gas supply amount for each section based on the selected drying course.
[0017] Here, the plurality of sections may be partitioned to include a first heating section located at the beginning of the drying process; an evaporation section located subsequent to the first heating section to activate moisture evaporation from the object to be dried so as to have a relatively low temperature increase rate; and a second heating section located subsequent to the evaporation section to have a relatively high temperature increase rate.
[0018] Furthermore, a gas supply amount during the first heating section may be greater than that during the evaporation section for at least one drying course. At this time, a gas supply amount during the second heating section may be less than that during the evaporation section for the at least one drying course.
[0019] Furthermore, gas supply amounts during the first heating section and evaporation section may be the same, and the clothes treating apparatus may further include a drying course with a relatively low gas supply amount during the second evaporation section.
[0020] Here, the control means may determine the weight of an object to be dried therein based on a temperature increase rate per hour at the beginning of the first heating section, and determine an initial gas input amount according to the determined weight.
[0021] According to aspects of the present disclosure having the foregoing configuration, an overall drying section may be partitioned according to the drying status as well as the temperature of hot air supplied to the drum, and then accordingly, the gas supply amount may be varied, thereby decreasing the drying time as well as reducing the amount of gas used.
[0022] Moreover, it may be possible to reduce the gas supply amount in the latter half of the drying process while preventing unnecessary energy consumption as well as reducing the damage of fabrics.
[0023] In addition, the weight of an object to be dried may be measured based on a temperature increase rate at the beginning of the drying process to know the weight of the object to be dried with no installation of an additional weight sensor, and as a result, an initial gas input amount can be determined at an optimal level, thereby further reducing the energy consumption amount.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and together with the description serve to explain the principles of the invention.
[0025] In the drawings:
[0026] FIG. 1 is a longitudinal cross-sectional view illustrating a clothes treating apparatus according to the present disclosure;
[0027] FIG. 2 is a perspective view illustrating the embodiment illustrated in FIG. 1 ;
[0028] FIG. 3 is an enlarged perspective view illustrating a hot air supply unit in the embodiment illustrated in FIG. 1 ;
[0029] FIG. 4 is a graph in which a temperature change of exhaust air is measured according to the drying process in the embodiment illustrated in FIG. 1 ;
[0030] FIG. 5 is a graph illustrating a difference between temperature changes of exhaust air and gas supply amounts for each drying course in the embodiment illustrated in FIG. 1 ;
[0031] FIG. 6 is a graph illustrating a difference between temperature increase rates during the first heating section according to a load change; and
[0032] FIG. 7 is a flow chart illustrating a process in which drying is carried out according to the foregoing embodiment.
DETAILED DESCRIPTION OF THE INVENTION
[0033] Hereinafter, a clothes treating apparatus according to an embodiment of the present disclosure will be described in detail with reference to the accompanying drawings.
[0034] FIG. 1 is a longitudinal cross-sectional view illustrating a clothes treating apparatus according to the present disclosure, and FIG. 2 is a perspective view illustrating the embodiment illustrated in FIG. 1 . The embodiment illustrated in FIGS. 1 and 2 relates to a dryer having only a drying function, but the present disclosure may not be necessarily limited to the dryer, and may be also applicable to any clothes treating apparatus having a drying function for supplying high-temperature hot air into the drum using a burner.
[0035] Referring to FIGS. 1 and 2 , the foregoing embodiment may include a cabinet 1 corresponding to the body of the dryer, and a drum 2 rotatably provided in the cabinet 1 to accommodate an object to be dried therein, a hot air supply unit 3 configured to form hot air supplied to the drum 2 , and a heat exchanger 4 configured to dehumidify humid air exhausted from the drum 2 while at the same time cooling hot air. Here, the heat exchanger 4 will be omitted in case of including a duct for directly discharging the exhausted humid air out of the building or the like.
[0036] An inlet 1 a for putting an object to be dried into the cabinet 1 is formed on a front surface of the cabinet 1 , and a front cover 5 for supporting the front side of the drum 2 is provided around an inner surface of the inlet 1 a, and an exhaust duct 6 for guiding humid air that has passed through the drum 2 to the outside of the cabinet 1 is provided at a lower side of the front cover 5 .
[0037] Furthermore, a rear cover 7 for supporting the rear side of the drum 2 is provided on a rear inner wall surface of the cabinet 1 , and a supply hole 7 a is formed at the rear cover 7 to supply hot air into the drum 2 . Furthermore, an intake duct 8 is provided on an rear outer wall surface of the cabinet 1 to communicate with the supply hole 7 a, and the hot air supply unit 3 is provided at an inlet side of the intake duct 8 .
[0038] Furthermore, a lint filter 9 for filtering out foreign substances from circulating air within the exhaust duct 6 is provided at the front cover 5 , and the heat exchanger 4 for dehumidifying humid air guided to the exhaust duct 6 is provided at the exhaust duct 6 .
[0039] In the foregoing embodiment, when power is supplied, the hot air supply unit 3 is operated to inhale and heat external air, and the heated air is guided to the side of the drum 2 through the intake duct 8 . Hot air guided to the drum 2 is supplied into the drum 2 through the supply hole 7 a provided at the rear cover 7 , and the hot air dries the laundry while being heat-exchanged with wet clothes within the drum 2 , and then humid air is guided to the side of the exhaust duct 6 provided inside the cabinet 1 . The humid air is passed through the lint filter 9 located at an upper stream of the exhaust duct 6 to filter out foreign substances, and the humid air from which the foreign substances have been filtered out is discharged to the outside of the cabinet 1 along the exhaust duct 6 . During the foregoing process, a series of processes in which the humid air is dehumidified while being passed through the heat exchanger 4 provided in the middle of the passage of the exhaust duct 6 and then discharged out of the cabinet 1 in a dry state will be repeated.
[0040] Here, as illustrated in FIGS. 2 and 3 , the hot air supply unit 3 may include a burner 10 for burning fuels such as LNG to generate heat, and a heating duct 20 provided around a flame port of the burner 10 to heat air inhaled from the outside of the cabinet 1 , and a catalyst burner 30 provided at an outlet side of the heating duct 20 to oxidize non-combusted gases, namely, harmful gases generated under imperfect combustion from the burner 10 .
[0041] A typical burner for burning fuels such as natural gases by mixing them with air is used for the burner 10 . Furthermore, the heating duct 20 is formed in a truncated conical shape in which the diameter of the inlet end is greater than that of the outlet end, and a flame port of the burner 10 is located and provided at the inlet end of the heating duct 20 .
[0042] The catalyst burner 30 is inserted and fixed to an outlet side on the basis of the length direction of the heating duct 20 , namely, a backwash side on the basis of the flow direction of the air, to minimize thermal deformation due to hot air.
[0043] Moreover, a linear valve 12 for adjusting the amount of gas supplied to the burner 10 is provided at a front end of the burner 10 . The linear valve 12 is connected to a gas supply pipe 14 to linearly adjust the amount of supplied gas.
[0044] Hereinafter, the operation of the embodiment will be described. Here, a change of the exhaust temperature being exhausted during the drying process will be first described. Referring to FIG. 4 , (for reference, a solid line in FIG. 4 denotes a graph regarding the foregoing embodiment, and a dotted line denotes a graph regarding a dryer employing an on-off valve in the related art), the supplied air is not sufficiently heated at the beginning of the drying process to have a low temperature, and accordingly, a moisture evaporation amount of the laundry put therein is low, and thus the temperature and humidity of the exhaust air is in a low state. However, since the amount of heat is continuously supplied by a gas burner, and a latent load is small, the temperature increase occurs at a relatively high speed. The section may be referred to as a first heating section as a matter of convenience.
[0045] Then, when the temperature of supplied hot air reaches a sufficient level enough to evaporate moisture, evaporation occurs from the laundry in a full scale. Accordingly, most of thermal energy contained in hot air is converted into latent heat due to a phase change of moisture, and the temperature of exhaust air is maintained in a substantially constant state. The section may be referred to as an evaporation section. Here, the temperature is gradually increased as approaching the latter half of the evaporation section when the evaporation of moisture is progressed, and thus the end time point of the evaporation section cannot be simply specified using only the temperature, and therefore, when a temperature increase rate is exhibited above a predetermined value in advance, it is determined that the evaporation section is terminated.
[0046] When the evaporation section is terminated, the latent load disappears, and thus the temperature of exhaust air is rapidly increased as shown in the first evaporation section. The temperature change behavior at this time is similar to the first evaporation section, and thus it may be referred to as a second evaporation section, and when the drying process is sufficiently carried out, the operation of the gas burner is suspended to perform cooling. On the other hand, according to the related art, as illustrated in FIG. 4 , the gas supply amount is controlled using an on-off valve, and thus the valve is open at the same level over the entire drying process. Accordingly, the amount of gas supplied during the first heating section and evaporation section is maintained at a constant level.
[0047] However, the supplied gas amount is adjusted while repeating the switching of the on-off valve to prevent an excessive temperature increase during the second heating section. Due to this, the exhaust temperature repeats the increase and decrease during the second heating section. The excessive gas supply can be reduced by shortening the on-off period of the on-off valve, but there exists a physical limit in a time interval reaching the extinguishment and re-ignition as well as the combustion efficiency should be taken into consideration and as a result it may be impossible to reduce the time interval to the extent it is intended.
[0048] However, according to the foregoing embodiment, a larger amount of gas is supplied at the beginning of the drying process compared to the related art to reduce a time consumed for temperature increase. It is seen in the graph that a gradient of the curve during the first heating section is greater than that of the related art, and a time point at which the first heating section is terminated is earlier than that of the related art.
[0049] Then, the gas supply amount is reduced during the section in which the first heating section is terminated. At this time, the amount of supplied gas may be determined at a level enough to evaporate the laundry put therein. It may be accomplished by measuring the exhaust temperature and sensing the measured temperature change to control the gas supply amount.
[0050] When the evaporation section is terminated to enter the second evaporation section, the gas supply amount is reduced. In other words, latent loads are all disappeared during the second evaporation section, and thus only small energy is required compared to the evaporation section. Taking it into consideration, the gas supply amount can be reduced, and the resultant energy consumption amount can be reduced, thereby solving a problem due to the excessive temperature increase.
[0051] As illustrated in FIG. 4 , according to an embodiment of the present disclosure shown in a solid line, the drying time point is 10 minutes earlier than that of the related art. Moreover, the consumed gas amount may be also reduced, and it will be described with reference to FIG. 5 .
[0052] FIG. 5 is a graph illustrating a change of exhaust temperature and a change of gas supply amount in a dryer in the related art and the foregoing embodiment, in which the foregoing embodiment has two drying courses in FIG. 5 . In other words, the drying course shown in a solid line corresponds to a rapid course, and the drying course shown in a dash-dot line corresponds to a saving course for reducing the energy consumption amount.
[0053] Specifically, the rapid course has a gas supply amount pattern similar to the foregoing course previously illustrated in FIG. 5 , and the redundant description thereof will be omitted. However, there is a difference in that a gas supply amount during the evaporation section is larger than that of the related art. Furthermore, the amount of supplied heat is large during the first heating section in the rapid course, and thus it has a characteristic in which the duration time is shorter than those of the other two courses.
[0054] The saving course is similar to a conventional course in part of the first heating section and evaporation section, but there is a difference in that the gas supply amount is reduced at the end of the evaporation section. Specifically, there is a difference in that the amount of heat of 15000 btu per hour is supplied at the end of the evaporation section in the saving course whereas the amount of heat of 20000 btu per hour is supplied at the beginning of the evaporation section and second heating section in the conventional course.
[0055] As described above, a latent load is smaller compared to the beginning of the evaporation section since moisture contained in the laundry is evaporated to a certain extent at the end of the evaporation section. Accordingly, even when the amount of supplied heat is reduced, it is taken into consideration that it does not have a significant effect during the drying time. Furthermore, the saving course temporarily cuts off gas supply during the second heating section. It is to prevent an excessive temperature increase, and it may be also possible to maintain the gas supply amount at a constant level when the temperature increase rate is small.
[0056] The following Table 1 summarizes the fuel consumption amount and drying time consumed during the conventional course, rapid course and saving course. Here, the initial percentage of water content for the laundry put therein is 70%, and the weight thereof is 3.714 kg.
[0000]
TABLE 1
Conventional course
Rapid course
Saving course
Fuel consumption
11.13
10.57
10.04
amount (ft 3 )
Drying time
42 min 55 sec
35 min 36 sec
40 min 18 sec
Final percentage
0.92
0.92
0.92
of water content
[0057] As illustrated in the above Table 1, it is seen that both the two courses in the foregoing embodiment use a smaller amount of gas and complete the drying process within a shorter period of time compared to the related art.
[0058] On the other hand, the weight of the laundry put therein may be indirectly measured through a gradient in the first heating section even without using an additional weight sensor. In other words, when it is assumed that the same amount of heat is supplied, the temperature increase rate is smaller as increasing the amount of the laundry put therein, and thus a gradient in the first heating section will be reduced as a graph illustrated in FIG. 6 . Accordingly, when a reference value is determined in advance, it may be possible to determine the weight of the laundry put therein only with the gradient of the graph.
[0059] FIG. 7 is a flow chart illustrating a process in which drying is carried out according to the foregoing embodiment, wherein the weight of the laundry put therein is determined by checking a course entered by the user through a course selection means provided in the manipulation panel in the initial stage, and then supplying a previously determined amount of heat and measuring a temperature increase rate.
[0060] The amount of heat to be supplied in the initial stage is determined based on the determined weight, and gas suitable to the amount of heat is supplied to start the drying process. During the process, the degree of drying is recognized based on the measured percentage of water content in the laundry through the temperature of air exhausted from the drum and the electrode sensor or the like, to determine that the measured time point corresponds to which one of the first heating section, the evaporation section and the second heating section.
[0061] When the section is determined, the gas supply amount is adjusted according to the entered course to maintain the drying process, and when the final percentage of water content reaches a target degree of drying, the operation of the burner is suspended to cool the inside of the drum.
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The present disclosure relates to a clothes treating apparatus having a hot air supply device and an operating method thereof, and according to an aspect of the present disclosure, a clothes treating apparatus may include a drum configured to accommodate an object to be dried; a linear valve configured to linearly adjust the amount of supplied gas; a burner configured to burn gas supplied by the linear valve; a hot air supply device configured to supply hot air heated by the burner into the drum; a temperature sensor configured to measure the temperature of air exhausted from the drum; and a control means configured to adjust the amount of gas supplied to the burner based on a temperature measured by the temperature sensor, wherein the control means partitions a drying process into a plurality of sections based on a temperature change of the exhaust air, and varies a gas supply amount for each section.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to holders for cartridge type electric fuses. More particularly it relates to an in-line fuse holder having a breakaway capability.
2. Description of the Prior Art
It is common practice to provide electric fuses in the power lines which supply electricity to street lights or other area lighting systems. In systems where the light is located at the top of a light pole it is, again, common practice to position the fuseholders for such fuses at the base of the pole. Such an arrangement allows the fuse to protect the wires passing through the pole, the light itself, as well as, any components associated with starting or controlling the light which may be mounted on the pole. All too often such light poles are severly damaged or broken off when errant motor vehicles strike them. Under such circumstances, particularly when a pole is broken off and moved, the tensile forces on the fuseholder, and the wires and connections within the pole could easily result in breaking of the fuseholder and/or separation of connections which, in turn, could result in dangerous exposed "live" wires or connections in the vicinity of the base of the pole.
It is an object of the present invention to provide an inline fuseholder, to be positioned, e.g. in the power line to a street light, with the capability of "breaking away" into two fully insulated undamaged components upon imparting a predetermined axial force thereto.
Other objects and advantages of the present invention will become apparent from an examination of the drawing and the accompanying description.
SUMMARY OF THE INVENTION
According to the present invention a holder for an electric fuse is provided which includes a first body portion which has a recess for receiving one end of an electric fuse. A nut having an internally threaded section includes a surface which interacts with a mating surface on the first body portion. The interaction between the nut and the first body portion allows relative rotational movement between the parts, but no axial movement therebetween when they are assembled to one another. The interacting surfaces are configured to allow separation of the nut from the first body portion when a predetermined axial separating force is imparted between the parts, without damaging either part. A second body portion includes a recess for receiving the other end of the fuse. An external thread is provided on the second body portion which is adapted to threadably engage the threads on the nut. As the threaded connection is made, the second body portion, and the assembly of, the first body portion and the nut, are drawn together to enclose and confine the electric fuse in the fuse receiving recesses of the two body portions.
BRIEF DESCRIPTION OF THE DRAWINGS
The novel features that are considered characteristic of the invention are set forth with particularity in the appended claims. The invention itself, however, both as to its organization and its method of operation, together with additional objects and advantages thereof, will best be understood from the following description of the preferred embodiment when read in connection with the accompanying drawings wherein like numbers have been employed in the different figures to denote the same parts and wherein:
FIG. 1 is a side elevational view of a fuseholder that is made in accordance with the principles and teachings of the present invention;
FIG. 2 is the fuseholder as shown in FIG. 1, attached to two conductors, with the end connections partially broken away;
FIG. 3 is a sectional view, on a larger scale, through the fuseholder of FIG. 1;
FIG. 4 is a sectional view similar to FIG. 3 with an electric fuse operatively received therein;
FIG. 5 is a prespective, exploded view of an end connector, fuse contact/retainer of one end of the fuseholder of FIG. 1;
FIG. 6 is a perspective exploded view of the fuseholder of FIG. 1;
FIG. 7 is a sectional view through the fuseholder FIG. 3 taken along the line 7--7 of FIG. 3; and
FIG. 8 is a side elevational view, partially broken away, of the fuseholder of FIG. 1 following separation according to the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to all of the drawing figures in detail, the numeral 10 generally denotes a preferred embodiment of a fuseholder that is made in accordance with the principles and teachings of the present invention. The fuseholder includes a first body 12 of cylindrical form which has a cylindrical fuse receiving recess 14 therein. A wall 16 is provided at one end of the cylindrical recess 14. The other end of the recess 14 is open. An opening 18 is provided in the wall 16, and, an annular recess 20, which is formed in the outer face of the wall 16, communicates with the opening 18.
As best shown in FIGS. 3, 4 and 6 a large outwardly directed annular shoulder 22, of rectangular cross section, is formed on the exterior of the body portion 12. The shoulder 22 is somewhat closer to the left-hand end, as seen in FIGS. 3 and 4, of the body 12 than it is to the right-hand end. Directly to the right of the large annular shoulder 22 is an annular groove 24 formed in the exterior of the body 12. The groove 24 is defined by: a wall 26 of the shoulder 22 on the left; a bottom 28 having a diameter substantially the same as the portion of the body 12 to the left of the shoulder 22; and, an inclined annular surface 30. The inclined surface 30 extends from the bottom 28 upwardly and axially toward the right hand end of the body 12 to a diameter defining a small annular lip or shoulder 32 slightly larger than the diameter of the annular groove 24. In the embodiment shown the diameter of the groove 24 is 0.600 inch and the inclined surface increases to a diameter of 0.660 inch at an angle of 60 degrees from the horizontal, as viewed in the drawing figures. From the maximum diameter of the small shoulder 32 the body portion 12 defines a section of decreasing diameter 34 which may be viewed as a frusto-conical surface. The frusto-conical section 34 terminates in a shallow annular groove 36 which is adapted to receive an o-ring 38 which will be described in more detail below. The end section 40 of the body portion 12 is cylindrical and has a substantially constant diameter. As best shown in FIG. 6, a pair of longitudinally extending slots 42 extend from the end thereof to a position just short of the groove 36. The body portion 12 is perferably molded from an inexpensive but strong plastic material. A thermoplastic synthetic resin, specifically a polycarbonate has been used satisfactorily.
As best shown in FIG. 3 and 5 the numeral 44 denotes a terminal which has an enlarged end 46 and a flanged inner face 48. The enlarged end 46 is dimensioned to fit snugly within the passage 18 in the wall 16 of the body portion 12. The flanged inner face 48 is dimensioned so it can not pass through the passage 18. The terminal 44 has an elongated shank 50 with an elongated recess 52 therein. The end surface 54 of the flanged inner face 48 is provided with a shallow socket 55 therein. When assembled the flanged inner face 48 will be pressed into engagement with the wall 16. The numeral 56 denotes a movable contact which has the form of a shallow cylinder with a radially extending flange 58 at the right hand face thereof. An axial opening 60 extends through the length of the contact 56. The right-hand end of a flexible conductor 62 extends into the opening 60 and is electrically conductively attached thereto by conventional means, e.g. a solder joint. The left-hand end of the flexible conductor 62 extends into the socket 54 in the terminal 44 and is similarly electrically conductively attached thereto.
A helical compression spring 64 surrounds the flexible conductor 62. The left-hand end of the spring 64 bears against the flanged inner face 48 of the terminal 44, while the right-hand end of the spring bears against the radially extending flange 58 on the contact 56. The helical spring 64 biases the movable contact 56 to the right as best seen in FIG. 3, but it can yield to permit the contact 56 to be moved to the left, as shown in FIG. 4 when an electric fuse 66 is installed in the fuseholder 10. The flexible conductor 62 provides a low resistance current path between the contact 56 and the terminal 44, thereby shunting the spring 64 and keeping it from being heated to temperatures at which the spring could lose some of its restorative force.
A sleeve 68 of heat shrinkable insulation is shrunk into intimate engagement with the shank of the terminal 44. The sleeve 68 extends into the recess 20 to abut the short portion of the terminal 44. A sealing material 70, such as an epoxy resin, is applied in the region of the annular recess 20 in a manner to provide a water tight seal between the terminal 44 and the body portion 12.
Reference numeral 72 denotes a nut having an internally threaded section 74 and a section thereof 76 for telescopically receiving and interacting with the body portion 12. The threaded section 74 is substantially larger in diameter than the body portion 12 and includes a plurality of threads 76, formed internally thereof, and a hexagonal wrench-receiving surface 77 at the exterior thereof. As viewed in FIGS. 1-4 the nut 72 has an end wall 78 on the right hand end which has a large opening 80 therein having a diameter slightly larger than the diameter of the end 40 of body 12. Extending to the left from the wall 78 are four elongated fingers 82 which define an elongated bore 84 for receiving the body 12. The fingers are arcuately shaped, as best seen in FIG. 6, and the interior of the bore 84, which they define, is dimensioned to receive the frustro-conical section 34 of the body 12 in a mating, clearance fit relationship.
As best seen in FIGS. 3 and 4, each of the arcuate fingers 82 has, at its outermost end, an inwardly directed annular shoulder 86. Each of the shoulders is arcuate and they cooperate to define a bore 88 having a diameter which is less than the diameter of the small annular shoulder 32 and greater than the diameter of the annular groove 24. The fingers 82 are resilient enough to allow the ends, bearing the shoulders 86, to be deflected radially outwardly. As a result of the above described structure it will be evident that the nut 72 and the body 12 may be readily assembled to one another by inserting the body 12, end 40 first, into the bore 88 of the nut 12 with sufficient force to cause the interaction, between the four shoulders 86, and the frusto-conical surface 34, to deflect the fingers 82 radially outwardly until the four shoulders 86 pass into the annular groove 24. In this condition, as shown in FIGS. 1-4 the nut 72 is free to rotate with respect to the body 12. At the same time, the nut 72 is restrained from moving axially with respect to the body 12. Following assembly of the nut 72 to the body 12 the o-ring 38 is passed over the end 40 of the body and caused to be seated in the o-ring groove 36.
With reference to FIGS. 3 and 4, the right hand facing surface 90 of each of the annular shoulders 86 is at a 60 degree angle which allows it to matingly engage the inclined surface 30 of the groove 24. The importance of this relationship to the invention and the functioning thereof will be described in more detail following the description of the remaining structural features of the fuseholder.
Referring again to all of the drawing figures, the reference numeral 92 refers to a second body portion of generally cylindrical form which has a cylindrical recess 94 therein. A wall 96 is provided at one end of the cylindrical recess 94, and the other end of the recess is open. A passageway 98 is provided in the wall 96, and, an annular recess 100, which is formed in the outer face of the wall 96 communicates with the passageway 98.
The numeral 102 denotes a terminal which has an enlarged end 104 and a flanged inner face 106. The enlarged end is dimensional to fit snugly within the passage 98 in the wall 96 of the body portion 92. The flanged inner face 106 is dimensioned so it can not pass through the passage 98. The terminal 102 has an elongated shank 108 with an elongated recess 10 therein.
Looking now at FIGS. 3 and 5 a fuse retainer element 116 is provided with a ring like section 118 which is adapted to encircle the enlarged end 104 of the terminal 102 in abutting relation with the flanged inner face 106. The retainer has an axially extending projection 120 formed with the ring section 118. The projection 120 includes a fuse contact portion thereof 122, which is partially punched out, which extends inwardly and rearwardly thereof. When assembled into the body 92 the flanged inner face 106 of the terminal 102 serves to press the ring section 118 against the wall 96 of the body 92, as shown best in FIG. 3.
As with the other terminal a sleeve 124 of heat-shrinkable insulation is telescoped over the shank 108 of the terminal 102. The sleeve 124 extends into the recess 100 to abut the enlarged end 104 of the terminal 102. A sealing material 126, such as an epoxy resin, is applied in the region of the annular recess 100 in a manner to provide a water tight seal between the terminal 102 and the body portion 92.
Integrally formed with the body portion 92 is an externally threaded nut 128 which includes a hexagonal wrench receiving surface 130 and a plurality of threads 132 which are sized to threadably mate with the internal threads 76 of the nut 72. The integrally formed nut 128 actually defines the above noted open end of the cylindrical recess 94. As best shown in FIGS. 3, 4 and 7 a number of inwardly facing axially extending projections are formed on the inner wall of the integrally formed nut 128. Two of these projections 134 are dimensioned to be received within the longitudinally extending slots 42 formed in the end 40 of the first body portion 12. The other smaller projections 136 serve to assure that the o-ring 38 is not displaced into the recess 94.
The second body portion 92 and the internally threaded nut 72 are preferably both made from the same thermosetting polycarbonate resin which is capable of having strong threads formed thereon. Both of the nuts 72 and 128, as mentioned, have wrench receiving surfaces, 77 and 130 respectively thereon which allow tightening thereof by appropriate sized wrenches.
As previously indicated, the reference numeral 66 denotes an electric fuse dimensioned to be operatively received within the cylindrical recesses 14 and 94, respectively, in the body portions 12 and 92. The fuse 66 is shown installed within the fuseholder 10 in FIG. 4. The fuse 66 has ferrule terminals at the opposite ends thereof, one 146 of which is urged into contact with the inner face of the radially extending flange 58 of the movable contact 56. The other end ferrule 144 of the fuse is urged into contact with the inner surface of the flanged inner face 106 of the other terminal 102. This ferrule 144 is also engaged on its lateral surface by the fuse contact portion 122, of the fuse retainer 116. Because of the angular relationship of the fuse contact portion 122, the electric fuse ferrule may be readily pressed into contact therewith, however, once inserted, the forces exerted on the ferrule serve to retain a fuse, and a considerable force is necessary in order to remove a fuse therefrom.
In using the fuseholder 10 of the present invention, the insulation-free end of a conductor 138 which is connected to the "line" side of an electrical circuit is inserted into the recess 52 formed within the shank 50 of the end terminal 44. Once inserted a crimping tool, not shown, is used to crimp the shank of the terminal tightly into the end of the conductor 138 as shown in FIG. 2. Following this, field installed insulation such as a splicing compound or electrical tape will be used to cover any insulation-free portion of the shank 50 and any insulation-free portion of the end of the conductor 138. The sleeve 68 of insulation formed over the shank 50 performs as an insulator and also provides a surface to which the field-installed insulation will readily adhere.
The insulation-free end of a second conductor 140 which is connected to the "load" side of the electrical circuit is similarly inserted within the recess 110 in the shank 108 of the second terminal 102. This connection is crimped and insulated in the same manner as described above with respect to the "line" side.
A fuse 66 will then be inserted into the cylindrical recess 94 in the second body portion 92. An appropriate amount of insertion pressure will result in the end surface 142 of the right-hand ferrule 144 abutting the flanged interface 106 of the terminal 102. The insertion pressure will cause the fuse contact portion 120 to yield to permit the fuse to be moved into engagement with the flanged inner face and the fuse contact section 122 will thereafter apply a holding force to the ferrule 144 to retain the fuse within the recess 94. The other end ferrule 146 of the fuse 66 will then project outwardly beyond the end of the body 92, however the electrician or maintenance man will not receive a shock if he touches that fuse terminal because the fuse is then engaged only with the "load" side rather than to the "line" side of the electrical circuit.
Assembly of the fuseholder is accomplished by taking the sub-assembly of the body portion 92 with fuse 66 installed as above described and inserting the other ferrule 146 into the cylindrical fuse receiving recess 14 of the first body portion 12. The electrician will grasp the wrench receiving surface 77 of the nut 72 in one hand and grasp the wrench receiving surface 130 of the externally threaded nut 128 in the other hand. The externally threaded nut 128, which of course forms a integral part of the second body portion, will be held stationary while the threaded nut 72, which is free to rotate with respect to the first body portion, will be caused to rotate in a direction consistent with engagement of the threads 76, of the nut 72, with the mating threads 132, on the externally threaded nut 128. Upon initiating such rotation, the first body portion 12 may rotate momentarily with the internally threaded nut 72, however, within less than half a revolution, the alignment projections 134, which are formed on the inner wall of the externally threaded nut 128, will engage with the longitudinally extending slots 42 formed in the end 40, of the first body portion 12. Such engagement will therafter prevent relative rotational movement between the first and second body portions 12, 92. Following this, continued rotation of the internally threaded nut 72 will cause the body sections to move axially towards one another, and will eventually cause contact of the other ferrule 146 with the radially extending flange 58 of the movable contact 56. FIG. 4 illustrates the assembled fuseholder with a fuse 66 installed therein and, it should be noted, that, when in the final assembled position the spring 64, engaging the movable contact 56, has been compressed, and the flexible conductor 62 has been taken out of tension. As a result, the spring force will assure a good electrical contact of both of the fuse ferrules 144, 146 with their respective contacts 106, 56.
It should be noted that, prior to the time the fuse ferrule 146 engages the radially extending flange 58 of the movable contact 56, the right-hand end 40 of the first body portion 12 will have telescoped within the left-hand end, i.e. the externally threaded portion of the second body portion 92. This arrangement assures that any arc which could form as the ferrule 146 of the fuse engages the radially extending flange of the contact 56 would be wholly enclosed and could not injure the person assembling the fuseholder.
As thus assembled the fuseholder comprises a water tight enclosure for the electric fuse 66, with the joint between the body portions sealed by the o-ring 38 which is carried in the o-ring groove 36 of the first body portion and which is compressed into contact with the inner surface of the externally threaded nut 128 when the fuseholder is assembled. Both end terminals of the fuse assembly are sealed by a waterproof epoxy adhesive, as described above, and as shown at reference numerals 70, and 126.
As mentined above a typical use for the fuseholder 10 is in the base of a support pole for a street lamp where the fuseholder would normally be mounted in a vertically extending position. When a support pole making use of a fuseholder 10 according to the present invention is broken off and moved, and a tensile force is imparted to the electrical line carrying the fuseholder 10, the fuseholder will pull apart into two fully insulated, undamaged components, when, the axial force imparted to the fuseholder exceeds a predetermined level. FIG. 8 illustrates the fuseholder 10, 5 and the fuse 66 contained therein, following such an axial force having been imparted thereto. It should be noted that in this condition the fuse continues to be retained by the fuse retaining contact 122 within the recess 94 of the second body portion. The internally threaded nut 72 which had previously been snap fit assembled to the first body portion 12 remains threadably engaged with the externally threaded nut 128 of the second body portion 92. The first body portion, i.e. the "line" side, remains fully insulated, with no "live" surfaces with which inadvertent contact by a repairman or the like could cause serious personal injury or death. It should be noted that, when the fuseholder pulls apart into the separated condition, the o-ring 38 is moved out of its retaining groove 36 when the inwardly facing shoulders 86 of the arcuate fingers 84 of the nut 72 are dragged thereover as the nut is removed from the first body portion.
Following a successful separation of the fuseholder to the condition as shown in FIG. 8 reassembly of the fuseholder may be readily carried out when the light pole is being repaired. Such reassembly requires unthreading of the internally threaded nut 72 from the second body portion 92; reassembly of the internally threaded nut 72 to the first body portion by the same procedure described hereinabove with respect to initial assembly, resulting in the inwardly facing annular shoulders 86 snap fitting into the annular groove 24 in the first body portion. Following this, the o-ring 38 is reassembled into the o-ring groove 36 and the fuseholder is ready to be used again.
Looking now at the physical design of the fuseholder which permits the above described "breaking away" into two fully insulated undamaged components, reference is made back to the description of the interface between the inclined annular surface 30 and the right-hand facing surfaces 90 of each of the annular shoulders 86 at the ends of the arcuate fingers 84. As described above, these surfaces define mating contact surfaces at a 60 degree angle from the horizontal. The frictional engagement between these mating surfaces and the degree of flexibility of the four arcuate fingers 84 are carefully selected such that upon imparting an axial force upon the conductors 138, 140 attached to the fuseholder the four fingers will flex outwardly and disengage the annular groove 24 in the first body portion 12 resulting in the separation described hereinabove prior to any damage occurring to the conductors 138, 140 or to the other structural components of the fuseholder 10.
Accordingly it should be appreciated that an inline waterproof fuseholder has been provided which is initially simple to assemble and which has the capability of "breaking away" into two fully insulated undamaged components upon the imparting of a predetermined axial force thereto. Further, following such separation, the fuseholder may be readily reassembled and continued in use for its designated purpose.
This invention may be practiced or embodied in still other ways without departing from the spirit or essential character thereof. The preferred embodiment described herein is therefore illustrative and not restrictive, the scope of the invention being indicated by the appended claims and all variations which come within the meaning of the claims are intended to be embraced therein.
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A holder for an electric fuse has a first receiving body which has an internally threaded nut assembled thereto in a manner allowing relative rotation between them. The assembly of the nut to the body allows separation of the nut from the body when a predetermined axial separating force is imparted between the parts, without damage to them. A second fuse receiving body has an external thread which engages the thread of the first body. As the threaded connection is made the body sections are drawn together to enclose the fuse therein.
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This U.S. Non-Provisional patent application claims the benefit of priority from U.S. Provisional Patent Application 61/736,434, filed Dec. 12, 2012, the entire disclosure of which is hereby incorporated by reference in its entirety.
FIELD OF THE INVENTION
The present invention relates generally to protective cases and covers for electronic devices. More specifically, the present invention relates to a folding case for accommodating a variety of electronic devices, such as tablet computers, e-readers, and other similar devices.
BACKGROUND
Portable electronic devices such as tablet computers and e-readers have become increasingly popular. An inherent convenience of these devices is that they are highly portable. With increased portability and enhanced electronics, however, comes the need to protect the device from the surrounding environment, impact, and abrasion. Accordingly, as the popularity of the devices continues to increase, so does the need and desire to protect or surround the device with a cost effective storage case. There is a need not only for protecting and transporting electronic devices, but also to use the case for the dual purpose of retaining the electronic device in a preferred orientation for viewing purposes.
SUMMARY OF THE INVENTION
Accordingly, the present invention contemplates a novel system and device for a protective case for an electronic device wherein the case is provided with features for selectively accommodating and retaining a variety of electronic devices of various shapes and/or sizes, as well as allowing the selective positioning of the device for viewing.
In various embodiments, the present invention comprises a plurality of hinges or folds, such that the case may be converted between: 1—a “closed” configuration; 2—an “open” configuration; and 3—a “propped open” or self-supported configuration. A case of the present invention may comprise at least two hinge features and at least one slot, indention, indentation, or trough, such that the case may be positioned in an open position and with a contained device residing at a predetermined angle, such as may be desirable for using the device.
In one aspect, the present invention comprises a protective case for retaining, displaying, and storing an electronic device, the case comprising a first cover portion, a second cover portion hingedly interconnected to the first cover portion by a first hinge, the second cover portion comprising a substantially rigid planar member and a second hinge, such that a portion of the second cover portion is rotatable with respect to the first cover portion about at least two parallel axes of rotation.
Another aspect of the present invention is to provide at least one slot or channel on the inside surface of the cover for engaging and retaining the substantially rigid planar member in a predetermined orientation. The predetermined orientation may position the electronic device such that it is tipped up or tilted in a reading position or other position of use.
In various aspects, protective cases of the present invention comprise various protective features including, but not limited to, rigid or hard-shell outer covers, cushioned materials, soft or non-abrasive interior portions to reduce risk of abrasion, etc.
In one embodiment, a case is provided for securing a device, such as a tablet. The tablet is positionable between at least a first position, wherein the tablet rests “screen-down” in a molded panel for safe storage and transport, and a “screen-up” position in the molded panel for handheld use. Additionally, an integrated/attached kickstand supports a device in multiple viewing angles using the molded EVA panel as a stable base. Grooves or other shapes molded into the panel create resting positions for lower edge of the device. Portions of the case are designed to interface with molded grooves without slipping. The molded panel is designed so that thickness of kickstand support nests into depressions within the panel so that the tablet rests smooth and flat within the molded panel in a plurality of positions.
In a preferred embodiment, a case for an electronic device is provided. The case comprises a first cover portion and a second cover portion wherein the device is secured within a first cover portion and the second cover portion is provided for additional protection of the device as well as providing means for displaying a device in a position of use. In certain embodiments, the second cover portion comprises a planar portion adapted for covering and protecting a planar portion of the device, such as the screen of a tablet device, and a peripheral edge portion comprising a lip for extending at least partially over at least one edge of a device and/or the first cover portion. Preferably, the second cover portion comprises a substantially rectangular cover portion with a planar portion and a peripheral edge portion or lip extending around each of the four sides of the substantially rectangular cover portion. The peripheral edge portion of such embodiments is sized to receive the first cover portion, which may comprise an electronic device secured therein, in both an open and a closed position such that the peripheral edge extends angularly away from the planar portion and covers or receives at least a portion of each of the four sides of the first cover portion. Thus, when the first cover portion and any corresponding device provided therewith is provided in both a closed position (i.e. with a screen of the device provided directly adjacent the second cover portion) and an open position (i.e. with a screen of the device oriented outwardly with respect to the second cover portion), the peripheral edge portion of the second cover portion surrounds or covers the perimeter of the first cover portion and/or device. As shown and described herein, cases of the present invention comprise at least three positions of storage and/or use including, the aforementioned closed position with a screen of the device provided directly adjacent the second cover portion, a first open position with a screen of the device oriented outwardly with respect to the second cover portion and the screen of the device provided substantially parallel to the planar portion of the second cover portion, and a second open position wherein the first cover portion is provided at an acute angle with respect to the second cover portion.
Various devices provide for protective coverings for an electronic device, including U.S. Patent Application Publication No. 2013/0134061, which is incorporated by reference in its entirety herein. Such devices, however, fail to provide various features and benefits of the present invention including, for example, a second cover portion comprising a peripheral edge or lip for receiving and protecting a first cover portion or electronic device in at least two positions.
In one embodiment, a protective case for retaining, displaying, and storing an electronic device is provided, the case comprising a first cover portion hingedly interconnected to a second cover portion, said first cover portion comprising a first panel and a second panel, said first panel comprising a device-receiving portion and said second panel opposing said first panel, wherein said protective case provides for selective positioning of said first cover with respect to said second cover portion, said first cover portion positionable between at least: (i) a closed position, wherein the first panel is provided adjacent to said second cover portion; (ii) a first open position, wherein said first panel is rotated approximately 180 degrees about a longitudinal axis from said closed position; and (iii) a second open position, wherein said first cover portion is provided at an angle between approximately 15 degrees and approximately 90 degrees with respect to said second cover portion. The second cover portion comprises a planar portion adapted for covering and protecting a planar portion of the device, and a lip extending from said planar portion for receiving the first cover portion in at least one of the closed position and the first open position. As used herein, reference to a 180 degree rotation of one portion or cover of the case with respect to a second portion of the cover or case generally refers to “flipping” the relevant portion and is not limited to an exact 180 degree rotation. One of skill in the art will recognize that, particularly in embodiments where a support member is disposed under a portion of the first cover portion, a full 180 degree rotation may not be achieved or required in order to convert the case between open and closed positions and vice versa. Thus, 180 degree rotation and “approximately” 180 degree rotation should not be read as limiting and generally relates to the concept of converting a downward facing cover portion to an upward facing cover portion.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate embodiments of the disclosure and together with the general description of the disclosure given above and the detailed description of the drawings given below, serve to explain the principles of the disclosures.
It should be understood that the drawings are not necessarily to scale. In certain instances, details that are not necessary for an understanding of the disclosure or that render other details difficult to perceive may have been omitted. It should be understood, of course, that the disclosure is not necessarily limited to the particular embodiments illustrated herein.
FIG. 1 is a front perspective view of a case according to one embodiment and provided in a first position;
FIG. 2 is a front perspective view of a case according to the embodiment of FIG. 1 and provided in a second position;
FIG. 3 is a perspective view of a case according to the embodiment of FIG. 1 and provided in a third position;
FIG. 4 is a perspective view of a case according to the embodiment of FIG. 1 and provided in a fourth position;
FIG. 5 is a perspective view of a case according to the embodiment of FIG. 1 and provided in a fifth position; and
FIG. 6 is a perspective view of a case according to one embodiment of the present invention;
FIG. 7 is a front perspective view of a portion of a case according to one embodiment of the present invention.
DETAILED DESCRIPTION
The present invention has significant benefits across a broad spectrum of endeavors. It is the applicant's intent that this specification and the claims appended hereto be accorded a breadth in keeping with the scope and spirit of the invention being disclosed despite what might appear to be limiting language imposed by the requirements of referring to the specific examples disclosed. To acquaint persons skilled in the pertinent arts most closely related to the present invention, a preferred embodiment of the method that illustrates the best mode now contemplated for putting the invention into practice is described herein by, and with reference to, the annexed drawings that form a part of the specification. The exemplary method is described in detail without attempting to describe all of the various forms and modifications in which the invention might be embodied. As such, the embodiments described herein are illustrative, and as will become apparent to those skilled in the arts, can be modified in numerous ways within the scope and spirit of the invention.
The detailed description is to be construed as exemplary only and does not describe every possible embodiment since describing every possible embodiment would be impractical, if not impossible. Numerous alternative embodiments could be implemented, using either current technology or technology developed after the filing date of this patent.
Embodiments of the present invention accommodate a wide variety of devices, such as an iPad®. While the embodiment illustrated is well suited for housing an iPad®, smaller and larger versions of the protective case are contemplated that are adapted for housing or protecting various devices, such as a Kindle®, a Galaxy®, a PlayBook®, an Android® tablet, an Iconia®, and various similar devices whether or not currently conceived of.
FIG. 1 is a front perspective view of one embodiment of a case 2 . The case 2 is provided in a closed position in FIG. 1 . The case 2 comprises a first cover portion 4 for receiving and selectively securing an electronic device, such as a tablet computer, an e-reader or the like. The first portion 4 , at least as shown in FIG. 1 , substantially covers a back or rear portion of such a device (not shown in FIG. 1 ). As will be described herein, the case 2 comprises various features for revealing and/or displaying a front surface (e.g. a screen surface) of a device. FIG. 1 , however, shows a closed, protected, and/or secured state of storage for such a device. The first cover portion 4 communicates with a second cover portion 14 , the second cover portion 14 comprising a shell with a lip 15 and being slightly larger than the first cover portion 4 to provide a protective perimeter shell which surrounds at least one edge of the electronic device to provide impact protection if the device is dropped, for example. Both first 4 and second cover portions 14 are preferably formed of a substantially rigid material suitable for protecting an enclosed device. Suitable materials include, but are not limited to, EVA, polycarbonate, polypropylene, and various combinations thereof.
The case 2 comprises an elastic securing means 6 for aiding in securing the device in at least the position shown in FIG. 1 . The case 2 further comprises a support member 8 . In various embodiments, support member 8 is hingedly secured to the first cover portion 4 at one end 10 of the support member 8 and hingedly secured to second cover portion 14 at a second end 12 of the support member 8 . In a preferred embodiment, the support member 8 comprises a first end and a second end, the first end being hingedly secured to the second portion at or proximal to a periphery of the second portion, and the second end of the support member 8 is hingedly secured to a side of the first portion. In various embodiments, the second end of the support member is hingedly secured to the first portion at a point in the middle third of a width of the first portion. In certain embodiments, the second end of the support member is hingedly secured to the first portion proximal a mid-point of a width of the first portion. Support member 8 thus allows first cover portion 4 to rotate with respect to second cover portion 14 about at least two parallel axes of rotation, the axes generally corresponding to hinges formed at the first and second ends 10 , 12 of the support member. When provided in the screen-down, closed position of FIG. 1 , support member 8 is disposed substantially flush with a rear surface of the first cover portion 4 .
In certain embodiments, the case 2 comprises features 16 a , 16 b for accommodating audio-visual features of a stored device, such as speakers ( 16 a ) and camera equipment ( 16 b ). In various embodiments, the first cover portion comprises a first panel or side and a second opposing panel or side, the first cover portion 4 generally comprising a planar rectangular member with two sides or panels and both a length and a width being substantially greater than a thickness of the member as shown in the Figures.
FIG. 2 is a perspective view of the embodiment of FIG. 1 wherein the case 2 is provided in a screen-up or open position. As shown, an electronic device 18 is provided and secured with a first cover portion 4 of the case 2 . The device 18 and first cover portion 4 are rotated approximately 180 degrees from the arrangement shown in FIG. 1 and with respect to the second cover portion 14 . First cover portion 4 and associated device 18 are thus “nested” within the lip 15 of the second cover portion 14 , and a screen or display surface of the device 18 is exposed for use (i.e. viewing, user contact, etc.). In FIGS. 1-5 , a case 2 is provided for use with an iPad 18 . Accordingly, the embodiment shown in FIGS. 1-5 and the various features provided therein are sized to secure an iPad of known dimensions. It will be expressly recognized, however, that the present disclosure is not limited to any particular device. Indeed, features and concepts of the present disclose may be employed with any number of devices, including, but not limited to, various sized tablets, smart-phones, and e-readers.
As shown in FIGS. 1-2 , the second cover portion 14 comprises a lip 15 which receives the first cover portion 4 and any associated device 18 . The second cover portion 14 and associated lip 15 receive first cover portion 4 and device 18 in a “nested” configuration, both when the device 18 is in a “screen-down” position ( FIG. 1 ) and a “screen-up” position ( FIG. 2 ). Rotation of the hinge members of support 8 allows for the device 18 and first portion 4 to be nested in the second portion 14 in both “screen-up” and “screen-down” arrangements, the two arrangements being approximately 180 degrees of rotation (about a longitudinal axis) apart.
In one embodiment, hinges of the support 8 comprise integral or stitched members with sufficient flexibility to allow for the described rotation. Accordingly, in various embodiments, first cover portion 4 , support 8 , and second cover portion 14 are hingedly interconnected and non-severable. Alternative embodiments, however, contemplate various connections between cover portions 4 , 14 and support 8 . Such connections include, but are not limited to, hook-and-loop connections, magnetic connections, snaps, etc., such that one or more of the components are selectively separable but still comprise the ability to rotate features as described herein.
FIG. 3 is a perspective view of the case 2 according to FIGS. 1-2 , wherein the first cover portion 4 is disposed at an angle with respect to the second cover portion 14 . The position of the case 2 depicted in FIG. 3 may be considered a transition position, wherein the case 2 is between at least two of a closed position, an open position, and a propped-up position. The support member 8 is shown as being flush with a rear portion of the first cover portion 4 . From the depicted position, a first edge 20 of the first cover portion 4 may be rotated downwardly (with respect to FIG. 3 ) about one end of the support member 8 and selectively received by at least of receiving portions 22 provided on an interior surface of the second cover portion 14 . Each of the receiving portion 22 correspond to a different display angle of the first cover portion 4 and a corresponding device. Each of the plurality of receiving portions 22 and associated angular positions may be selected by a user based on user-preference. The support member 8 is provided in a non-supportive position in FIG. 3 (i.e. folded against the first cover portion 4 ). As will be shown and described herein, however, the first cover portion 4 is rotatable about the support member 8 such that a first edge 20 of the first cover portion 4 is received in a receiving portion and supported therein.
FIG. 4 shows the case 2 , first cover portion 4 and associated device 18 disposed in an angled position of use. As discussed, support member 8 is secured at one end 12 to the second cover portion 14 of the case and further secured at a second end to the first cover portion 4 . Both connections comprise hinged members to allow the cover first portion 4 and/or second cover portion 14 to rotate at least with respect to the support member 8 . Additionally, at least a portion of the support member 8 comprises a substantially rigid member for supporting at least a portion of the weight of the first cover portion 4 and any associated device 18 . One end 20 of the first cover portion 4 is disposed in one of a plurality of receiving portions 22 to further facilitate the support of the device 18 in an angled or partially-upright position.
FIG. 5 provides an additional side perspective view of a case 2 disposed in an angled position of use. FIG. 5 is generally similar to FIG. 4 , with the exception that the first cover portion 4 and associated device of FIG. 5 are disposed in a different receiving portion 22 such that the device is inclined at a greater angle with respect to the second cover portion 14 . In various embodiments, receiving portions 22 are provided such that the first cover portion may be selectively positioned in any one of a plurality of predetermined positions between approximately 30 degrees and approximately 90 degrees with respect to the second cover portion.
FIG. 6 is a perspective view of a case according to one embodiment of the present invention. FIG. 6 shows the case 2 and with a first cover portion 4 disposed in an angled position of use. Various retaining means, including those shown and described in U.S. patent application Ser. No. 13/722,167, filed Dec. 20, 2012 and incorporated by reference in its entirety herein, are contemplated for use with the present invention.
FIG. 6 depicts one embodiment of a protective case comprising elastic securing means. The elastic securing means of the depicted embodiment comprise elastic loops 32 a , 32 b for engaging a corner or other portion of an electronic device. As shown, the elastic straps 32 a , 32 b are provided and stitched or secured to a panel 34 . The panel 34 preferably comprises a non-abrasive material for receiving an electronic device. However, it should be expressly recognized that elastic securing means 32 a , 32 b of the present invention may be provided in any number or arrangements. Additionally, the present invention is not limited to two elastic securing means as shown in FIG. 6 . Indeed, any number of geometrical arrangements may be provided in accordance with the present invention.
The embodiment of FIG. 6 further comprises a substantially rigid member 30 . The substantially rigid member 30 comprises at least one of a clip, hook, loop, projection, post, recession, etc. for receiving a portion of an electronic device and that generally opposes a force applied to the electronic device by the loops 32 a , 32 b . In FIG. 6 , the substantially rigid member 30 is depicted as being provided generally in the center of a length of the panel 34 . It will be recognized, however, that the placement of the substantially rigid portion 30 is not critical, so long as it is appropriately positioned so as to resist the force applied by the elastic members and secure a device.
FIG. 7 is a front elevation view of a second cover portion 14 comprising securing means for the first cover portion 4 . In the depicted embodiment, the securing means comprise resilient extensions 40 , such as rubber flap or extension members. The resilient extensions 40 are deformable to selectively secure and release respective corners of the first cover portion 4 , which is shown as secured within the second cover portion 14 and in the closed position in FIG. 7 . In certain embodiments, the resilient extensions 40 are secured to or proximal a lip 15 of the second cover portion 14 and extending into an area defined by a perimeter the lip 15 of the second cover portion 14 . The resilient extensions 40 secure the first cover portion 4 in both an open (see FIG. 2 ) and closed (see FIG. 1 ) positions. Preferably, a user-applied force is sufficient to remove the first cover portion from either of an open and a closed position.
In various embodiments, the resilient extensions 40 extend into an internal area of the second cover portion 14 and comprise a curvilinear shape. In the depicted embodiment, the curvilinear shape comprises a pair of inflection points 42 bordering a recess 44 . The inflection points 42 further comprise points of maximum extension into the area or volume defined by the second cover portion 14 . In certain embodiments, the inflection points extend between approximately 1 and 10 mm from a respective edge or lip 15 of the second cover portion 14 . In preferred embodiments, the inflection points extend between approximately 3 and 8 mm from a respective edge or lip 15 of the second cover portion 14 . In a more preferred embodiment, the inflection points extend between approximately 6 mm from a respective edge or lip 15 of the second cover portion 14 . It will be recognized, however, that devices of the present invention are not limited to any particular size, and thus resilient extensions 40 are not limited to any particular dimensions. That is, devices of the present invention are contemplated as being sized to receive any number of devices, including relatively small smartphones and larger tablet devices. Accordingly, it is further contemplated that resilient members 40 will scale based on the size of the case and device contemplated by a particular embodiment.
The resilient extensions 40 comprise the combination of inflection points 42 and the recess 44 to provide for sufficient flexibility of the extension 40 when inserting and/or removing a device. Recess 44 increases flexibility of the extension 40 , while inwardly-extending inflection points provide for sufficient coverage and securing of a device and/or first cover portion 4 to be held within the second cover portion 14 .
In certain embodiments, the extension members 40 are provided in at least two corners of the case 2 . In preferred embodiments, an extension 40 is provided in each of the four corners of the case 2 . Extensions 40 may be glued to the second cover portion 14 , which may comprise EVA or a similar material.
In a preferred embodiment, a protective case of the present invention comprises a plurality of elongated ridges, indentions, indentations, or slots, each of the elongated ridges or slots corresponding to a predetermined angle at which a contained-device may be situated. While various embodiments contemplate that the case and device may be maintained at a desired position based on the weight and geometry of the case, slots, and/or device, it is further contemplated that additional securing features may be provided. Additional securing features include, but are not limited to Velcro®, magnets, snaps, rubber grips, and various similar features as will be recognized by one of skill in the art.
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A protective case for accommodating at least one electronic device is provided. The case comprises internal features including an articulating support member to allow the selective orientation and positioning of the electrical device in one of at least three user-selected positions and also allows for the nesting of the electronic device in either the closed or open position.
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CROSS-REFERENCE TO RELATED APPLICATIONS
The present invention is a continuation-in-part of allowed U.S. utility patent application Ser. No. 09/885,848 filed Jun. 20, 2001 of the same inventive entity as herein, now U.S. Pat. No. 6,479,965, incorporated herein by reference.
FIELD OF THE INVENTION
The present invention is drawn to the field of illumination, and more particularly, to a novel rechargeable lamp system.
BACKGROUND OF THE INVENTION
Candles may be moved and placed to provide illumination and/or ambience. While their utilitarian and aesthetic advantages are well-known, candles suffer from an undesirable self-consumption, needing to be replaced when used-up; produce smoke especially when snuffed, which may foul the air; require vigilant attendance to mitigate an ever-present fire hazard; are susceptible to being extinguished by gusts of air when used outdoors or moved around; and may give rise to undesirable wax build-up, which in many instances needs removed from candle support members or underlying structures.
There is thus a need to provide a rechargeable lamp system that enjoys the many utilitarian and aesthetic advantages of candles but is not subject to their disadvantages.
SUMMARY OF THE INVENTION
It is accordingly a general object of the present invention to disclose a rechargeable lamp system that provides candle-like lighting for indoor or outdoor use that avoids the problems associated with candles.
In accordance therewith, the autoilluminating rechargeable lamp system of the present invention includes a recharging platter adapted to receive a set of luminaries including a first circuit coupled to each luminary of said set of luminaries received thereon operative in response to supplied AC power to provide a charge signal to each luminary of said set of luminaries received thereon; and a set of luminaries each having a light emitting element connected to a rechargeable battery pack via a second circuit operative in one mode to charge said rechargeable battery pack in response to said charge signal when each luminary of said set of luminaries is received on said recharging platter and operative in another mode to activate said light emitting element in response to the absence of said signal, whereby, each said luminary lights if removed from said recharging platter and lights if no AC power is supplied to said recharging platter when received therein.
In the presently preferred embodiments, the set of luminaries includes one or more luminaries each of which is inductively coupled to the first circuit of the recharging platter. The inductive coupling provides automatic, hands-free recharging of the rechargeable battery pack of a luminary upon its receipt by the recharging platter, and provides automatic, hands-free actuation of a luminary when it is removed therefrom.
In the presently preferred embodiments, each luminary of the set of luminaries is self-standing and includes a diffusor that may be shaped to resemble a candle releasably mounted to a base member supporting said light emitting element therewithin.
In further accordance therewith, the autoilluminating rechargeable lamp system of the present invention includes a wall mountable charging base adapted to support a set of luminaries including a first circuit coupled to each luminary of said set of luminaries supported thereon operative in response to supplied AC power to provide a charge signal to each luminary of said set of luminaries supported thereon; and a set of luminaries each having a light emitting element connected to a rechargeable battery pack via a second circuit operative in one mode to charge said rechargeable battery pack in response to said charge signal when each luminary of said set of luminaries is supported thereon and operative in another mode to activate said light emitting element in response to the absence of said signal, whereby, each said luminary lights if removed from said wall mountable charging base and lights if no AC power is supplied to said wall mountable charging base when supported thereon.
In the presently preferred embodiments, the wall mountable charging base may be plugged directly into an AC wall outlet and/or mounted adjacent an AC wall outlet by any suitable mounting hardware.
In further accordance therewith, the autoilluminating rechargeable lamp system of the present invention includes a charging base adapted to support a set of luminaries including a first circuit coupled to each luminary of said set of luminaries supported thereon operative in response to supplied AC power to provide a charge signal to each luminary of said set of luminaries supported thereon; a sensor to provide a seat signal representative that each luminary of said set of luminaries is supported on said charging base; and a set of luminaries each having a light emitting element connected to a rechargeable battery pack via a second circuit operative in one mode to charge said rechargeable battery pack in response to said charge signal when each luminary of said set of luminaries is supported thereon and operative in another mode to activate said light emitting element in response to the absence of said seat signal, whereby, each said luminary lights if removed from said charging base and does not light if no AC power is supplied to said charging base when supported thereon.
In the presently preferred embodiments, the charging base maybe provided with a removable cover that protects the luminaries during charging, storage, and a handle that aids in transit.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other objects, advantageous features and inventive aspects of the present invention will be more fully appreciated as the same becomes better understood from the following detailed description of the preferred embodiments when considered in connection with the accompanying drawings, in which:
FIG. 1 is a perspective view of an exemplary embodiment of the present invention, showing a charging stand and one lamp module;
FIG. 2 is a top view of the charging stand;
FIG. 3 is a front view of the charging stand;
FIG. 4 is a bottom view of the charging stand;
FIG. 5 is a sectional view of the charging stand, taken along line 5 — 5 of FIG. 2 ;
FIG. 6 is a sectional view of the charging stand, taken along line 6 — 6 of FIG. 2 ;
FIG. 7 is a circuit diagram of the charging stand circuit;
FIG. 8 is an exploded perspective view of an exemplary embodiment of a lamp module according to the present invention;
FIG. 9 is a front view of the lamp module;
FIG. 10 is a right side view of the lamp module;
FIG. 11 is a top view of the lamp module;
FIG. 12 is a bottom view of the lamp module;
FIG. 13 is a sectional view of the lamp module taken along line 13 — 13 of FIG. 9 ;
FIG. 14 is a sectional view of the lamp module taken along line 14 — 14 of FIG. 10 .
FIG. 15 is a sectional view of the lamp module taken along line 15 — 15 of FIG. 9 ;
FIG. 16 is an exemplary embodiment of a circuit diagram of the lamp module circuit board according to the present invention;
FIG. 17 is a pictorial view of another exemplary embodiment of the present invention, showing a wall mountable charging base and four lamp modules;
FIG. 18 is a pictorial view of another exemplary embodiment of the present invention, showing a wall plug mountable charging base and single lamp modules;
FIG. 19 is a pictorial view of another exemplary embodiment of the present invention, showing a carrier/charging base and eight lamp modules;
FIG. 20 is a pictorial view showing one module-to-carrier/charging base interface;
FIGS. 21 and 22 are block diagrams respectively of exemplary carrier/charging base and lamp module circuitry.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIG. 1 , reference numeral 10 generally refers to the rechargeable lamp system of the present invention. Lamp system 10 comprises a charging stand 12 and a plurality of lamp modules 110 , 111 , 112 and 114 .
As shown in FIGS. 1 and 2 , stand 12 comprises slots 16 , 18 , 20 and 22 which are each adapted to removably receive one of said lamp modules 110 , 111 , 112 and 114 . Slots 16 , 18 , 20 and 22 each include a respective cylindrical wall 38 , 40 , 42 , and 44 and a substantially planar floor 46 , 48 , 50 and 52 .
A power cord 24 having an inline power switch 26 and a “wall-block” style transformer provides power to charging stand 12 via ordinary 120-volt household current. In alternate embodiments, the transformer may be dispensed with.
As will be described in greater detail herein, each of modules 110 , 111 , 112 and 114 is battery-powered and designed to be charged by magnetic induction when placed in a respective one of slots 16 , 18 , 20 and 22 . Modules 110 , 111 , 112 and 114 are each designed to illuminate when removed from slots 16 , 18 , 20 and 22 , or when AC power is cut off to charging stand 12 .
The number of lamp modules (and a corresponding slot for each module) shown in the preferred embodiment is intended to be merely exemplary. It should be understood that the lamp system 10 of the present invention maybe constructed with any number of modules.
Referring now to FIGS. 3-4 , stand 12 also includes an upper portion 30 and a lower portion 32 . In an exemplary embodiment, upper portion 30 is ceramic. However, upper portion 30 may be made from other suitable materials, such as wood or plastic. In the interest of economy, lower portion 32 in the exemplary embodiment is formed of injection-molded plastic, but may as well be made of other suitable materials, such as steel or other metal or other material. In the exemplary embodiment, upper portion 30 and lower portion 32 snap together. However, any suitable means, such as bonding, screws, etc. could be used to secure upper portion 30 and lower portion 32 .
As shown in FIGS. 2 , 5 and 6 , stand 12 further includes a circuit board 58 which is hard-wired to cord 24 and four primary induction coils (wired in parallel), one coil encircling each of walls 38 , 40 , 42 and 44 , respectively. FIG. 5 shows a pair of primary induction coils 54 and 56 that encircle walls 44 and 42 , respectively. Identical primary coils (not shown) encircle walls 38 and 40 .
FIG. 7 shows the circuit formed by transformer 28 , inline power switch 26 , and primary induction coil 54 . As shown in FIG. 7 , transformer 28 converts 120 volts AC to 12 volts AC. The three other primary induction coils, not shown, are preferably wired in parallel with primary induction coil 54 . In other embodiments, the transformer component can be replaced by the inductor coils (on the platter and luminaries), whose turn-ratios are selected to provide a stepped-down voltage to the lamps. As will be appreciated by those of skill in the art, an oscillator providing frequencies higher than line frequency may be employed to improve efficiency (inductor size and attendant cost).
Modules 110 , 111 and 112 are identical to module 114 . Thus, it will only be necessary to describe module 114 in detail.
As shown in FIGS. 8-16 , module 114 comprises a diffuser 116 , a light bulb 118 , a battery pack 120 , a circuit board 122 , a secondary induction coil 124 and a base 126 .
Diffuser 116 in the exemplary embodiment is formed of blow-molded plastic (or glass) having a frosted outer surface 142 . It could also be injection-molded plastic with a frosted, translucent finish. In the exemplary embodiment, diffuser 116 is slender and elongated in shape and includes a mid-section 146 that tapers upwardly to a tip 144 and tapers slightly to a tail 148 . This shape is chosen to provide optimal light color and transmission, as well as even diffusion of light from bulb 118 . Obviously, numerous alternative shapes for diffuser 116 are possible. However, the internal volume created by diffuser 116 must be sufficient to envelop bulb 118 , battery pack 120 and circuit board 122 . In addition, because of the heat generated by bulb 118 , it is desirable to provide air space between bulb 118 and diffuser 116 to prevent diffuser 118 from melting or deforming.
Base 126 comprises a lower portion 128 that provides stable support for module 114 when placed on a level surface or within slot 16 . Nick 130 is adapted to removably receive diffuser 116 (to enable access to bulb 118 and battery pack 120 ). Neck 130 includes tabs 134 , 136 , 138 and 140 and a lip 135 that cooperate to secure tail 148 of module 114 to neck 130 (see FIGS. 8 , 13 and 14 ).
Battery pack 120 in the exemplary embodiment comprises three “AA” Nickel-Cadmium (Ni-Cad) cells wrapped in PVC shrink-wrap and having a total output of 3.6 Vdc and 500-800 mA. Of course, other types and sizes of rechargeable cells, such as Nickel-Metal-Hydride or Lithium cells, could be substituted for the Ni-Cad cells. Such cells would provide more power, and charge more quickly than Ni-Cads, but are substantially more expensive.
The power requirements for bulb 118 are, of course, chosen to match the power output of battery pack 120 . In the exemplary embodiment, bulb 118 is a conventional miniature incandescent bulb, such as Chicago Miniature Lamp, Inc. part #CM1738, having an output of 1 candela and having design power requirements of 2.80V and 60 mA and an expected life of 6,000 hours. Of course, other lamps and types of light sources, such as a light-emitting diode (L.E.D.) may be substituted for bulb 118 . The incandescent bulb shown is preferred because of its balance of cost, heat generation, power consumption, expected service life and brightness characteristics.
As shown in FIGS. 13 and 14 , bulb 118 and battery pack 120 are preferably hard-wired to circuit board 122 . As shown in FIG. 16 , circuit board 122 comprises four primary circuits that control the charging of battery pack 120 and the lighting of bulb 118 .
A charging circuit 150 regulates the voltage and current flowing to battery pack 120 from secondary induction coil 124 to prevent damage to battery pack 120 . A latch circuit 154 cuts off current to bulb 118 when the voltage output of battery pack 120 drops below 3.1 volts, thus preventing damage to battery pack 120 which could be caused by fully draining battery pack 120 . A charge-sensing switch 156 works in cooperation with latch circuit 154 to turn off current to bulb 118 when current is detected in charging circuit 150 . A constant current source circuit 152 provides a constant flow of current (65 mA in the exemplary embodiment) to bulb 118 . This enables bulb 118 to shine at a constant brightness despite fluctuations in the output current from battery pack 120 . In alternate embodiments, a constant voltage source could be employed.
As described above, battery pack 120 is charged by magnetic induction. The magnetic field created by primary induction coil 54 (when current is applied) induces a current in secondary induction coil 124 when secondary induction coil 124 is concentrically located relative to primary induction coil 54 . In the present invention, this occurs when module 114 is placed within slot 16 (see FIG. 1 ).
It is preferable to ship battery pack 120 fully charged, as this will increase the shelf life of the Ni-Cad cells. However, shipping battery pack 120 fully charged requires the inclusion of means for electrically isolating battery pack 120 from lamp 118 between the time battery pack 120 is charged and when module 114 is first used by an end consumer. Such means could comprise a Mylar tab (not shown) inserted between two electrical contacts after the initial charging which would be removed by the consumer before first use. Alternatively, such means could comprise a fusible link (not shown). The fusible link would be adapted to close current regulating circuit 152 when current is sensed in charging circuit 150 (i.e., the first time the consumer plugs in charging stand 12 ).
Operation of lamp system 10 is elegantly straightforward. As described above, bulb 118 is designed to illuminate when no current is sensed in charging circuit 150 . Thus, bulb 118 will automatically turn on when module 114 is removed from slot 16 . Charging stand 12 and module 114 can also function as a table lamp by leaving module 114 in slot 16 and switching off inline power switch 26 . Module 114 also functions as an emergency light—automatically turning on during a power failure.
Referring now to FIG. 17 , reference numeral 200 generally refers to another exemplary embodiment of the rechargeable lamp system of the present invention. Lamp system 200 comprises a wall mountable charging base generally designated 202 and four lamp modules generally designated 204 . The number of lamp modules shown in the preferred embodiment is intended to be merely exemplary. It should be understood that the lamp system 200 of the present invention may be constructed with any number of modules.
As shown, the wall mountable charging base 202 comprises projections 206 spaced laterally apart a distance larger than the width of each lamp module 204 , and each lamp module 204 comprises an opening thereinthrough generally designated 208 adjacent to its top surface. The projections 206 cooperate with the openings 208 to removably support the lamp modules 204 on the wall mountable charging base 202 . Projections 206 and openings 208 are each of generally cylindrical geometry, although projections and openings of another geometry or other removable supporting means may be employed without departing from the inventive concepts.
Each projection has a free end, and a diffuser 210 is removably or fixedly mounted to the free end over an LED and ambient light sensor mounted thereon not shown, that switches the LED “on” in response to a condition of ambient darkness, Each lamp module 204 has a flat base 212 and a front face diffuser 214 that extends from top to bottom and surrounds the opening 208 . The flat base 212 enables to place each lamp module 204 on a shelf or table and the opening 208 allows it to be carried about or hung on a hook to provide illumination in a wide variety of situations.
A power cord 216 having an inline power switch, not shown, provides power to wall mountable charging base 202 via ordinary 120-volt household current. The base 202 may be wall mounted over or spaced in relation to the AC wall outlet by any suitable mounting means, and a recess and/or power cord wrap or other means may be employed to stow any excess cord within the wall mountable charging base 202 . In alternate embodiments, the power switch may be dispensed with.
As in the embodiment described above in connection with the description of the FIGS. 1-16 , each lamp module 204 is designed to be charged by magnetic induction. Inductive magnetic coupling is provided by primary and secondary coils, not shown, carried on the projections 206 of the charging base and about the openings 208 of the lamp modules 204 when supported by a respective one of the projections 206 . Other coupling means such as mating electrical contacts or other means could be employed without departing from the inventive concepts,
As in the embodiment described above in connection with the description of the FIGS. 1-16 , modules 204 are each designed to illuminate when removed from projections 206 , or when AC power is cut off to wall mountable charging base 202 , The wall mountable recharging base includes a first charge circuit responsive to supplied AC power to provide a charge signal and each lamp module includes a light emitting element connected to a rechargeable battery pack via a second circuit operative in one mode to charge the rechargeable battery pack in response to the charge signal when each lamp module is supported by the wall mountable charging base and operative in another mode to activate the light emitting element in response to the absence of the charge signal, whereby, each lamp module lights if removed from the wall mountable recharging base and lights if no AC power is supplied to the wall mountable recharging base when supported thereon.
A switch, not shown, may be provided to independently turn each lamp module 204 on/off to conserve charge or to use the light as needed.
Referring now to FIG. 18 , reference numeral 230 generally refers to another exemplary embodiment of the rechargeable lamp system of the present invention. Lamp system 230 comprises a wall plug mountable charging base generally designated 232 and a single lamp module generally designated 234 . The embodiment 230 is generally the same as the embodiment 200 described above in connection with the description of FIG. 17 , except the wall plug mountable charging base 232 includes extending plug members 236 adapted to plug the base directly into a standard AC wall outlet.
Referring now to FIG. 19 , reference numeral 250 generally refers to another exemplary embodiment of the rechargeable lamp system of the present invention. Lamp system 250 comprises a carrier/charging base generally designated 252 and ten lamp modules generally designated 254 . A cover 256 , preferably translucent, is removably mounted by any suitable means to the carrier/charging base 252 and a handle member 258 , preferably of aluminum but which could be of other metal or material, is attached by any suitable means to be carrier/charging base 252 . The cover member 256 protects the lamp modules during charging, storage and transit, and the handle member 258 provides for ease of transport. The number of lamp modules shown in the preferred embodiment is intended to be merely exemplary. It should be understood that the lamp system 250 of the present invention may be constructed with any number of modules.
Referring now to FIG. 20 , reference numeral 270 generally shows a pictorial view of one module-to-carrier/charging base interface. Unlike inductive coupling employed for the hereinabove described embodiments, contacts 272 on carrier/charging base 252 cooperate with contacts 274 to provide the charge signal to each lamp module 254 when supported on the carrier/charging base 252 . Spring-loaded arms 276 are provided to hold each lamp module 254 when seated in receptacles generally designated 278 provided therefore on the carrier/charging base 252 . And on/off membrane switch 280 (or other suitable means) is provided on each lamp module 254 by which they may be independently turned on/off. A charging status LED 282 for each module is provided on the carrier/charging base 252 that lights when the associated lamp module 254 is fully charged. Seat sensor contacts 284 , 286 provides a seat signal used by each lamp module in a manner to be described to inhibit lighting of each lamp module when supported on the carrier/charging base if no AC power is supplied. The seat signal is preferably at ground potential, although any suitable sensor contact or other means providing any signal representative of a lamp module being in supported condition could be employed without departing from the inventive concepts
Referring now to FIG. 21 , reference numeral 270 generally shows a block diagram of the carrier/charging base circuitry. As shown, an AC/DC converter 272 responds to standard AC power to provide a charge signal output signal and the seat sensor 274 provides a seat signal at ground potential. The AC/DC converter 272 preferably includes a timer to turn off the charge signal after a predetermined time determined to provide a full charge for each rechargeable battery pack.
Referring now to FIG. 22 , reference numeral 300 generally shows a block diagram of the lamp module circuitry. A charging circuit 302 regulates the voltage and current flowing to battery pack 304 (of each module) to prevent damage to battery pack 304 . A latch circuit 306 cuts off current to each lamp when the voltage output of battery pack 304 drops below a predetermined value, thus preventing damage to battery pack 304 which could be caused by fully draining battery pack 304 . Latch circuit 306 works in cooperation with a charge-sensing switch 308 to turn off current to each lamp when current is detected in charging circuit 302 or when the seat signal is detected. A constant current source circuit 310 provides a constant flow of current to each lamp. This enables the lamps to shine at a constant brightness despite fluctuations in the output current from battery pack 304 . In alternate embodiments, a constant voltage source could be employed.
The present invention in its broader aspects is not limited to the described embodiments, and departures may be made therefrom without departing from the principles of the invention and without sacrificing its primary advantages. Obviously, numerous modifications may be made to the present invention. Thus, the invention may be practiced otherwise than as specifically described herein. One feature of one embodiment may be employed in another disclosed embodiment. The power cord may be made removable to base placement without cord limitations. Other modifications will be readily apparent to one of skill in the art without departing from the scope of the present invention.
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An autoilluminating rechargeable lamp system includes a set of one or more self-standing rechargeable lighting fixtures (luminaries) removably supported on a recharging and support member. The luminaries each include a light diffusor that may resemble a candle that turn on when removed from the recharging and support member. The luminaries may also turn on when power to the recharging and support member is turned off, turning the luminaries on automatically as during a power failure. The luminaries may each be inductively coupled to the recharging and support member, which enables to provide an aesthetically pleasing interface free of electrical contacts.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority to an earlier filed co-pending Provisional Patent application No. 61/366,356 filed Jul. 21, 2010 entitled Innovative Water Sprays Applications for Dust Control on Mining Machines.
FIELD OF THE INVENTION
This invention relates to mining. More specifically, it relates to dust control around a continuous miner or similar mining machine through the use of water spray applications.
BACKGROUND OF THE INVENTION
Increased productivity and high out-of-coal seam dilution (25% to 30%) in the US and around the globe continue to generate dust control problems in mining areas. After a significant decrease in the number of incidents of coal worker's pneumoconiosis (CWP) over the last several decades, the number of reported cases in this decade is increasing. The primary cause of CWP is inhalation of respirable dust in a confined workplace; specifically, the inhalation of coal and quartz dust in a mine. The National Institute for Occupational Safety and Health recognizes this disease as being severely disabling, potentially lethal, and entirely preventable through respirable (less than 10 micron) dust control. The typical protocol for prevention of this disease has been monitoring mine workers for symptoms of this disease and, once a CWP diagnosis has been made, moving the miner to a low-dust exposure job. Prevention of this disease through a significant reduction in mine workers' exposure to respirable dust is a high priority. Additionally, several mines are now facing reduced dust standards due to high respirable quartz content in the dust. In underground US coal mines, miner operator (MO), haulage unit operator (HO), and roof bolting (RB) unit operator are typically overexposed to respirable dust.
The conventional approach to dust control in a mine has been the use of water sprays located on the mining machines to wet the coal. Approximately located and intuitively designed water sprays on the cutter drum and around the continuous miner chassis have been extensively used to control dust for the miner operator (MO), batch haulage unit operator (HO), haulage roadways, and material transfer points. A continuous miner or CM is extensively used for coal production in partial extraction mining areas. Typical spray systems, provided by manufacturers, have 15-45 sprays located across the top and the sides of the cutter boom ( FIGS. 1A and 1B ). In addition, under-the-boom and loading pan sprays on some miners provide water sprays to contain and wet the dust in the face area. However, there is no consensus in the art area on the type and location of sprays, volume of water and water pressure to be used in sprays. Although general guidelines have been developed by researchers based on laboratory and field studies, there is no systematic method of design or apparatus for using a spray system to meet the specific conditions to be encountered.
Several studies over the last several decades have attempted to locate the source of and have attempted a solution to the dust problems in mining environments. The conventional wisdom is that presented by Chang and Zukovich (Cheng L and Zukovich P. P. 1973. Respirable dust adhering to run-of-face bituminous coals. Pittsburgh, Pa.: U.S. Department of the Interior, Bureau of Mines, RI 7765. NTIS No. PB 221-883.) Their position was that a large amount of dust created does not become airborne and stays attached to the broken material. Therefore, spraying more water on the broken material tends to reduce dust. Adding water directly at the cutting picks that gets mixed with fragmented coal is more important than creating a shroud of water around the miner or shearer. Based on this observation, the conventional practice of mixing the water uniformly with broken coal was developed. However, this approach alone has not been effective in mine dust control.
More recently it has been observed that water can be used to control dust through the wetting of broken material and capture of airborne dust. (Kissel, F., “Handbook for Dust Control in Mining”, NIOSH, Information Circulation (IC 9465), 2003, pp. 131.) Although the methods of wetting broken material have been more uniform throughout the industry, a haphazard approach has been taken to the capture of airborne dust through the use of water sprays. This is most likely due to the problem and sometimes conflicting proposed solutions. It is suggested that a large number of smaller-volume sprays is better for dust control than smaller number of larger-volume sprays. Jayaraman and others concluded that many spray systems can create turbulent airflow in the face area that can result in rollback of dust. (Jayaraman, N, Fred N. Kissel, and W. E. Schroder (1984), “Modify Spray Heads to Reduce Dust Rollback on Miners,” Coal Age, June 1984)
However, certain research has proven valuable in the design of water spray systems. Courtney and Cheng concluded that typical water sprays operating at 100 psi do not capture more than 30% airborne dust in an open environment. (Courtney W. G. & Cheng L. 1977. Control of respirable dust by improved water sprays. In: Respirable Dust Control—Proceedings of Technology Transfer Seminars, Pittsburgh, Pa., and St. Louis, Mo., IC 8753, pp. 92-108. NTIS No. PB 272 910.) Furthermore, inappropriately designed sprays can displace dust clouds rather than wet or capture airborne dust. Reducing the water droplet size through the use of atomizing or fogging sprays may temporarily improve the airborne dust capture efficiency. However, small droplets tend to collapse/evaporate easily and release the captured dust. (McCoy J., Melcher J., Valentine J., Monaghan D., Muldoon T. & Kelly J. 1983. Evaluation of charged water sprays for dust control. Waltham, Mass.: Foster-Miller, Inc. U.S. Bureau of Mines contract no. H0212012. NTIS No. PB83-210476.) Atomizing nozzles are most efficient in airborne dust capture followed by hollow cone, full cone, and flat sprays. Hollow cone sprays are less likely to clog due to larger orifice area.
Nozzles operating at higher pressures are likely more efficient in the use of water while providing similar airborne dust capture efficiency as those operating at lower pressures. However, high-pressure sprays tend to disperse more dust. Therefore, their use is more appropriate in a relatively confined environment.
Courtney and others reported that the primary release point for dust from a CM is from under the boom when the cutter head shears down. (Courtney, W. G, N. I. Jayaraman, and P. Behum (1978), “Effect of Water Sprays for Respirable Dust Suppression with Research Continuous Mining Machine”, BuMines RI-8283, 17 pp) Thus, under-boom sprays should be considered. However, location and maintenance of under-boom sprays presents significant problems. Jankowski reported results for an alternate under-boom spray system with about 25% improved dust reduction (Jankowski, Robert A, N. I. Jayaraman, and C. A. Babbitt (1987), “Water Spray System for Reducing Quartz Dust Exposure of the continuous Miner Operator,” Proceedings of the 3 rd U.S. Mine Ventilation Symposium, Pennsylvania State University, PP 605-611.)
In spite of considerable excellent research by the U.S. Bureau of mines (USBM) and the National Institute of Occupational Safety and Health (NIOSH) over the last 40 years, there are significant limitations to the current practice. These include use of high water pressure on the chassis (100 psi or more); similar water pressure on the chassis and under-boom sprays leading to escape of airborne dust from the sides; only one point of dust control on the top of the chassis; no control on roll-back dust travel; use of only one type of sprays such as hollow-cone for all sprays; poor orientation of sprays, etc. There is a need to revisit the design concepts of sprays on continuous miners to control respirable dust (including quartz dust) in and around the mining face area.
In the industry there is a need for improving spray efficiency. A more reasoned and systematic design is needed that more effectively reduces the respirable dust around mining machinery.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 A—A top view of a continuous miner featuring an exemplary conventional spray system.
FIG. 1 B—A side view of the continuous miner of FIG. 1A .
FIG. 2 A—A top view of a continuous miner featuring an embodiment of a spray configuration, with Second Line of Defense (SLD) sprays, and Third Line of Defense (TLD) sprays.
FIG. 2 B—(a) An operator side view of the continuous miner of FIG. 2A ; (b) A scrubber side view of the continuous miner of FIG. 2A .
FIG. 2 C—A detailed view of the cutter boom of the continuous miner of FIG. 2B .
FIG. 3 A—(a), (b) A side view of the dust containment of an exemplary conventional spray system around the cutter boom of a continuous miner.
FIG. 3 B—(a), (b) A side view of one embodiment of the dust containment spray system around the cutter boom of a continuous miner featuring a spray configuration including SLD sprays.
FIG. 4 A—(a) A sectional view of the side head sprays block; (b) Another sectional view of the side head sprays block.
FIG. 4 B—(a) A sectional view of the center head sprays block; (b) Another sectional view of the center head sprays block.
FIG. 4 C—A top view of the center and side head sprays blocks.
FIG. 5 —(a) A sectional view of the TLD scrubber side spray block; (b) Another sectional view of the TLD scrubber side spray block.
SUMMARY OF INVENTION
In order to revisit the sources of mine dust and to analyze how the conventional technology is failing to provide adequate control of mining dust, it is important to analyze the sources and locations of respirable dust around continuous miners in multiple environments. It is also important to identify several areas in the mine where dust control could be introduced or improved: along the roof level of the mine, at the location of the conventional spray blocks, at the sides and under the miner, and at transfer points near the last open crosscut return.
A high concentration of respirable dust occurs near and along the roof level. Location of boom sprays for the cutter drum, loading pan sprays, under-boom spray pressure, type of sprays used and high water spray pressure (˜100 psi) used can displace dust-laden air along the roof level, towards the sides, and back of the miner and results in roll-back on the miner chassis toward the miner operator and batch haulage unit operator. This dust-laden air is moving at a relatively high velocity based on water pressure used and seam height and, due to its fine size dust particles, is not captured by suction inlets of a scrubber.
Spatial location of sprays on the spray blocks and type of sprays used can typically result in significant interaction among sprays. These interactions (caused by different sprays colliding with each other) can result in droplet size increase after interaction. Conventional cutter drum head sprays are directed at the rotating drum and cutting bits at different angles in the horizontal plane so that air moves across the face and is directed in the return entry. In several cases, these sprays intercept each other upon discharge from the orifice resulting in not only larger droplets that negatively impact dust control, but also in wasted energy. Since the ability to capture dust requires that the water droplet size be near the size of the dust particle, this interaction significantly reduces the potential to wet the finer fractions of dust. Furthermore, most of the spray energy is dissipated in interactions rather than in wetting the dust.
The side sprays on the miner operator side tend to contain the dust in the face area. These sprays attempt to create a seal between the sides of the excavation and the continuous miner. However, the seals are generally incomplete due to the large distance between the sprays and the excavation sides and interactions between these side sprays and the boom and under-boom sprays. Again, dust is pushed towards the roof level, or to the sides, or underneath the miner.
Most of the dust load in the scrubber is from the scrubber suction inlet at the bottom over the coal conveyor. Even if the scrubber does an excellent job of wetting the dust, the dust generated during the material discharge from the conveyor into the haulage unit significantly increases dust concentration in the last open crosscut return (LOXC). In an attempt to control dust at material discharge points, throat sprays may be located above the conveyor carrying the cut material to be discharged in the haulage unit. Since conveyor speed is very high, water discharged from throat sprays only wets the surface of coal and it is not uniformly distributed in the entire mass of the material. This results in significant dust creation when the material is dumped into the haulage unit.
Movements of batch haulage units around the face area further complicate dust concentration and turbulence in the face area and intake air flow to the face area.
In the industry there is a need for improving spray efficiency. Various embodiments of the present invention are designed for improving the dust suppression using hydraulic sprays on the continuous miner: utilizing appropriate spray pressures spatially to minimize pushing the dust toward the roof, sides, and underneath the miner; wet and surround the airborne dust to allow the scrubber to capture it; and further wet the airborne dust escaping the scrubber inlets area before it enters the area behind the miner and the LOXC.
Various embodiments of the present invention utilize spatial distribution, spray pressure and type of sprays to address the problems identified in the prior art. Principles on spray configurations include: solid-cone sprays are ideal for wetting the broken coal but not good for wetting the air-borne fine particle dust; hollow-cone sprays are more efficient for wetting the airborne dust than flat sprays; flat sprays are more efficient for creating a hydraulic curtain than wetting the dust; narrow-angle sprays at a particular pressure reach farther than wide-angle sprays; narrow angle sprays cover a small area and therefore more number of sprays is needed to cover an area; inappropriate spatial location of sprays can increase interaction among sprays that may result in increasing spray droplet size, wasted spray pressure energy, and hollow-cone behaving more like a solid cone spray; and using high pressure water sprays can decrease likelihood of contact between dust particles and water droplets and decrease residence time for wetting the dust and low water pressure results in larger droplet sizes that are not effective for wetting fine particle sizes.
REFERENCE NUMERALS IN DRAWINGS
11 Material Transfer Conveyor
12 Material Load Pan
15 Cutter Drum Hinge Point
16 Cutter Boom
21 Scrubber
22 Scrubber Suction Inlet
31 Scrubber Water Discharge Bar
32 Water Port Inlet
33 Water Supply Inlet
34 Sprays Nozzle Recess
41 SLD Sprays
42 Head Sprays Block
44 Outer Bit-ring Sprays
51 TLD Top Sprays Block
52 TLD Operator Side Sprays Block
53 TLD Scrubber Side Spray Block
61 Conventional Side Cutter-boom sprays
63 Conveyor Throat Sprays
68 Side Cutter-boom sprays
72 Center Head Sprays Block
73 Under Cutter-boom sprays
74 Existing Cutter Drum Head Sprays
75 Side Chassis Sprays
77 Conventional Throat Sprays
82 Outer Bit-ring Sprays
84 Throat Sprays
86 Cutter Drum Head Sprays
88 Material Load Pan
89 Scrubber Water Discharge Bar
90 Cutter Boom
92 Cutter Drum Hinge Point
94 Scrubber Suction Inlet
96 Material Transfer Conveyor
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The primary means of dust control should be preventing the dust generated at the cutting faces from becoming airborne. Hollow-cone or flat sprays directed into the bits and the cutting face should help achieve this objective and cool the cutting bits.
Once the dust is airborne, the flooded-bed scrubber is an efficient mechanism at the face to capture the dust and wet it within the scrubber. Hence, the goal should be to maximize the amount of airborne dust that gets directed into the scrubber. To accomplish this, appropriately angled flat sprays or wide-angle hollow-cone sprays on the boom behind the first set of sprays create a shroud containing the generated dust near the face area in a restricted volume.
Similarly, flat or hollow-cone sprays underneath the cutting boom may envelope the gap between the pan and the boom and contain the airborne dust such that the central suction port of the scrubber is able to draw it inside the scrubber. Some miners have under-boom sprays that are directed away from the face toward the conveyor. However, such sprays reduce the residence time or contact time between the dust and water rather than increase it. However, spraying water toward the face area into the loading pan where it can be mixed with the entire volume of cut coal would help reduce generation during material discharge and during transport to dump point.
Under-boom sprays should be operated at a slightly lower pressure (10-20 psi lower) than the chassis sprays on the top of the cutter drum. This will allow the dust laden air to be pushed into the conveyor throat and bottom scrubber suction inlet rather than be pushed toward the roof, sides, or bottom of the miner.
Once the dust is airborne, its capture using hydraulic sprays requires sprays producing droplet sizes in the range of the respirable dust particle sizes or slightly higher. Hence, really fine, misting or atomizing sprays need to be used subject to the constraints of available water pressures and more importantly the constraints involving very small spray orifice sizes which are likely to get plugged in a typical mine environment. These sprays will be placed at the back corner of the loading pan on both sides and directed inside the pan. These sprays are introduced to allow capture of some dust (respirable and coarser than respirable) even before it actually enters the scrubber.
Despite the created shroud of sprays, some of the dust will still escape due to gaps in the shroud where the sprays do not overlap and due to the fact that at times, the cut coal traveling to the conveyor may partially obstruct the central scrubber suction port. Hence, there is a need to employ an improved line of defenses on the side of the continuous miner. This line of defense is implemented in the form of sprays on the left side of the miner located behind the left side suction ports of the scrubber. These sprays should be wide-angle, hollow-cone sprays that essentially create a seal with water curtain from the continuous miner to the left rib and to the roof top to contain the dust such that it gets an opportunity to enter the side suction port. These sprays can be located only on the left side of the miner as the prevailing air flow pattern in the face carries the escaping dust from the right side over the top of the miner and through the area between the left side of the miner and the rib.
As discussed above, dust-laden air along the roof level is moving at a relatively high velocity based on water pressure used, seam height, and rotational speed of the cutting drum. This air is not captured by suction inlets of scrubbers. To capture the dust escaping over the top of the miner, a set of misting sprays may be installed on the top of the miner directed towards the roof and angled towards the face such that the escaping dust contacts the mist and is captured. Furthermore, such sprays contain the dust in the face area and allow time for it to be sucked by the side suction inlets. These Second Line of Defense sprays (SLD sprays) are located on the top, the side, and on the top and sides of the CM chassis and spray water toward the roof and are angled toward the face. An additional set of sprays referred to herein as a Third Line of Defense (TLD) sprays generally located proximate to a set of scrubber suction inlets. Collectively or interchangeably, the SLD sprays and TLD sprays are referred to as a first set of water sprays and a second set of water sprays depending on their position and function. Due to the low inertia of the mist droplets, the mist migrates away from the face concurrently with the air and the respirable dust increasing the residence time for the dust and mist droplets to come in contact and attach resulting in the dust-droplet aggregates to drop out and fall to the ground. The SLD sprays can be small-volume misting sprays and operate at an appropriate pressure so that the resulting water curtain creates a seal against the roof. Appropriate sprays are selected that utilize orifice diameters similar to those of the conventionally used miner sprays, but which produce a very fine mist of water. Spraying Systems Company, Inc. in Chicago, Ill. produces sprays; however, this is not limiting and other fine-misting types of sprays can be substituted.
The various embodiments of the present invention are further described in reference to the figures. FIG. 2A shows a top view of one embodiment of the present invention on a CM with a new spray configuration and the TLD and SLD sprays blocks. Around the cutter boom area 90 , three sets of sprays serve to contain dust in the face area: the top of chassis sprays, including the center head spray block 72 and two side head sprays blocks 42 ; the outer bit-ring sprays 82 ; and the side cutter-boom sprays 68 . In the center head spray block 72 and the side head spray blocks 42 , the lower sprays include cutter drum head sprays 86 directed at the cutting bits of the CM drum. The SLD sprays 41 are located above the cutter drum head sprays 86 and are angled in the range of 10°-45° higher than traditional head sprays in the vertical plane to create a hydraulic seal behind the lower sprays and the immediate roof; in a preferred embodiments, the SLD sprays 41 are angled approximately 20° above traditional head sprays. The SLD sprays 41 are angled toward the roof of the mine excavation. These sprays perform several functions: the dust generated during cutting of material is contained near the face area and has a chance to be wetted and sucked in by the wet scrubber suction inlets 22 ; some of the generated dust not wetted by the head sprays gets sucked in the space between the SLD sprays 41 and the cutter drum head sprays 86 and has a chance to get wetted; the dust generated during the cutting of immediate roof material has a chance to be wetted since these sprays are located right behind the cutting drum; and the dust generated in the cutter drum area does not travel toward the mine operator or haulage unit operator (minimizing dust rollback). A sectional view of the side head sprays block 42 is shown in FIG. 4A . A sectional view of the center head spray block 72 is shown in FIG. 4B . A top view of the head sprays is shown in FIG. 4C .
The second set of sprays that contain the dust emanating from the cutter boom area 90 are the outer bit-ring sprays 82 ; these sprays are oriented differently than conventional sprays so that there is no interference between adjacent sprays. The outer bit-ring sprays 82 , as a whole, create air movement toward the face of the cutter drum to remove volatile gas and dust particles.
The third set of sprays around the cutter boom 90 are configured differently than conventional sprays. These sprays are designed to create a seal around the sides of the material loading pan 88 so that dust cannot escape and is wetted in the material loading pan 88 and sucked-in through the wet scrubber suction inlet 94 located on the top of the material transfer conveyor 96 . These sprays are oriented to establish seal along the sides of the mining excavation over as large an area as possible. Furthermore, these sprays are directed slightly inward (between 5°-20°) toward the loading pan to push the dust toward the scrubber suction inlet 94 .
On both sides of the CM behind the cutter drum, the TLD sprays prevent any dust not captured by the head sprays, the outer bit-ring sprays 82 , or the side cutter-boom sprays 68 from reaching the miner operator or haulage unit operator. The TLD top spray block 51 creates a hydraulic curtain across the excavation between the miner chassis and the roof of the excavation so that escaping dust can be wetted in this area before leaving the face area and without affecting the miner operator, haulage unit operator and other workers working on the downwind side of the miner. The TLD operator side spray block 52 and scrubber side spray block 53 create a seal between the side chassis of the miner and the sides of the excavation. The TLD top spray block 51 is located on the top of the chassis or along the sides of the chassis to ensure that roof falls will not impair their operation. The TLD top spray block 51 consists of 2-3 sprays angled horizontally and vertically in such way that the miner operator can see the mining face cutting area. The operator side spray block 52 and scrubber side spray block 53 also consist of 2-3 sprays oriented vertically and horizontally away from the chassis to create a seal between the chassis and sides of the excavation; sectional view of these spray blocks are shown in greater detail in FIG. 5 . The orientation depends upon the height of the excavation, width of the excavation and the size of the cutting drum.
One embodiment of the TLD spray system was installed in a Joy 14 CM, similar to the miner shown in FIG. 2B in order to prove the concept. The CM chassis was 36-inches high, the miner cutting drum was 11.5 ft wide and 38-inches in diameter, and the length of the CM from the front bits on the miner cutting drum to the back end of the continuous miner chassis was 35 ft. The CM was extracting a 60-inch thick coal seam with 9-12 inches of immediate floor strata and about 6-inches of immediate roof strata. Significant amount of airborne dust was produced during the cutting of the immediate roof strata. In an effort to reduce the airborne dust rollback, TLD top spray blocks 51 and TLD operator side 52 and scrubber side 53 spray blocks were installed. Two TLD top spray blocks 51 were installed on the top of the continuous miner chassis: one spray block was installed on the top of the miner chassis on the operator side of the CM approximately 42-inches behind the side scrubber suction inlet 94 and the other spray block was installed on the top of the miner chassis on the scrubber side of the CM approximately 42-inches behind the side scrubber suction inlet 94 . The TLD operator side spray block 52 and the TLD scrubber side spray block 53 were temporarily installed approximately 195 inches behind the cutting bit of the miner cutting drum; all of the sprays were directed toward the face of the continuous miner. The TLD scrubber side spray block 53 had three sprays—one oriented N 22° W, one oriented N 00° E, and one oriented N 22° E (where N=North and oriented toward the face, W=West, E=East). The TLD scrubber side spray block 53 had installed misting sprays with about an 80 degree cone angle with a capacity of 0.6 gpm at 80-psi. The TLD operator side spray block 52 consisted of only two installed misting sprays to allow the CM operator to be able to see about 33% of the cutting face and to provide good visibility of the face. The sprays were inclined about 45 degrees from the vertical. This spray system implementing the TLD sprays was tested extensively in the field and compared side-by-side with the conventional spray system. The results indicated that the TLD modified spray system design significantly improved dust control at the MO. HO, and LOXC locations 62%, 38%, and 19%, respectively. The spray orientations, spray capacity, location of the sprays, spray types, and location of the TLD spray blocks listed above are dependent on the type, configuration, and size of the CM as well as the type and configuration of the coal seam and are in no way meant to be limiting.
In FIGS. 1A and 1B , a continuous miner chassis is shown, and it can be 42-inches high and a cutting drum that is 11.5 ft wide with a diameter of 42-inch. The length of the CM from the front bits on the miner cutting drum to the back end of continuous miner chassis is about 35 ft. The continuous miner may be extracting an approximately 96-inch thick coal seam with 3-6 inches of immediate roof only. A significant amount of airborne dust can be produced during the production process due to high seam height. In order to minimize the dust rollback from the miner cutting drum, the TLD spray system can include two TLD top spray blocks 51 and TLD operator side 52 and scrubber side 53 spray blocks were installed. Two TLD top spray blocks 51 can be mounted on the top of the continuous miner chassis about 54-inches behind the right and left side scrubber suction inlets 22 . TLD operator side 52 and scrubber side 53 spray blocks can be simultaneously located about approximately 200 inches behind the cutting bit of the miner cutting drum on the CM operator side and the return side of the CM chassis, respectively. The sprays in the TLD operator side 52 and scrubber side 53 spray blocks can be directed towards the face of the CM. The TLD scrubber side spray block 53 can have three misting sprays with about approximately an 80 degree cone angle with about approximately a capacity of 0.6 gpm at 80-psi—one oriented N 22° W, one oriented N 00° E, and one oriented N 22° E. These sprays may be operated at about approximately 100 psi pressure. The TLD operator side spray block 52 can include two sprays to allow the CM operator to be able to see about 33% of the cutting face and to provide visibility of the face. The TLD operator side spray block 52 sprays may be inclined about 45 degrees from the vertical and operated at about approximately 100 psi pressure. This spray system was tested extensively in the field and compared side-by-side with a conventional spray system. The results indicated that the modified spray design significantly improved dust control in the face area by 55% at the MO location and 10% at the LOXC locations. The spray orientations, spray capacity, location of the sprays, spray types, and location of the TLD spray blocks listed above are dependent on the type, configuration, and size of the CM as well as the type and configuration of the coal seam and are in no way meant to be limiting.
FIG. 2B is a side view of the CM demonstrating the spatial orientation of the side cutter-boom sprays 68 along the cutter boom 90 . The under cutter-boom sprays 73 are placed on the underside of the cutter boom 90 behind the cutter drum and are oriented towards the floor of the mining excavation. FIG. 2C is a detailed side view of the cutter boom showing directional orientation of the sprays.
FIG. 3A shows a detailed view of conventional spray coverage and dust rollback from a cutter drum when (a) the CM is cutting the roof of the mining excavation and (b) when the CM is sumping in. In contrast, FIG. 3B illustrates one embodiment of the present invention including spray coverage and minimal dust rollback from the cutter drum of the instant invention when (a) the CM is cutting the roof of the mining excavation and (b) when the CM is sumping-in.
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This invention refers to innovative water sprays applications to significantly improve coal and quartz dust control around a continuous miner. Significant dust control is achieved through utilizing different types of sprays at locations on the top and sides of the miner chassis to create water curtains or shrouds of water around zones of high dust concentration and zones of high concentration dust transport. This is called “multiple lines of defense” spray system (MLD.) This invention also provides a method of reducing dust around a continuous miner by configuring a spray system, located at the top or sides of the cutter boom, thereby improving control of respirable dust.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 12/352,766, filed on Jan. 13, 2009, which is a continuation of International Patent Application No. PCT/CN2008/070975, filed on May 15, 2008. The International Application claims priority to Chinese Patent Application No. 200710099398.9, filed on May 18, 2007. The aforementioned patent applications are hereby incorporated by reference in their entireties.
FIELD
[0002] The present invention relates to the field of electronic communication technology, and more particularly to a sector-based base station.
BACKGROUND
[0003] Currently, the mobile communication technology has been widely used in various aspects of daily life and work. Mobile communication is defined as a kind of communication in which the information is transmitted while at least one or both parties in communication are in a mobile state. The two parties in a mobile communication are a base station and a terminal.
[0004] Base station, as a form of the radio station, is a radio transceiver station for transmitting information with mobile phone terminals through a mobile switching center in a particular radio coverage area. A base station is mainly constituted by a transceiver, a clock unit, and a baseband processing unit. The transceiver includes an intermediate radio frequency (RF) unit adapted to perform conversion between a baseband signal and an RF signal. After receiving an RF signal from a terminal, the base station converts the received RF signal into a baseband signal through the RF unit of the transceiver, and converts a baseband signal to be sent into an RF signal and sends the RF signal.
[0005] The networking modes of different base stations may employ different solutions about the intermediate RF units, and generally the following two solutions are adopted.
[0006] First, an omni-directional base station is implemented by a concentric circle mode. That is, the electric wave coverage of a single sector (i.e., one circle) is achieved through a single base station. The whole base station only has one set of intermediate RF unit, so the communication capacity of the base station is rather small.
[0007] Secondly, in order to increase the communication capacity of the base station, a multi-sector base station is implemented by a cellular networking mode. That is, one base station covers multiple sectors (as shown in FIG. 1 , one base station covers 3 sectors marked with F 1 ). Generally, several sets of antennas pointing to different directions are adapted to form several mobile communication sectors. Each sector is corresponding to a different intermediate RF unit, and the intermediate RF units are independent from each other.
[0008] FIG. 2 is a structural block diagram of an intermediate RF unit in an omni-directional base station, which aims at illustrating the processing of receiving signals and transmitting signals by the intermediate RF unit in the base station. In the structural block diagram shown in FIG. 2 , the intermediate RF unit is in a typical form with two inputs and one output (i.e., two receiving units plus one transmitting unit). Currently, the specific implementation modes of the intermediate RF unit also include one input and one output (i.e., one receiving unit plus one transmitting unit) and multiple-input multiple-output (MIMO) (i.e., multiple receiving units plus multiple transmitting units). It is understandable that, the signal processing carried out by each unit is similar to that in the typical two-input one-output form of FIG. 2 , so that the signal processing carried out by the intermediate RF unit in the typical two-input one-output form will be illustrated in detail below.
[0009] The intermediate RF unit processes a receiving master signal from a transmitting/receiving antenna through an RF signal receiving unit built therein. The detailed process includes the following steps. First, the receiving master signal from the transmitting/receiving antenna is isolated and filtered from a transmitting signal by a filter unit (for example, a duplexer filter (DUP) in FIG. 2 ). Next, the signal is amplified by an amplifier unit (for example, a low noise amplifier (LNA) in FIG. 2 ) and filtered by a filter unit (for example, an RF filter in FIG. 2 ) and processed by a mixer unit (for example, a mixer in FIG. 2 ) to obtain a lower frequency, and then the signal is further amplified by an amplifier unit (for example, an amplifier (AMP) in FIG. 2 ), and filtered by a filter unit (for example, an intermediate frequency filter in FIG. 2 ). Afterwards, an analog-to-digital conversion is performed on the signal by an analog-to-digital converter unit (for example, an analog-to-digital converter (ADC) in FIG. 2 ), and then a digital signal processing is performed on the signal in a digital signal processing unit including a digital signal processor (DSP) & field-programmable gate array (FPGA). Finally, the signal is sent out for the baseband signal processing.
[0010] The intermediate RF unit processes a receiving diversity signal obtained from a diversity antenna through the RF signal receiving unit built therein. The detailed process includes the following steps. First, the receiving diversity signal is processed by a filter unit (for example, a receiving filter (RX Filter) in FIG. 2 ), and then the subsequent processing is similar to that of the receiving master signal.
[0011] The intermediate RF unit processes a transmitting baseband signal through an RF signal transmitting unit built therein. The detailed process includes the following steps. First, the transmitting baseband signal is processed by a digital signal processing unit including a DSP & FPGA, and then sent to a digital-to-analog converter unit (for example, a digital-to-analog converter (DAC) in FIG. 2 ) to finish a digital-to-analog conversion. Afterwards, the signal is modulated by a modulation unit (for example, a modulator (MOD) in FIG. 2 ) to an RF frequency. Then, the signal is amplified by an amplifier unit (for example, the AMP in FIG. 2 ), and then, the power of the signal is amplified by a power amplifier unit (for example, a power amplifier (PA) in FIG. 2 ). Finally, the signal is transmitted to a filter unit (for example, the DUP in FIG. 2 ), and sent out by an antenna (ANT).
[0012] The intermediate RF unit processes a transmitting feedback signal through a transmission feedback unit built therein. The detailed process includes the following steps. First, a part of the power of the transmitting signal is coupled by a coupler and down-converted into a lower frequency by a mixer unit (for example, the mixer in FIG. 2 ). Then, the signal is processed by an amplifier unit (for example, the AMP in FIG. 2 ) and a filter unit (for example, the filter in FIG. 2 ) and then sent to an analog-to-digital converter unit. Finally, the signal is sent to a digital signal processing unit including a DSP & FPGA to be processed, so as to serve as a feedback input of a power-amplification digital predistortion signal. The power-amplification digital predistortion technology is a way of improving the power amplification linearity.
[0013] In a multi-sector base station implemented in a cellular networking mode, the base station generally covers two or more than two sectors, each sector employs an independent intermediate RF unit, and each intermediate RF unit is designed in a different module. The intermediate RF unit in each sector includes all the parts of the intermediate RF unit in the omni-directional base station of FIG. 2 . In the multi-sector base station, the intermediate RF unit of each sector works independently.
[0014] During the research, the inventor found that, in the multi-sector base station, each sector has an intermediate RF unit, and the intermediate RF unit of each sector is independent from each other. As a result, the circuit design is rather complicated. Moreover, as the circuit unit has a poor adaptability, the cost is rather high. US 2004/157644 relates to a communication system transmitter or receiver module having integrated radio frequency circuitry directly coupled to antenna element. In this patent, only a shared RX/TX LO and a baseband circuitry have been depicted.
[0015] Therefore, till now, there is no sector-based base station with a simpler circuit design and a lower cost.
SUMMARY
[0016] Accordingly, in an embodiment, the present invention is directed to a sector-based base station, which is capable of sharing an intermediate radio frequency (RF) unit among different sectors.
[0017] The embodiment of the present invention is implemented in the following technical solution.
[0018] In an embodiment of the present invention, a sector-based base station including at least two sets of RF signal transmitting units and RF signal receiving units is provided. Each of the RF signal transmitting units is provided with a modulation unit or a mixer unit and a digital-to-analog converter unit. Each of the RF signal receiving units is provided with a mixer unit and an analog-to-digital converter unit. The base station includes at least one of a shared transmission RF local oscillator TX_LO, a shared receiving RF local oscillator RX_LO, a shared digital signal processing unit, and a shared transmission feedback unit.
[0019] The shared TX_LO is connected to the modulation unit or the mixer unit in each of the RF signal transmitting units, and serves as a transmission RF local oscillator for all sectors in the base station.
[0020] The shared RX_LO is connected to the mixer unit in each of the RF signal receiving units, and serves as a receiving RF local oscillator for all the sectors in the base station.
[0021] The shared digital signal processing unit is connected to the digital-to-analog converter unit and/or the analog-to-digital converter unit, and adapted to process digital signals of all the sectors in the base station.
[0022] The shared transmission feedback unit is connected to at least two of the RF signal transmitting units that requires a transmission feedback, and adapted to perform a feedback processing on transmitting signals of all the sectors in the base station.
[0023] As seen from the above embodiment of the present invention, the technical solution of sharing the intermediate RF unit circuit in the sector-based base station is adopted to reduce the number of elements used in the circuit while ensuring the communication capacity of the base station. As such, the reliability index of a single board is improved, and the system reliability is also enhanced. Meanwhile, the material cost and the time required for debugging are both reduced, thus lowering the cost of the base station.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] The present invention will become more fully understood from the detailed description given herein below for illustration only, which thus is not limitative to the present invention.
[0025] FIG. 1 is a schematic view of a cellular networking sector coverage in the prior art;
[0026] FIG. 2 is a structural block diagram of an intermediate RF unit of an omni-directional base station in the prior art;
[0027] FIG. 3 is a structural view of an intermediate RF unit according to an embodiment of the present invention; and
[0028] FIG. 4 is a structural view of an intermediate RF unit in a 3-sector base station according to an embodiment of the present invention.
DETAILED DESCRIPTION
[0029] In the embodiment of the present invention, through the design of sharing an intermediate RF unit in the sector-based base station, an intermediate RF circuit for a multi-sector base station is configured in one module, so as to achieve a large communication capacity with a low cost. When the base station covers N (N≧2) sectors, the intermediate RF unit includes N sets of RF signal transmitting units and RF signal receiving units. Each of the RF signal transmitting units is provided with a modulation unit or a mixer unit and a digital-to-analog converter unit. Each of the RF signal receiving units is provided with a mixer unit and an analog-to-digital converter unit.
[0030] The design of sharing an intermediate RF unit includes at least one of the following circumstances: completely or partially sharing the transmission feedback unit of each sector, sharing the transmission RF local oscillator of each sector, sharing the receiving RF local oscillator of each sector, and sharing the digital signal processing unit (for example, DSP & FPGA, or other digital signal processing elements) of each sector. In particular, the following four sharing circumstances are included.
[0031] Circumstance 1: sharing the transmission feedback unit, the transmission RF local oscillator, the receiving RF local oscillator, and the digital signal processing unit of each sector;
[0032] Circumstance 2: sharing one unit selected from the transmission feedback unit, the transmission RF local oscillator, the receiving RF local oscillator, and the digital signal processing unit of each sector;
[0033] Circumstance 3: sharing any two units selected from the transmission feedback unit, the transmission RF local oscillator, the receiving RF local oscillator, and the digital signal processing unit of each sector; and
[0034] Circumstance 4: sharing any three units selected from the transmission feedback unit, the transmission RF local oscillator, the receiving RF local oscillator, and the digital signal processing unit of each sector.
[0035] The above units after being shared may respectively serve as a shared transmission feedback unit, a shared transmission RF local oscillator, a shared receiving RF local oscillator, and a shared digital signal processing unit.
[0036] Moreover, in the above four circumstances, if the transmission feedback unit of each sector is shared, the following circumstances may exist.
[0037] Circumstance 1: sharing the mixer unit, a feedback RF local oscillator, an amplifier unit, a filter unit, and an analog-to-digital converter unit in the transmission feedback unit of each sector;
[0038] Circumstance 2: sharing one unit selected from the mixer unit, the feedback RF local oscillator, the amplifier unit, the filter unit, and the analog-to-digital converter unit in the transmission feedback unit of each sector;
[0039] Circumstance 3: sharing any two units selected from the mixer unit, the feedback RF local oscillator, the amplifier unit, the filter unit, and the analog-to-digital converter unit in the transmission feedback unit of each sector;
[0040] Circumstance 4: sharing any three units selected from the mixer unit, the feedback RF local oscillator, the amplifier unit, the filter unit, and the analog-to-digital converter unit in the transmission feedback unit of each sector; and
[0041] Circumstance 5: sharing any four units selected from the mixer unit, the feedback RF local oscillator, the amplifier unit, the filter unit, and the analog-to-digital converter unit in the transmission feedback unit of each sector.
[0042] The circumstances 2 to 5 illustrate the situations of partially sharing the transmission feedback unit. It is understandable that, when the mixer unit is shared, the feedback RF local oscillator is also shared. However, when the feedback RF local oscillator shared is shared, the mixer unit may be shared or may not be shared. Moreover, when any of the mixer unit, the feedback RF local oscillator, the amplifier unit, the filter unit, and the analog-to-digital converter unit in the transmission feedback unit is shared, the above units may be completely or partially shared. For example, when the base station covers N (N≧3) sectors, if the amplifier units are shared, the amplifier units may be completely shared, i.e., the transmission feedback unit only has one shared amplifier unit without any amplifier unit, or the amplifier units may be partially shared, i.e., the transmission feedback unit has n shared amplifier units and m amplifier units, i.e., 1<(n+m)≦(N−1).
[0043] The above units after being shared may respectively serve as a shared mixer unit, a shared feedback RF local oscillator, a shared amplifier unit, a shared filter unit, and a shared analog-to-digital converter unit.
[0044] FIG. 3 is a structural view of an intermediate RF unit according to a first embodiment of the present invention.
[0045] The intermediate RF unit includes at least one of a shared transmission RF local oscillator TX_LO, a shared receiving RF local oscillator RX_LO, a shared digital signal processing unit, and a shared transmission feedback unit. That is, in this embodiment of the present invention, the intermediate RF unit may include the shared transmission RF local oscillator TX_LO, the shared receiving RF local oscillator RX_LO, the shared digital signal processing unit, and the shared transmission feedback unit; or one unit selected from the shared transmission RF local oscillator TX_LO, the shared receiving RF local oscillator RX_LO, the shared digital signal processing unit, and the shared transmission feedback unit; or any two units selected from the shared transmission RF local oscillator TX_LO, the shared receiving RF local oscillator RX_LO, the shared digital signal processing unit, and the shared transmission feedback unit; or any three units selected from the shared transmission RF local oscillator TX_LO, the shared receiving RF local oscillator RX_LO, the shared digital signal processing unit, and the shared transmission feedback unit.
[0046] The shared TX_LO is connected to the modulation unit in each RF signal transmitting unit (for example, the RF signal transmitting units 1 to N in FIG. 3 ), and serves as a transmission RF local oscillator for all the sectors in the base station. The modulation unit is adapted to perform a quadrature modulation on signals. If the quadrature modulation portion of the modulation unit is disposed in the shared digital signal processing unit, the modulation unit is substituted by the mixer unit in each RF signal transmitting unit. In this case, the shared TX_LO is connected to the mixer unit in each RF signal transmitting unit, and serves as a transmission RF local oscillator for all the sectors in the base station.
[0047] The shared RX_LO is connected to the mixer unit in each RF signal receiving unit (for example, the RF signal receiving units 1 to N in FIG. 3 ), and serves as a receiving RF local oscillator for all the sectors in the base station.
[0048] The shared digital signal processing unit is connected to the digital-to-analog converter unit and/or the analog-to-digital converter unit, and is adapted to process digital signals of all the sectors in the base station.
[0049] The shared transmission feedback unit is connected to the RF signal transmitting unit that requires a transmission feedback in each sector, so as to perform a feedback processing on the transmitting signals of all the sectors in the base station, in which the connection process may be implemented through, for example, a coupling manner.
[0050] In addition to the shared transmission feedback unit, the base station further includes a switch.
[0051] The switch is connected to the shared transmission feedback unit and the RF signal transmitting unit that requires a transmission feedback, and may be a single-pole multi-throw switch or other switches with selective functions.
[0052] When the shared transmission feedback unit is partially shared, the shared transmission feedback unit specifically includes at least one of a shared mixer unit, a shared feedback RF local oscillator TXF_LO, a shared amplifier unit, a shared filter unit, and a shared analog-to-digital converter unit. That is, in this embodiment of the present invention, the shared transmission feedback unit may include the shared mixer unit, the shared feedback RF local oscillator TXF_LO, the shared amplifier unit, the shared filter unit, and the shared analog-to-digital converter unit; or one unit selected from the shared mixer unit, the shared feedback RF local oscillator TXF_LO, the shared amplifier unit, the shared filter unit, and the shared analog-to-digital converter unit; or any two units selected from the shared mixer unit, the shared feedback RF local oscillator TXF_LO, the shared amplifier unit, the shared filter unit, and the shared analog-to-digital converter unit; or any three units selected from the shared mixer unit, the shared feedback RF local oscillator TXF_LO, the shared amplifier unit, the shared filter unit, and the shared analog-to-digital converter unit; or any four units selected from the shared mixer unit, the shared feedback RF local oscillator TXF_LO, the shared amplifier unit, the shared filter unit, and the shared analog-to-digital converter unit. Moreover, in any of the above circumstances, the shared transmission feedback unit may include at least one of a mixer unit, a feedback RF local oscillator TXF_LO, an amplifier unit, a filter unit, and an analog-to-digital converter unit.
[0053] The shared mixer unit is connected to the amplifier unit and/or the shared amplifier unit in the shared transmission feedback unit, and is adapted to perform a mixing processing on all feedback signals during a feedback processing on the transmitting signals of all the sectors in the base station.
[0054] The shared TXF_LO is connected to the mixer unit and/or the shared mixer unit in the shared transmission feedback unit, and serves as a feedback RF local oscillator for all the feedback signals during the feedback processing on the transmitting signals of all the sectors in the base station.
[0055] The shared amplifier unit is connected to the mixer unit and/or the shared mixer unit in the shared transmission feedback unit and the filter unit or the shared filter unit in the shared transmission feedback unit, and is adapted to perform an amplification processing on all the feedback signals during the feedback processing on the transmitting signals of all the sectors in the base station.
[0056] The shared filter unit is connected to the amplifier unit and/or the shared amplifier unit in the shared transmission feedback unit and the analog-to-digital converter unit or the shared analog-to-digital converter unit in the shared transmission feedback unit, and is adapted to perform a filter processing on all the feedback signals during the feedback processing on the transmitting signals of all the sectors in the base station.
[0057] The shared analog-to-digital converter unit is connected to the filter unit and/or the shared filter unit in the shared transmission feedback unit and the shared digital signal processing unit and/or the DSP, and is adapted to perform an analog-to-digital conversion processing on all the feedback signals during the feedback processing on the transmitting signals of all the sectors in the base station.
[0058] When the shared transmission feedback unit is completely shared, the switch is located between the RF signal transmitting unit and the shared transmission feedback unit. When the shared transmission feedback unit is partially shared, the switch is used to connect the RF signal transmitting unit to the shared units in the shared transmission feedback unit. That is, depending upon different circumstances of the shared units, one or more switches are required (for example, if only the shared amplifier unit exists, two sets of switches are required, one is used to connect the RF signal transmitting unit to the shared amplifier unit, and the other is disposed between the shared amplifier unit and the filter unit, so as to connect the shared amplifier unit to the filter unit in the shared transmission feedback unit).
[0059] A 3-sector base station is taken as a second embodiment below to demonstrate the specific implementation of the device of the present invention.
[0060] FIG. 4 is a structural view of an intermediate RF unit in a 3-sector base station according to an embodiment of the present invention. The structural view of FIG. 4 includes the following circumstances of sharing the transmission feedback unit of each sector, sharing the RF local oscillator of each sector, and sharing the DSP & FPGA in the intermediate frequency signal processing portion of each sector. In particular, the shared intermediate RF unit includes a transmission feedback unit, two RF local oscillators, a DSP & FPGA processing portion, three receiving master channels, three receiving diversity channels, and three transmitting channels.
[0061] The transmission feedback unit is adapted to realize a function of sharing the transmission feedback unit of each sector. Generally, the function of transmission feedback unit is to provide a feedback input of digital predistortion, and the total power of transmitting signals of each sector is relatively stable. However, after the feedback input disappears, the intermediate frequency signal processing portion still maintains an original state. Therefore, a single-pole three-throw switch can be adopted to take turns to select a power-amplification feedback signal of each sector at different time divisions. In this manner, the three transmission feedback units in the 3-sector base station can be integrated into one unit to share the whole transmission feedback unit among multiple sectors, so that the number of the RF local oscillators TXF_LO in the feedback unit is reduced to one.
[0062] The two RF local oscillators include a shared TX_LO adapted to serve as the transmission RF local oscillator of each sector and a shared RX_LO adapted to serve as the receiving RF local oscillator of each sector. That is, the RF signal receiving units and the RF signal transmitting units respectively adopt one local oscillator. Therefore, as for a base station covering N sectors, the number of the receiving/transmission RF local oscillators can be reduced by 2(N−1).
[0063] The DSP & FPGA processing portion is adapted to share the DSP & FPGA in the digital signal processing portion of each sector, so as to form the DSP & FPGA in the intermediate frequency signal processing portion into a resource pool for sharing.
[0064] The three receiving master channels are adapted to receive master signals.
[0065] The three receiving diversity channels are adapted to receive diversity signals.
[0066] The three transmitting channels are adapted to transmit baseband signals.
[0067] The third embodiment of the present invention is an improvement on the basis of the second embodiment of the present invention. That is, the sharing of a transmission feedback channel of each sector is set as the partial sharing of the transmission feedback channel of each sector, while the sharing of the RF local oscillators of each sector and the sharing of the DSP & FPGA in the intermediate frequency signal processing portion of each sector remain unchanged.
[0068] The partial sharing of the transmission feedback channel of each sector is implemented as follows. The single-pole three-throw switch in the feedback channel of the second embodiment of the present invention is moved backwards. Thus, only the part of the circuit behind the switch can be shared, and the part in front of the switch cannot be shared. In this case, three groups of circuits are still needed before the switch. For example, if the single-pole three-throw switch is disposed between the AMP and Filter, three groups of the Mixer, TXF_LO, and AMP circuits and one group of the Filter and ADC circuits are required.
[0069] In the second embodiment of the present invention, the receiving and transmission of RF signals and baseband signals implemented by the intermediate RF unit in the sector-based base station are described below.
[0070] The intermediate RF unit processes a receiving master signal from the transmitting/receiving antenna in the following manner. First, the receiving master signal from the transmitting/receiving antenna is isolated from a transmitting signal by a DUP, and then amplified by an LNA, filtered by a Filter, and processed by a Mixer to obtain a lower frequency. Afterwards, the signal is again amplified by an AMP, filtered by a Filter, and processed through an analog-to-digital conversion by an ADC. Finally, the signal finishes the digital signal processing in a DSP & FPGA, and then sent out for a baseband signal processing. During the above process, the three receiving master signals share the same RX_LO when being processed by the Mixer to obtain a lower frequency respectively, and share the same DSP & FPGA during the DSP & FPGA processing.
[0071] The intermediate RF unit processes a receiving diversity signal from the diversity antenna in the following manner. First, the receiving diversity signal first passes through an RX Filter, and the subsequent processing thereof is similar to that of the receiving master signal. During the above process, the three receiving diversity signals share the same RX_LO when being processed by the Mixer to obtain a lower frequency, and share the same DSP & FPGA during the DSP & FPGA processing.
[0072] The intermediate RF unit processes a transmitting baseband signal in the following manner. First, the transmitting baseband signal is processed by the DSP & FPGA, then sent to a DAC for digital-to-analog conversion, and then modulated by a MOD into an RF frequency. Afterwards, the signal is amplified by an AMP, and the power thereof is amplified by a PA. Finally, the signal is sent to a DUP and transmitted by an ANT. During the above process, the three baseband signals share the same DSP & FPGA during the digital signal processing, and share the same TX_LO when being modulated by the MOD respectively.
[0073] The intermediate RF unit processes a transmitting feedback signal in the following manner. First, a part of the power of the transmitting signal is coupled by a Coupler and down-converted into a lower frequency by a Mixer. Then, the signal is processed by the AMP and Filter and then sent to an analog-to-digital converter unit, and is finally sent to a DSP & FPGA to be processed, so as to serve as a feedback input of a power-amplification digital predistortion signal. The power-amplification digital predistortion technology is a way of improving the power amplification linearity. During the processing of the transmission feedback signal, the single-pole three-throw switch is set at the current position to achieve the feedback of the transmitting channel 1, and similarly, the single-pole three-throw switch can be moved leftwards by one or two channels to achieve the feedback of the transmitting channel 2 or 3 respectively.
[0074] Likewise, if the multi-sector base station covers N sectors (N is a natural number), the embodiment of the present invention can be adopted to achieve the sharing of the intermediate RF unit in the base station. That is, as for the base station covering N sectors, in a desired circumstance, (N−1) feedback channels, (N−1) DSP & FPGA processing portions, and 2(N−1) receiving/transmission RF local oscillators can be saved.
[0075] It is understandable that, the intermediate RF units in different base stations have different structures, which may result in variations of the processing of transmitting and receiving signals by the intermediate RF units. However, the method of sharing at least one selected from the RX_LO, the TX_LO, the digital signal processing unit, and the transmission feedback unit in the embodiment of the present invention still can be adopted to process the signals. Moreover, the shared transmission feedback unit can be partially shared.
[0076] It will be apparent to those skilled in the art that various modifications and variations can be made to the structure of the present invention without departing from the scope or spirit of the invention. In view of the foregoing, it is intended that the present invention cover modifications and variations of this invention provided they fall within the scope of the following claims and their equivalents.
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A sector-based base station includes at least one of a shared transmission RF local oscillator TX_LO, a shared receiving RF local oscillator RX_LO, a shared digital signal processing unit, and a shared transmission feedback unit. A technical solution of sharing an intermediate RF unit circuit in the sector-based base station is adopted, so as to reduce the number of elements used in the circuit without sacrificing the communication capacity of the base station. As such, the reliability index of a single board is improved, and the system reliability is also enhanced. Meanwhile, the material cost and the time required for debugging are both reduced, thus lowering the cost of the base station.
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BACKGROUND
[0001] For many industries where fluids are managed in pipelines of various sorts and with actuable valves to permit and prevent fluid flow, water hammer is a problem. The commonly termed water hammer is a tube wave created when a flow of fluid is suddenly stopped by a structure such as a valve. Upstream of the valve, fluid continues to move into the closed valve, increasing pressure in a local volume of fluid, which pressure propagates as a wave back in the upstream direction potentially causing damage as it propagates and when it reflects off other structures. Downstream of the valve the fluid also continues to move thereby creating a localized low-pressure in the fluid, which also can propagate as a wave in the downstream direction. In extreme cases, cavitation can occur at the downstream side of the valve with all of the intrinsic problems that are known to practitioners.
[0002] In the drilling and completion arts, water hammer can be a significant problem for a number of different components of downhole systems such as safety valves for example. Means to address water hammer would be well received by the art.
SUMMARY
[0003] A water hammer mitigating flow control structure for a downhole completion including a tubular member configured for the downhole environment; a valve member in operable communication with the tubular member and positionable with respect to the tubular member to allow or prevent fluid movement through the tubular member; and an absorber in operable communication with the valve member and configured to allow movement of the valve member the movement absorbing a pressure rise against the valve member in use.
[0004] A method for mitigating water hammer in a flow control structure for a downhole completion including allowing a valve member to move relative to a tubular member with which the valve member is operable to allow or prevent fluid movement through the tubular member; absorbing a pressure rise against the valve member with the movement.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] Referring now to the drawings wherein like elements are numbered alike in the several Figures:
[0006] FIG. 1 is a schematic view of one embodiment of a flow control valve configured to mitigate water hammer in a position open to flow;
[0007] FIG. 2 is a schematic view of the embodiment of FIG. 1 in a reactive position following closure of the valve;
[0008] FIG. 3 is a schematic view of another embodiment of a flow control valve configured to mitigate water hammer; and
[0009] FIG. 4 is a schematic view of another embodiment of a flow control valve configured to mitigate water hammer.
DETAILED DESCRIPTION
[0010] In each of the following embodiments it is to be noted that the “ringing” of the water hammer effect is mitigated. In some applications the most important place to mitigate that ringing is where the formation is directly exposed thereto. For example, in an injection system, a ringing downhole of the injection valve is detrimental to the formation. Mitigation of the ringing downhole of the valve would accordingly be of paramount importance. Ringing in other parts of the system may also however be of detrimental effect and might advantageously be mitigated as well. Some of the embodiments below will mitigate water hammer in either or both directions.
[0011] Referring to FIG. 1 , a first embodiment of a flow control structure 10 configured to mitigate water hammer is schematically illustrated. The structure 10 includes a tubular member 12 , a valve member 14 and an absorber 16 that together allow for a mitigation in the origination of a tube wave upon closure of the valve or a mitigation of the reflection of a tube wave originated at the valve member 14 earlier in time or originated elsewhere in a system in which the structure 10 is installed. The above noted components may be disposed within a housing 18 . The tubular member is, in the embodiment illustrated in FIGS. 1 and 2 , sealed to an inside surface 20 of housing 18 with one or more seals 22 such as o-rings, or other similar configurations capable of providing a sliding seal against a surface such as surface 20 . As illustrated there are three seals 22 but it will be understood that more or fewer could be employed without departing from the invention. Disposed in operable communication with the tubular member 12 is valve 14 , which as illustrated is a ball valve but could be of other structure including but not limited to a flapper, illustrated in conjunction with the embodiment of FIG. 4 , discussed hereunder. In FIG. 1 the absorber 16 is shown both upstream and downstream of the valve member 14 but it will be understood that it is contemplated that only upstream or only downstream locations of the absorber will not depart from the invention. Further it is to be noted that the absorber may operate in compression, extension or both depending upon application. It is also to be appreciated that it is the valve member that need be movable and that this can occur with the tubular member as illustrated in FIGS. 1 and 2 or can occur within the tubular member where that member is fixed and the absorber is in contact with the valve member.
[0012] Returning to discussion of FIG. 1 directly, it will be noted that a means for actuating the valve member is provided in the form of a hydraulic line 24 . This is but one embodiment of means to actuate the valve member and others are contemplated such as electromagnetic means, pneumatic means, mechanical shifting means, etc. The particular means of actuating the valve member does not impact the operation of the invention.
[0013] It will be appreciated from the view of FIG. 1 that with the valve member open, fluid will flow (see arrows 26 ) through the device substantially unimpeded. When the valve member 14 is actuated to the closed position ( FIG. 2 ) however, the force of fluid 26 causes a pressure thereof to build against the closed valve member 14 . It is this pressure build up that originates a tube wave that will reflect from the valve member 14 back along a tubing 28 in the upstream direction to potentially do damage to components therealong. Because of the construction of the embodiment of FIGS. 1 and 2 , the tube wave originated by the actuation of the valve member 14 to the closed position will be substantially mitigated due to the ability of the valve member 14 to move in the downstream direction. Since the energy of the tube wave comes from the pressure buildup against a member and the reflection of that energy back in the direction from which it came, the movement of the member against which pressure would naturally build will mitigate the ultimate energy buildup and reflection. Accordingly the resulting wave is in fact mitigated. Further, the same thing will happen if the valve member 14 is impacted by a tube wave generated somewhere else in the tubing. This then results in mitigation of that tube wave also hence positively affecting the entire system. Because in one embodiment the absorber exists on both upstream and downstream positions relative to the valve member 14 , the device will operate on tube waves originating or propagating in or from either direction. This also can be the case however if the absorber is only on one side of the valve member 14 depending upon how the absorber is set up, i.e. with compressive capability, extensive capability or both and the position of the absorber at rest relative to the housing 18 .
[0014] Although the absorber 16 is illustrated as a coil spring, it is contemplated that the absorber 16 may comprise other configurations such as a gas spring, a rubber spring, capillary spring or other resilient configurations. It is further noted that the spring rate may be constant or variable in embodiments. In each iteration, the valve member 14 will be allowed to move in at least one direction and in some embodiments will be allowed to move in both directions, and in either case, will be decelerated to a stop gradually after movement begins pursuant to a valve closure.
[0015] It is noted that most of the discussion herein is related to the pressure rise on the upstream side of the valve member 14 . It will be appreciated however that the same action that mitigated that rise on the upstream side of the valve member will mitigate the low-pressure event caused at the downstream side of the valve member in a prior art system. This is because the valve member is following the fluid in the downstream direction and therefore not allowing the fluid to pull the pressure down in the local area immediately downstream of the valve member 14 , as it would do in a fixed valve member prior art system.
[0016] In another embodiment, referring to FIG. 3 , the resilient member is not needed and rather friction alone is relied upon to cause a controlled deceleration of the movement of the valve member 14 . Since it is the reduction in the speed of deceleration of the fluid flowing through the tubular that acts to reduce the origination of or reflection of a tube wave, this can be accomplished with a bore in housing 18 in which the valve member may slide providing that the valve member 14 will slide more rapidly upon closure of the valve member and then progressively slow down to a stop. Such an embodiment may be configured as a frustoconical polished bore 30 with the smaller dimensioned end 32 of the bore being downstream of the valve member 14 . Upon closure of the valve member, the member 14 will move in the downstream direction (arrow) under the influence of the flowing fluid. As the valve member 14 is entering a smaller and smaller dimension range of the frustocone, friction on the valve member is progressively higher. The valve will hence slow to a stop smoothly and generate and or reflect little or no tube wave. In this embodiment, the valve member 14 will not reset itself as it does in the embodiments that use a resilient member.
[0017] In another embodiment, referring to FIG. 4 , the foregoing embodiments are modified to include one or more openings 30 in the housing 18 . In this embodiment the tubular member 12 and seal(s) 22 cover the one or more openings 30 that extend to a chambers that allow for pressure diffusion such as atmospheric chambers, or “bags” of fluid impermeable material. Upon the actuation of the valve member 14 (actuated in any of the known ways to actuate a flow control valve, in the illustrated case a flapper or a ball valve), the valve member 14 will move in the downstream direction as did the embodiment of FIG. 1 but in this case, the tubular member 12 , moving with the valve member 14 will uncover the one or more openings 30 thereby providing a pressure diffusion pathway for the building pressure of the fluid flow due to the closure of the valve member 14 . This action in combination with the movement of the valve member 14 , will act to mitigate the origination and/or reflection of a tube wave. Depending upon the application, if there is no prohibition to fluid flow into an annulus of the configuration, the openings 30 may open to that annulus. In other configurations, such as a safety valve for example, a fluid pathway to the annulus would be prohibited and hence this embodiment could not be used for such an application.
[0018] It is further noted that each embodiment where there is a resilient absorber, a dashpot, and particularly a single acting dashpot that allows rapid initial movement but slows the return movement of the valve member, could be added to damp the resilience particularly upon the rebound stroke after compression of the absorber due to valve closure.
[0019] While one or more embodiments have been shown and described, 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 illustrations and not limitation.
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A water hammer mitigating flow control structure for a downhole completion including a tubular member configured for the downhole environment. A valve member in operable communication with the tubular member and positionable with respect to the tubular member to allow or prevent fluid movement through the tubular member. An absorber in operable communication with the valve member and configured to allow movement of the valve member the movement absorbing a pressure rise against the valve member in use. Also included is a method for mitigating water hammer in a flow control structure for a downhole completion
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to the treatment of a disorder known as facial blushing, or excessive redness of the face elicited by emotional or social stimuli, by the electrical stimulation of the corresponding cluster of nerves and/or ganglia in the sympathetic chain and more specifically, for example, stimulation of the inferior cervicothoracic (stellate) down to the second and/or third thoracic ganglia is employed to treat facial blushing.
2. Description of the Prior Art
Within the field of neurosurgery, the use of electrical stimulation for the treatment of pathologies, including such disorders as uncontrolled movement, such as Parkinson's disease and essential tremor, as well as chronic pain and eating disorders, has been widely discussed in the literature. It has been recognized that electrical stimulation holds significant advantages over alternative methods of treatment, for example lesioning, inasmuch as successful lesioning destroys all nerve activity. Collateral damage to non-targeted tissues is also a significant risk in lesioning treatments. In many instances, it is, therefore, the preferred effect is to stimulate or reversibly block nervous tissue. Electrical stimulation permits such stimulation of the target neural structures, and equally importantly, it does not require the destruction of the nervous tissue (it is a reversible process, which can literally be shut off or removed at will). In addition, stimulation parameters can be adjusted so that benefits are maximized, and side effects are minimized.
The particular application which the present invention is directed to, is the treatment of facial and neck blushing. The principle symptom of this disorder is excessive and frequent redness of the face which is easily elicited by emotional or social stimuli. The instantaneous appearance of blushing is produced by normal events in daily life such as eating with other people, meeting someone, shopping, speaking in public, an so on. The disorder can be quite pronounced, and it effects a significant percentage of people who suffer from social phobia. The prevalence rate of social phobia is approximately 10%, or 30 million people in the United Sates alone. While many in the medical community consider facial blushing trivial or normal, many patients, in fact, state that it causes a significant negative impact on their quality of life. In a recent study of 244 patients undergoing ablative surgery for this disorder, 17% of patients were forced to take periodic sick leave or early retirement. Suicide was considered among a quarter of patients, while half of patients used alcohol as a means of relieving their facial blushing.
Normal blushing of skin, and in particular, the face, is a reflection of the vasodilatory effects of blood vessels in the skin caused by emotional stimuli. This effect is mediated by the sympathetic nervous system originating in the upper thoracic portion of the sympathetic chain. The cause of the condition is a dysfunction in the nerve cluster known as the cervicothoracic (lower stellate and upper thoracic) ganglia, which is one of the sequence of nerve clusters extending along the outside of the spinal column, and forms the sympathetic nervous system. The sympathetic, along with the parasympathetic, nervous system is part of the autonomic, or vegetative, nervous system. The effects of the autonomic system are extensive, and range from the control of blood pressure, heart rate, sweat, and body heat, to blood glucose levels, sexual arousal, and digestion. With respect to the current embodiment, the sympathetic outflow to the faces originate in the lower portion of the stellate, and the first 2-3 thoracic ganglia. These peripheral nerve fibers synapse, or converge, in small nodes of nerve cells, called ganglia which lie alongside the vertebral bodies in the neck, chest, and abdomen. In particular, the stellate ganglion is located laterally adjacent to the intervertebral space between the seventh cervical and first thoracic vertebrae. The first, second, and third thoracic ganglia lie next to their respective vertebral bodies on either side of the thoracic cavity. In patients suffering from facial blushing, it is these ganglia which play a major role in the abnormal signal generation to the blood vessels of the face and neck. There is presently no effective medicinal treatment for the condition. In the aforementioned study, 22% of patients had tried medications called beta-blockers with minimal or no relief. Many patients also undergo expensive psychological treatments, such as cognitive and behavioral therapies, without significant relief of symptoms. The present standard of care for the interventional treatment of facial blushing is the lesioning of the stellate and upper thoracic ganglia via one of several surgical approaches.
While there are a variety of different techniques and mechanisms which have been designed to focus the lesioning means directly onto the target nerve tissue, collateral damage is inevitable. Were it even possible to direct all lesioning energy onto the target nerve cluster, it is a significant drawback that other functioning of these nerves is lost, even when such functioning may not be pathological. In addition, there are several common side effects described in the medical literature, including an ipsilateral Horner's syndrome (drooping eyelid and smaller pupil), compensatory sweating (increased sweating in other areas), and gustatory sweating (sweating, particularly of the face, at the smell of certain foods). Additionally, many patients suffer a variety of side effects from medications such as beta blockers, including lethargy, hallucinations, nausea, diarrhea, impotence, hypoglycemia without the normally accompanying tachycardia, fever, and arthralgias.
These complications can be minimized to a large extent, or possible eliminated, by the use of chronic electrical stimulation or continuous drug infusion. The reasons are many, and include the possibility of changing which contacts of a multipolar lead are stimulated to minimize stimulating the superior portion of the stellate ganglion which can lead to a Horner's syndrome, to adjusting the parameters such as frequency or pulse width to affect changes in compensatory and gustatory sweating, should they arise.
It is therefore the principle object of the present invention to provide a less destructive and fully reversible and adjustable method of treating facial blushing.
SUMMARY OF THE INVENTION
The preceding objects are provided in the present invention, which comprises new and novel methods of treating facial blushing disorders by implantation of stimulation electrodes at specific locations along the sympathetic chain. More particularly the present invention comprises a method of therapeutically treating facial and cervical blushing by surgically implanting an electrode adjacent to a predetermined site along the sympathetic chain on the affected side of the body, or if clinically indicated, bilaterally. This involves the surgical implantation of a stimulating electrode over the inferior portion of the stellate ganglion, and usually over T2-3. The most commonly employed surgical approach is aided by video-assisted thoracoscopy, which involves the placement of 2-4 small incisions or ports in the chest wall, through which instruments may traverse en route to the lateral aspect of the vertebral bodies where the sympathic chain lies extrapleurally. The distal end of the lead can be secured to surrounding tissues and be placed either directly over the sympathetic chain or over the internal aspect of the parietal pleura. The proximal end of the lead can be passed out of the thoracic cavity via one of the neighboring surgical ports, and tunneled subcutaneously to an electrical signal source which, in turn, is operated to stimulate the predetermined treatment site over the sympathetic ganglia, such that the clinical effects of the facial blushing disorder are reduced with minimal side effects.
Alternatively, a catheter with either end- or side-apertures placed over the ganglia of interest is connected in a similar fashion to a infusion pump. In addition, this embodiment is extended to include a combination electrical contact and drug delivery system, as well as a system which has the capacity to sense or record electrical or chemical activity in the region of interest.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic illustration of a patient lying in the lateral decubitus position having one visualization port in the fifth intercostal space at the mid-axillary line and two instrument ports at the fourth and fifth intercostal space at the anterior and posterior axillary lines, respectively;
FIG. 2 is an axial cross section view of the upper thoracic region including one visualization port and two instrument ports wherein the two instrument ports have disposed therethrough endoscopic instruments accessing the ipsilateral paravertebral region where the sympathetic chain lies;
FIG. 3 is an exposed view of the left hemithorax displaying one instrument tenting the parietal pleura while the second endoscopic instrument is incising the parietal pleura to expose the sympathetic chain; and
FIG. 4 is a side view of an exposed superior thoracic ganglia in which an electrical stimulation lead is disposed adjacent thereto.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
There are many several approaches described in the literature that have been employed in the lesioning of the stellate and superior thoracic sympathetic ganglia. With respect to this embodiment, any one or a combination of these methods, as well as modifications of this technique not herein described, may be possible without deviating from the broad spirit and principle of the present invention. Specifically, it will be apparent to those skilled in the art that variations and modifications are possible without deviating the scope of the current embodiment which describes the technique of changing the functional state of the upper thoracic and cervicothoracic (stellate) sympathetic ganglia via chronic electrical stimulation or infusion of drug known to modulate its function.
Referring now to FIG. 1, in which a patient 100 is illustrated in the decubitus position, having been prepared by the surgical insertion of three ports 102 , 104 , 106 into the left hemithorax. This preparation is anticipation of a thoracoscopic approach, which is a typical and feasible surgical technique utilized for lesioning of these ganglia. More specifically, this approach commonly involves positioning the patient in the lateral decubitus position, with the hips below the flexion joint of the operating room table. Subsequent flexion of the table allows some separation of the ribs by dropping the patient's hips and therefore increasing the intercostal space to work through. The ipsilateral arm is abducted on an arm holder. Rotating the table somewhat anteriorly and using reverse Trendelenburg positioning further maximizes the exposure to the superior paravertebral area by allowing the deflated lung (see FIGS. 2 and 3) to fall away from the apical posterior chest wall. The patient is under placed under general anesthesia and intubated via a double lumen endotracheal tube. This allows for ventilation of one lung, and collapse of the lung on the side to be operated upon without using carbon dioxide insufflation. Three 2 cm incisions for the thoracoscopic sympathectomy are ordinarily used. One incision is in the midaxillary line in the fifth intercostal space and is used as the telescopic video port 104 . The second incision, performed under endoscopic observation, is placed in the third or fourth intercostal space at the anterior axillary line and is used as one of two instrument channels 106 . The third incision is made at the posterior axillary line just below the scapular tip in the fifth interspace, and it is used as the second instrument channels 102 . Additional incisions/ports can be made as necessary.
Referring now also to FIGS. 2 and 3, in which axial cross section and exposed views of the surgical field are provided, respectively, the surgical exposure and preparation of the relevant portion of the sympathetic chain for the treatment of facial blushing is described. After the lung 110 is collapsed, and if necessary, retracted down by a fanning instrument via one of the working ports, the sympathetic chain 112 is visualized under the parietal pleura 114 as a raised longitudinal structure located at the junction of the ribs 116 and the vertebral bodies 118 . The parietal pleura 114 is grasped between the first and second ribs in the region overlying the sympathetic chain 112 and the endoscopic cautery or scissors 120 is used to incise the pleura 114 in a vertical manner just below the first rib thereby exposing the sympathetic chain 112 .
Referring now also to FIG. 4, in which the placement of the multichannel electrode adjacent to the symnpathetic chain is shown, the implantation of the stimulation electrode is now described. Once the sympathetic chain 112 has been exposed, a multipolar electrode 122 is placed over sympathetic chain of interest, typically the inferior third of the stellate ganglion to the T2 ganglion, and sutured in place to the nearby tissue or parietal pleura 114 .
Alternatively one may prefer not to incise the parietal pleura 114 if electrical stimulation is used, as the current which is generated may modulate the functioning of the ganglia through the pleural surface. Pending the preference and comfort level of the surgeon, a temperature probe may be placed on the ipsilateral face, and electrical stimulation (or in the case of the alternate drug infusion embodiment) testing may be performed prior to closure of the chest cavity to maximize the probability of future effective therapy. The temperature should rise during high frequency stimulation.
This procedure can most easily be accomplished by using existing electrode configurations, or modifications thereof, with the distal tip being more superior, and the proximal tip and the connection cable being more inferior. The lead can be inserted into the thoracic cavity and held in place via the posterior axillary line incision and sutured by using the other working port. The proximal connecting cable can be left at the posterior axillary line port after the lead has been secured with some remaining “slack” of connecting sable being left in the inter-pleural space. The proximal end of the connecting cable/tube can be brought out of the thoracic cavity, and via an extension cable/tube, be tunneled subcutaneously and connected to an electrical pulse generator or infusing pump. The pulse generator or pump may be placed in the subcutaneous tissues of the flank area, abdominal wall area, or buttock area, etc. Any excess fluid is suctioned from the thoracic cavity and the lung is reinflated. A suctioning chest tube may or may not be used depending on the presence or absence of damage to the visceral pleura of the lung. The incisions are closed, and a chest X-Ray is obtained in the recovery room to ensure the lung has reinflated. Electrical stimulation or drug infusion therapy may be started immediately, or after a delay, allowing for some healing to occur first.
Alternative approaches include posterior open extrapleural techniques, posterior percutaneous approaches, the anterior supraclavicular method, as well as the open transthoracic approach. However, while there has been described and illustrated specific embodiments of new and novel methods of treatment for facial and cervical blushing, and it will be apparent to those skilled in the art that variations and modifications are possible, such alterations shall be understood to be within the broad spirit and principle of the present invention which shall be limited solely by the scope of the claims appended hereto.
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A method for treating excessive facial blushing by applying an oscillating electric field to the stellate ganglion. The method includes the steps of inserting an electrode into the vacinity of the sympathetic ganglion, for example the stellate ganglion, such that the necessary electric field may be applied to the ganglion. The necessary field oscillation frequency and strength, as well as other characteristics of the signal are determined individually for each patient. Continued driving of the pathological activity of the ganglion into the normal function is the long-term, reversible palatative remedy for the condition.
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This application claims priority from U.S. patent application Ser. No. 08/989,333, filed Dec. 11, 1997, now U.S. Pat. No. 6,003,278.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to the field of prefabricated concrete wall construction, and more specifically, to a prefabricated concrete stud wall panel and method of forming the same.
2. Description of the Prior Art
In response to problems with traditional block construction methods, prefabricated wall panels were developed for rapid construction of buildings. Prefabricated wall panels are shown in U.S. Pat. Nos. 4,751,803, 4,934,121, 5,055,252 and 5,313,753. Two types of prefabricated concrete walls which are commonly used are cavity walls having open pockets between spaced vertical studs and planar walls having insulation panels between the vertical studs to form a substantially planar surface. While both of these types of prefabricated wall panels are generally superior to traditional block construction in terms of costs, performance and reliability, there are still problems associated with both.
Many cavity walls use preformed concrete studs from a prior pour where they are formed separately from the top and base beams. A subsequent pour is then necessary to integrate the vertical studs with the top and base beams. As a result, walls formed in this manner require additional pouring and curing time and are often weaker than walls formed from a monolithic pour. Monolithic concrete cavity walls are typically formed by pouring concrete into frames which have forming channels for the vertical studs and the top and base beams. However, it is often difficult to remove the finished wall panel from the forming channels without damaging the concrete studs or beams.
In addition to the above, it is often necessary to provide a wood stud at the face of the concrete studs. This is often accomplished by laying wood strips in the forming channels prior to pouring. Typically, the wood strips have a series of nails projecting therefrom and the concrete cures around the nails to secure the wood studs. The process of providing nails in each of the wood strips is time consuming and adds to the manufacturing costs. Additionally, the wood strips are susceptible to cracking and warping, particularly when they are exposed to the wet concrete.
The planar walls are typically formed by placing wall studs, insulation, and reinforcing means in a forming assembly and filling the assembly with concrete. The studs and insulation are generally provided with projections which are surrounded by the concrete to integrate the studs and insulation into the wall. Planar walls which utilize wood studs often experience the same problems as the cavity walls do. U.S. Pat. Nos. 5,313,753 and 5,381,635 suggest mounting other common studs, metal or plastic studs, to the front faces of the concrete studs. However, these studs are merely secured to the front of the concrete studs by narrow flanges which may pull from the concrete. As the size of the flanges is increased, the chance that the concrete will fail to flow between and around the flanges also increases. Another problem associated with these metal and plastic studs on the vertical concrete face is that there is no way of passing service lines, such as, plumbing and electrical wiring, through the vertical studs.
Accordingly, there exists a need for a monolithic concrete wall which is easy to form, includes integral attachment stud surfaces and overcomes the disadvantages of the prior art.
SUMMARY OF THE INVENTION
The present invention generally relates to a stud form of a type used in forming a preformed concrete wall panel having a solid portion and a plurality of vertical concrete studs joined to the solid portion. The stud form includes a substantially U-shaped channel having a face portion that defines an elongated plane and leg portions extending along side of and away from the elongated plane to define a predetermined channel depth. The stud form further includes means for integrally connecting the stud form to the solid portion of the wall panel with the channel opened toward the solid portion.
The present invention also includes preformed concrete walls which incorporate the stud form and a system for forming such.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 an isometric view of a cavity wall panel made in accordance with the present invention.
FIG. 1A is a partial sectional view of an alternate cavity wall panel.
FIG. 2 is an isometric view of a planar wall panel made in accordance with the present invention.
FIG. 3 is an elevation view of a vertical stud form used in the wall panel shown in FIG. 1 .
FIG. 4 is a section view taken along the line 4 — 4 in FIG. 3 .
FIG. 5 is a section of a cavity wall showing an alternate vertical stud form.
FIG. 6 is a partial isometric view of the vertical stud form of FIG. 5 .
FIG. 7 is a section of a cavity wall showing an alternate vertical stud form.
FIG. 8 is a section of a cavity wall showing an alternate vertical stud form.
FIG. 9 is a partial isometric view of an alternate vertical stud form.
FIG. 10 is an elevation view of a vertical stud form used in the wall panel shown in FIG. 2 .
FIG. 11 is a section view taken along the line 11 — 11 in FIG. 10 .
FIG. 12 is an isometric view showing an assembly for the formation of the wall panel shown in FIG. 1 .
FIG. 13 is an isometric view of a portion of an assembly for formation of the wall panel shown in FIG. 1 utilizing an alternate stud form.
FIG. 14 is an isometric view of a portion of the top and bottom forming members.
FIG. 15 is an alternate embodiment of the top and bottom forming channels.
FIG. 16 is an isometric view of a horizontal stud form positioned in the forming assembly.
FIG. 17 is an isometric view showing an alternate assembly for the formation of the wall panel shown in FIG. 1 .
FIG. 18 is an isometric view showing an assembly for the formation of the wall panel shown in FIG. 2 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The preferred embodiments will be described with reference to the drawing figures wherein like numerals represent like elements throughout. References to orientation refer to the orientation of an installed wall panel and are for clarity only.
FIG. 1 shows a cavity wall panel 1 made in accordance with the present invention. The cavity wall panel 1 preferably comprises spaced vertical studs 10 extending between top beam 32 and base beam 34 . The vertical studs 10 include a filled stud channel 12 formed integral with the wall panel 1 . Insulation panels 30 are recessed from the inside face of the wall 1 and extend between the vertical studs 10 and top and base beams 32 and 34 . A concrete surface 36 extends along the back of the wall panel 1 .
As shown in FIG. 1A, the wall panel 1 may also include a connection plate 27 extending along the top beam 32 . The connection plate 27 is preferably a wood stud with a plurality of lag bolts 29 extending therefrom. The connection plate 27 is positioned in the frame prior to pouring and then the poured concrete cures around the lag bolts 29 to secure the connection plate 27 . The connection plate 27 permits additional framing members to be nailed directly to the wall panel 1 .
FIG. 2 shows a preferred planar wall panel 101 made in accordance with the present invention. The planar wall panel 101 generally comprises spaced vertical studs 110 extending between top beam 132 and base beam 134 . The vertical studs include a filled stud channel 112 which is integral with the wall panel 101 . Insulation panels 130 extend between the vertical studs 110 and with studs 110 form a planar inside face on the wall 101 . The outside face of the wall has a planer concrete surface 136 . A wire lath 138 may also be included behind the insulation panels across the entire area of the wall panel 101 . A connection plate 27 may also be provided in the planar wall panel 101 .
A first embodiment of a stud form 12 used in the cavity wall panel 1 is shown in FIGS. 3 and 4. It is preferably made from metal or plastic and forms an integral part of the vertical studs 10 . The stud form 12 is generally a U-shaped channel. It is preferably slightly longer than the length of a vertical stud 10 so that it extends into the top and base beams 32 and 34 of the finished wall. Rebar 20 is positioned in each of the stud forms 12 to tie the vertical studs with the top and base beams 32 and 34 . Flanges 22 extend outward from each open end of the channel and are substantially parallel to the face of the form 12 . Each of the flanges 22 has a plurality of projections 24 extending therefrom for maintaining the insulation panels 30 in position during forming of the cavity wall panel 1 , as will be described in more detail hereinafter. Insulation 14 is placed in the stud form 12 U-channel and extends the length thereof. The insulation 14 provides an area in each vertical stud 10 which is substantially concrete free and allows screws or other fasteners to be set directly into the stud forms 12 in the finished wall. Since finishing materials, such as sheet rock, can be fastened directly to the integral stud forms 12 , separate nailing strips are not required.
As shown in FIGS. 3 and 4, sleeves 16 extend between the sides of the stud form 12 at various positions along its length. Each end of each sleeve 16 is preferably flattened over to hold the side walls of the stud form 12 between the ends of the sleeve 16 . In the finished wall panel 1 , the sleeves 16 are enclosed in the cured concrete and thereby integrate the forms 12 with the finished wall. The sleeves 16 also provide a conduit for electrical wires, plumbing and the like.
A plurality of weep holes 18 are provided through each side of the stud form 12 near the front thereof. The weep holes 18 are checked during pouring of the cavity wall panel 1 to ensure that concrete is properly flowing to the front of the stud form 12 .
Alternate embodiments of the cavity wall stud form 212 are shown in FIGS. 5-9. Each of these alternate cavity wall stud forms 212 has a structure similar to that of stud form 12 of FIGS. 3 and 4, however, the support flange 222 extends inward and has a interconnection flange 230 extending therefrom. The support flanges 222 may be provided with projections for maintaining the insulation panels 30 in position, but are generally not required.
In the embodiments of FIGS. 5, 6 and 9 , each interconnection flange 230 is a generally L-shaped member with a first portion 232 extending generally parallel to the legs of the U-shaped channel and a second portion 234 extending generally perpendicular thereto. The second portion 234 extends into and embeds in the concrete vertical stud 10 to maintain the stud form 212 in position. In the embodiment shown in FIG. 7, the interconnection member 230 extends from the support flange 222 at a substantially 45° angle and embeds into the concrete stud 10 to maintain the stud form 212 in position. In the embodiment shown in FIG. 8, the interconnection member 230 extends generally perpendicular to the support flange 222 . A plurality of holes 238 are provided in the interconnection flange 230 along its length. The poured concrete flows through the holes 238 and thereby interconnects the stud form 212 with the concrete stud 10 . As shown in FIG. 6, the interconnection flanges 230 of each of these embodiments may be provided with holes 238 to further assist securing of the stud form 212 .
As shown in FIGS. 5-8, insulation 214 generally occupies the U-shaped channel of stud from 212 . Since electrical wires, plumbing and the like can be passed through openings 226 along the legs of the U-shaped forms 212 and directly through the insulation 214 , sleeves will generally not be required. In an alternate embodiment shown in FIG. 9, the insulation 214 may occupy only a portion of the U-shaped channel, thereby allowing concrete to flow into and provide support therein. In such an embodiment, sleeves 216 are preferably provided to allow the electrical wires, plumbing and the like to pass through the vertical stud 10 .
The vertical stud form 112 used to form the planar wall panels 101 is shown in FIGS. 10 and 11. The stud form 112 is generally the same as the cavity wall stud form 12 shown in FIGS. 3 and 4 except that the planar wall panel stud form 112 does not have flanges for supporting the insulation since the insulation 130 will be adjacent to the stud form 112 . The stud form 112 may be provided with projections 124 to hold the insulation panels 130 .
Formation of a cavity wall panels 1 will now be described with reference to FIGS. 12-17. Formation is generally the same for each of the cavity wall stud forms 12 , 212 . FIG. 14 shows the intersection of two walls of the forming assembly 50 . The forming assembly 50 preferably comprises linear side walls 52 and top and bottom forming channels 54 . The interior sides of the top and bottom forming channels 54 have a number of spaced notches 56 for receiving the vertical stud forms 12 , 212 . The notches 56 are preferably centered at sixteen or twenty-four inches depending on the desired configuration of the wall panel 1 . As can be seen in FIG. 14, the end notches 56 preferably butt against the side walls 52 to allow the end vertical stud forms 12 , 212 having a flange along only one edge or an inwardly extending flange, to be placed against the framing side walls 52 .
In an alternate embodiment, shown in FIG. 15, the top and bottom forming channels 54 have an interchangeable inner wall 54 b which fits into a permanent section of the channel 54 a . This allows varying inner channel sections 54 b , having differently spaced notches, at sixteen or twenty-four inch centers for example, to be quickly interchanged to produce a cavity wall panel 1 having the desired configuration.
With the forming assembly 50 in its desired configuration, the vertical stud forms 12 are laid in the notches 56 . The stud forms 12 preferably extend slightly into the top and bottom channels 54 to lock them into the top and base beams 32 and 34 of the finished wall panel 1 . Alternatively, the end of each stud form 12 , 212 , or a portion thereof, extends the width of the respective channel 54 to abut the exterior wall of the channel 54 as shown in FIGS. 13 and 17. This helps to ensure that the stud form 12 , 212 maintains its position during pouring.
The rebar 20 in each stud form 12 also extends into the top and base channels 54 . The vertical rebar 20 is attached to horizontal rebar 60 extending in the top and bottom channels 54 . Various spacers and the like are preferably used to maintain the rebar in position prior to pouring. With the vertical stud forms 12 in place, the insulation panels 30 are placed on the flanges 22 of adjacent stud forms 12 and extend between the top and bottom channels 54 and from one stud form flange 22 to the adjacent stud form flange 22 . In this position, the insulation does not cover the top and bottom channels 54 or the vertical stud form 12 U-channels. The flange projections 24 maintain the insulation panels 30 in position during pouring of the concrete. A monolithic concrete pour is used to fill the forming assembly 50 . The concrete fills the top and bottom channels 54 to form the top and base beams 32 and 34 and the vertical stud forms 12 to form the vertical studs 10 . The concrete also provides a solid back wall 36 of approximately two inches.
After the concrete cures, the wall panel 1 is lifted from the forming assembly 50 . Since the vertical stud forms 12 are integral with the wall panel 1 , the likelihood that the vertical studs 10 will crack or be improperly formed is greatly reduced. Furthermore, since the sleeves 16 are integral with the wall panel 1 , there is no need for drilling or cutting conduit passages in the vertical studs 10 .
In an alternate embodiment of the cavity wall 1 , all of the forming members 50 are linear walls. The top and bottom channels 54 are formed by horizontal stud forms 70 placed within the forming assembly 50 , as shown in FIG. 16 . The horizontal stud forms 70 are similar to the vertical stud forms 12 and also form an integral part of the wall panel 1 . The horizontal stud forms 70 differ from the vertical stud forms 12 in that each has a side wall with notches 56 to receive the vertical stud forms 12 . Formation of the wall panel 1 is simplified since the wall panel 1 does not require lifting from the top and bottom channels. Instead, the forming members 50 can simply be disassembled.
Another embodiment of the cavity wall panel 1 is shown in FIG. 17 . As with the previous embodiment, the forming members 50 are linear walls. The stud forms 12 , 212 within the forming members 50 in their desired locations. Horizontal insulation panels 35 are positioned between the adjacent stud forms 12 , 212 and prevent the poured concrete from passing from the top and bottom beams 32 and 34 between adjacent stud forms 12 , 212 . Use of various size horizontal insulation panels 35 permits greater flexibility in positioning of the stud forms 12 , 212 . Once the stud forms 12 , 212 are positioned, the remaining components are placed in the frame, a monolithic concrete pour is provided and the completed wall panel 1 is removed from the forming members in manner similar to that described above. The horizontal insulation panels 35 may be maintained in the finished wall panel 1 or removed after removal of the wall panel from the forming members 50 .
FIG. 18 shows the formation of a planar wall panel 101 . Forming members 152 are connected to define forming assembly 150 . In the preferred embodiment, a stud form 112 is laid flat in the frame so that it extends along one of the end frame members 150 . Additional stud forms 112 are placed parallel to the first stud form 112 on sixteen or twenty four inch centers. The studs forms 112 have a length which is less than the length of forming members 152 whereby channels 154 exist at the top and bottom of the forming assembly 150 .
Four inch thick expanded foam insulation panels 130 , extending the length of the stud forms 112 , are placed between adjacent stud forms 112 . Reinforcing steel bars 160 , extending the length of the wall panel 101 , are placed in the top and bottom channels 154 . A wire mesh 138 is laid over the entire surface within the framing members. Conventional wet concrete is poured into the form 150 , filling all of the empty space within the form and providing a slab of at least two inch (2″) thick concrete along the entire back of the wall. The concrete will fill the top and bottom channels and form the top and bottom beams 132 and 134 . The concrete surrounds the sleeves 116 and thereby forms the integral vertical studs 110 .
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A stud form and system for forming a preformed concrete wall panel having a solid portion and a plurality of vertical concrete studs joined to the solid portion. The stud form includes a substantially U-shaped channel having a face portion that defines an elongated plane and leg portions extending along side of and away from the elongated plane to define a predetermined channel depth. The stud form further includes means for integrally connecting the stud form to the solid portion of the wall panel with the channel opened toward the solid portion.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to rf plasma sources and the use of such sources for cleaning surfaces in space, and more particularly to helicon wave plasma sources suitable for cleaning spacecraft thermal radiators and telescopes.
2. Description of the Related Art
There is a need for a low power, self-contained cleaning system for removing contaminants that build up on the exposed surfaces of a spacecraft, without damaging the device being cleaned. For example, thermal radiators are used to cool a spacecraft by radiating more energy than they absorb. This results from their having a high emissivity in the infrared (IR) wavelengths corresponding to blackbody radiation from the warm spacecraft, and a low absorbtance over the wavelengths of the solar spectrum.
Thermal radiators become contaminated in space due to the condensation of hydrocarbon vapors outgassed from organic materials carried onboard the spacecraft, such as adhesives, potting compounds, conformal coatings and thermal blankets. Ultraviolet light from the sun causes photopolymerization of the hydrocarbons, which would otherwise re-evaporate to some degree; this generates high molecular weight films that do not re-evaporate. These contaminants can greatly increase the radiator's solar absorbtance, and thus reduce its cooling capacity. To counter this, extra large radiator panels are typically used. The extra radiators not only add weight and cost to the spacecraft, but also cool the spacecraft excessively before they become contaminated. This requires valuable onboard electrical power to be used to heat the radiators; the greatest heating is needed during eclipse seasons, when power is least available. Near the end of the spacecraft life, the radiators exhibit a poor heat rejection performance that can cause the onboard electronics to be subjected to large thermal extremes, thereby reducing their lifetime and reliability.
Imaging optics such as telescopes that are used on spacecraft also become contaminated in this way. The condensed hydrocarbon vapors form a scum that causes absorption and scattering of the light being imaged by the telescope, blurring the images. This contamination process is significantly worsened if the telescope is designed to view the sun, which result in the photopolymerization mentioned above.
Telescopes that are cooled to cryogenic temperatures, on the order of tens of Kelvins, to permit observations in the infrared, are also subject to a buildup of surface contaminants. Such cryotelescopes suffer from condensation not only of hydrocarbon vapors, but also of water vapor, carbon dioxide, ammonia and other cryocondensible gases. The frozen gases absorb incident radiation, and in time become roughened by sublimation roughening, increasing their optical scatter. Cryotelescopes have previously been warmed to sublime the frozen gases. However, this renders the instrument "blind" during the sublimation process, and consumes a great deal of cryogen. The residual hydrocarbon contaminants have been simply allowed to accumulate.
Previous attempts to develop a cleaner for space borne telescope optics used high energy ion beams to remove the contaminants. However, this resulted in damage to the delicate optical surfaces because of ion beam sputtering. Radiators often use conductive coatings such as indium oxide, and the potential for sputter damage to such coatings has also made ion beam cleaning inapplicable to radiators.
Another approach involves the use of an ultraviolet lamp to create ozone within the telescope tube. The ozone oxidizes hydrocarbon contaminants on the telescope optics. Unfortunately, this approach requires the telescope tube to be pressurized with oxygen gas, which imposes a substantial burden upon the spacecraft in terms of telescope mass, large oxygen tankage and cryogen loss due to convective warming during cleaning.
Another approach to cleaning spacecraft surfaces is described in U.S. Pat. No. 4,846,425 to Champetier and assigned Hughes Aircraft Company, the assignee of the present invention. This technique uses the negative charge that is typically accumulated on a spacecraft, which collects more active electrons than relatively inactive positive ions. Neutral oxygen is released from the spacecraft, ionized by the background space plasma, and drawn back to the spacecraft by its negative charging to react with the surface contaminants. A very large oxygen supply is required, however, because most of the oxygen escapes and is not drawn back to the spacecraft. This is because the oxygen must be ionized within a few debye lengths (about 10-100 m) from the spacecraft to be drawn back, and the majority of the oxygen is not ionized within this zone.
The use of plasmas is well known in ground applications for removing hydrocarbons. Nascent oxygen atoms and ions in the plasma oxidize the hydrogen and carbon atoms that make up the contaminants, and the reaction energy propels the volatile oxide from the contaminated surface. One type of plasma source that has been used for this purpose is based upon a Penning electron discharge; such a plasma source is described in U.S. Pat. No. 4,800,281, also assigned to Hughes Aircraft Company. Penning-type sources generally include either a filamentary cathode or a hollow cathode for achieving thermionic electron emission. However, filamentary cathodes predictably burn out over time, and are therefore unacceptable for use in spacecraft applications in which replacement of the cathode is not possible. For hollow cathodes, the electronic emissive material that is used to coat the hollow cathode is often incompatible with reactive gases such as oxygen that are desirable plasma fuels for cleaning optical surfaces.
Another plasma source that has been used for ground-based cleaning applications is the helicon wave source. This type of device operates by coupling externally generated electric and magnetic fields into a plasma that is confined by an axial magnetic field. An antenna consisting of two loops diametrically positioned on the outside of the source tube produces a transverse rf magnetic field, perpendicular to both the tube axis and a constant axial magnetic field. The rf field excites a helicon wave in the source tube, and energy is transferred from this wave to the plasma electrons. The helicon wave theory is discussed in Chen, "Plasma Ionization By Helicon Waves", Plasma Physics and Controlled Fusion, Vol. 33, No. 4, 1991, pages 339-364. The use of helicon wave plasma sources for semiconductor cleaning is described in Singer, "Trends in Plasma Sources: The Search Continues", Semiconductor International, July 1992, pages 52-57.
Helicon plasma sources use versions of an rf antenna that have complicated wiring schemes to avoid establishing an rf magnetic field parallel to the source tube axis. This type of antenna, commonly referred to as a Nagoya Type III antenna, is described in Watari et al., "Radio Frequency Plugging of a High Density Plasma", Physics of Fluids, Vol. 21, No. 11, November 1978, pages 2076-2081. The overall plasma sources are quite large and massive, and consume too much power and gas to be considered for spacecraft applications.
Other reactive plasma sources such as parallel-plate reactors are also used to clean hydrocarbons in ground applications. In addition to excessive weight and power consumption, those sources produce ion energies high enough to risk damaging optical surfaces.
SUMMARY OF THE INVENTION
The present invention seeks to provide an improved method for removing contaminants from the surface of a body in space with low power and gas consumption requirements, and without damaging the surface being cleaned. In particular, it seeks to provide a reactive rf plasma source that has these characteristics and is small enough in size to be useful for practical spacecraft applications. A neutralization of charge buildup on the spacecraft surface is also desired.
These goals are achieved by generating a substantially spaced-charge neutral plasma of a type that reacts with the contaminant to be removed from the spacecraft surface, directing the plasma onto the contaminated surface at an energy below the surface sputtering energy, and reacting the plasma with the contaminant to remove it from the surface. A new type of helicon wave source is used to provide the plasma at a low energy level, less than 20 eV, at which sputter damage to delicate optical surfaces is avoided. The new plasma source can also be made sufficiently compact and light weight to be useful for spacecraft applications. This reduction in scale is made possible by the use of permanent magnets to establish the uniform axial magnetic field, as opposed to the prior use of electromagnets with their attendant high power consumption, coupled with a unique rf antenna design that is greatly simplified compared to the prior Nagoya-type antennas.
The new antenna includes a pair of conductive rings that extend around the tube and are axially spaced from each other. The rings are preferably formed in a unitary construction with a conductive base bar that extends generally parallel to the tube axis, with the rings rigidly supported by and integral with the opposite ends of the base bar. A conductive rf feed bar extends generally parallel to the tube axis between the two rings on the opposite side of the tube from the base bar, with an input rf signal delivered to opposite sides of an interruption in the feed bar. The two rings are designed to divide an rf current from the feed bar symmetrically and then recombine the current in the base bar, thereby avoiding the generation of any substantial net axial rf magnetic field through the tube.
In a preferred embodiment, the feed bar interruption is provided between one of the rings and the adjacent end of the feed bar. Localized enlargements of the ring and feed bar include openings to receive the sheath and inner conductor of a coaxial rf feed cable, respectively. The antenna is durable, easy to assemble to the tube, and contributes to the reduction in overall size.
These and other features and advantages of the invention will be apparent to those skilled in the art from the following detailed description, taken together with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional view of a compact rf plasma source in accordance with the invention;
FIG. 2 is a perspective view of an rf antenna used in the plasma source of FIG. 1;
FIG. 3 is a sectional view of a spacecraft telescope with a mirror that is cleaned with the compact rf plasma source of the invention; and
FIG. 4 is a simplified perspective view illustrating the exterior surface of a spacecraft being cleaned with the new plasma source.
DETAILED DESCRIPTION OF THE INVENTION
A preferred embodiment of a compact rf plasma source that can be used for orbiting spacecraft is shown in FIG. 1. It includes a cylindrical plasma tube 2, formed from a material such as alumina, ceramic or glass, within which the plasma is generated. An rf antenna 4 is provided around the exterior of the plasma tube and provides a flow path for rf current that generates an oscillating magnetic field (a magnetic dipole) in a plane perpendicular to the tube's axis. The antenna could at least theoretically be located around the interior of the plasma tube, but that would add to the surface area within the tube and thereby increase the rate of plasma recombination loss. As described below, the antenna has a unique configuration that avoids the generation of an oscillating field along the tube axis, and is much simpler in design than the Nagoya-type antennas previously used for this purpose.
The remainder of the assembly is held in place between upper and lower stainless steel endcaps 6 and 8, which are notched to retain the opposite ends of the tube 2. A series of tie bolts 10 are used to secure the endcaps together. An outer wire mesh shield 12 provides additional structural support and protection for the assembly. The antenna 4 is secured against slippage on the plasma tube, such as by a ceramic-to-metal braze.
A number of permanent bar magnets, of which two magnets 14 and 16 are illustrated although typically six-ten magnets would be employed, are provided at various azimuthal positions around a source and housed in a magnet tube 18 that forms a protective housing. The magnets, which can be formed from samarium cobalt or neodymium-iron-boron, establish a magnetic field within the tube that is generally parallel to the tube axis. A cylindrical shell magnet might also be used in place of the bar magnets. The magnetic field is kept generally uniform within the tube through the use of pole pieces 20 and 22 at the upper and lower ends of the assembly. The pole pieces, which are preferably iron or other high permeability magnetic material, are shaped to provide the desired field uniformity; similarly shaped pole pieces are employed in known ion thrusters. The magnet tube 18 is preferably formed from stainless steel to avoid shorting the magnetic circuit.
A plasma source gas is supplied from a gas reservoir 24 through a valve 26 and nipple 28 into the back end of the plasma tube. Oxygen is commonly used as a source gas because it reacts with hydrocarbon contaminants, but other sources such as nitrogen, CF 4 , argon, air or water vapor could also be used. In general, any gas or vapor that reacts with the contaminant to be removed and does not condense at the plasma source's operating temperature (estimated at about 100° C.) could be considered. Instead of using a valve 26, a heater might be employed to control the gas or vapor flow rate into the plasma tube.
An rf source 30 is coupled to the antenna 4, most conveniently via a coaxial cable 32. The cable includes an outer sheath 34 that is connected to one of the antenna electrodes 36, and an inner conductor 38 that extends through terminal 36 and is connected to a second antenna terminal 40.
If desired, the structure shown in FIG. 1 can be modified to add an additional permanent magnet structure, downstream from the magnet structure illustrated in the figure, to provide a more consistent field gradient that encourages outward plasma drift through the tube's open discharge end 42. This type of magnet configuration is used, for example, in the plasma generator of U.S. Pat. No. 4,977,352 to Williamson, one of the present inventors, assigned to Hughes Aircraft Company.
It has been found that the plasma source illustrated in FIG. 1 can be successfully used to generate a highly reactive plasma that will clean contaminated spacecraft surfaces with low rates of power and gas consumption, and at an energy level below that at which sputter damage to optical surfaces is produced. This is accomplished with a structure that is considerably smaller and lighter than ground based helicon wave plasma sources currently available.
In a typical application of the invention, a 22 mm diameter plasma source is supplied with gas at a flow rate of 0.5-20 sccm (standard (temperature and pressure)cm 3 /minute). Higher or lower fluences can be obtained by increasing or decreasing the gas flow rate or power. The input rf power is in the 5-25 W range, while the magnets provide an axial field of about 150 milliTesla (the field is somewhat stronger at the pole faces). With an rf frequency of 100 MHz, a maximum oxygen ion current of 50 mA is generated. The energy of the plasma ions and neutrals ranges up to about 15 eV, which is sufficiently below the approximate threshold of 20 eV at which sputter damage to optical surfaces can commence.
A novel rf antenna configuration that replaces the Nagoya-type antenna and is instrumental in enabling a more compact plasma source is shown in FIG. 2. The antenna 4 is formed from a conductive material such as copper, preferably in a unitary integral construction. The antenna includes a pair of rings 44 and 46 at its opposite ends whose inside diameter is approximately equal to the plasma tube's outer diameter. The two rings are electrically and mechanically connected by a base bar 48, which extends parallel to the common ring/plasma tube axis. The opposite ends of the base bar 48 merge into the rings, and rigidly support them to keep them mutually separated. An rf feeder bar 50 extends between the rings on the diametric opposite side of the antenna from base bar 48. The feeder bar 50 has an interruption 52, allowing the rf signal to be connected across the opposite sides of the interruption. This interruption is preferably between one of the rings 46 and the remainder of the feed bar 50, which extends integrally up from the other ring 44. However, if desired the feed bar can extend in from both rings, with the interruption near its middle.
The terminals 36 and 40 consist of enlarged areas on the opposed ends of the feed bar 50 and upper ring 46. A relatively large axial opening 54 is formed through the feed bar terminal 36 to accommodate the outer sheath of the coaxial cable 32, while a smaller axial opening 56 is formed through the ring terminal 40 to accommodate the cable's inner conductor. Set screw openings 58 and 60 are provided in the terminals perpendicular to the cable openings 54 and 56 so that the cable sheath and inner conductor can be secured in place with set screws. Although the upper ring 46 is illustrated as progressively expanding in width from the base bar 48 to the terminal 40, its width can be held equal to that of the base bar, with a tab on the opposite side of the ring for terminal 40.
The illustrated antenna configuration results in a symmetrical flow of rf current that produces substantially zero net oscillating magnetic field parallel to the tube axis. This is because the antenna provides symmetrical clockwise and counter-clockwise current flow paths around the plasma tube. As illustrated by the arrow 61, the current during one-half of each rf cycle flows from the terminal 36 through the feed bar 50, and divides equally in opposite directions around the lower ring 44. The ring currents recombine at the base bar (arrow 62), and again divide equally in opposite directions around ring 46 at the upper end of the base bar (arrow 64). The upper ring 46 provides a return path to the rf source via terminal 40. This current flow reverses during the other half of the rf cycle, but it still divides symmetrically around the rings and thus avoids the production of a net oscillating magnetic field in the axial direction.
Typical dimensions for the antenna are a 28 mm inside diameter, an overall axial length of 57 mm, and a base bar/feed bar thickness of 1 mm.
The application of the invention in cleaning an optical surface of a spacecraft telescope is illustrated in FIG. 3. The telescope housing 66 is mounted to the spacecraft's outer skin 68, with light entering the telescope through an opening 70 in the skin. The telescope is shown as consisting of a primary mirror 72, a secondary mirror 74 and a focal plane array 76. Light baffles 78 are positioned along the edges of the telescope tube 80 to reject scattered light.
An rf plasma source 82 in accordance with the invention is supplied with gas and/or vapor from a supply tank 84, and is energized by an rf power source 86. The plasma source 82 is shown mounted on the tube 80 that carries the baffles 78, and oriented to direct a cleaning plasma 90 onto the mirror surface.
If the telescope's optical components are warm, such as from solar heating and heat radiated from the spacecraft, an oxygen plasma can be used to remove both condensed hydrocarbon vapors that are outgassed onto the mirror surface from organic materials carried onboard the spacecraft, and the photopolymerized hydrocarbons that result from exposure to the sun. In a demonstration of the invention, a buildup of ultraviolet-absorbing scum on an optical surface had caused a high-resolution telescope-spectrometer (HRTS) to lose its ability to image the sun in its designed far-UV (122 nm) range after only a few orbital periods. An unsuccessful attempt was first made to remove the scum by scrubbing with a solvent. However, an exposure to an oxygen plasma produced with the invention visibly removed the contaminant layer. In other cleaning experiments, the reflectance of a mirror similar to that used on HRTS at 122 nm had degraded from a pristine level of 0.68 to a contaminated level of 0.33, but was restored by oxygen cleaning with the invention to a reflectance of about 0.64. A window had a transmittance at 122 nm of 0.64 in its pristine state, which deteriorated to 0.21 after contamination. After an oxygen plasma cleaning of one side the transmittance increased to 0.39, and was restored to 0.64 when both sides of the window were cleaned.
For hydrocarbon and silicone-containing contaminants that commonly occur from spacecraft outgassing, a plasma formed from an oxygen and CF 4 mixture can be used. This type of mixture has previously been used in ground applications. It has also been found that liquid compounds containing both oxygen and flourine, such as hexafluoro acetone, hexafluoro acetone hydrate or trifluoro acetic acid, can be used as a plasma source, thereby reducing the complexity of the equipment that would otherwise be required to handle two separate plasma source components.
The use of the invention to clean an exterior spacecraft surface, such as a thermal radiator, is illustrated in FIG. 4. The body to be cleaned is illustrated generically by a cube 92 having a contaminated upper surface 94; the lower surface would also typically be contaminated. In actual practice, the typical construction for a thermal radiator is thin transparent silica with silver coating on the spacecraft side. Solar panels 96 and 98 are supported respectively by yokes 100 and 102 on opposite sides of the spacecraft. The solar panels rotate once each day to track the sun, while the spacecraft antennas track the earth. A plasma source 104 is shown mounted on one of the solar panels 96 at an angle to the yoke 100, so that an oval shaped spot 106 is exposed to the plasma and cleaned. A similar plasma source could be provided on the other solar panel 98. The diurnal rotation of the solar wing allows the entire radiator panel to be cleaned in a single day; calculations indicate that one such cleaning per month would keep the radiators clean even in worst-case contamination situations. The yokes provide a transmission path for unregulated DC voltage generated by the panels into the spacecraft, and for the return of a regulated voltage to the rf source 107 used for the plasma source.
It has been discovered that special advantages are possible with this type of cleaning by using water vapor plasma instead of oxygen. When ionized in the rf discharge, water vapor decomposes into a number of species that include the highly reactive radicals and radical ions H+, H, OH-, OH, O and O+. Water vapor plasmas have been found to clean hydrocarbons with an effectiveness equal to that of oxygen plasmas.
The easy storage of water offers a major advantage for its use as a cleaning agent in applications such as spacecraft radiator cleaning. Instead of the relatively costly and heavy high pressure cylinder required for oxygen storage, water can be contained in a very compact, light weight vessel at low pressure. The vessel can be kept warm by thermal-blanket design so that the vapor pressure of the water is adequate to supply the plasma generator. An additional advantage of water tankage is that micrometeorite hits on the tank, while ultimately fatal to the cleaning system, pose no hazard to the spacecraft. The water would slowly be lost into space, as opposed to a punctured high pressure oxygen tank that could produce a gas jet with sufficient force to generate unacceptable torques on the spacecraft. The plasma generator 104 is illustrated as including a plasma generation section 104a, to the rear of which a water storage tank 104b is directly coupled.
Water plasma cleaning is not suitable for a cryotelescope application, since any water molecules that fail to become ionized in the rf discharge would freeze onto the optical surfaces and could contaminate these surfaces faster than they could be cleaned. Cryotelescope cleaning, however, requires only small oxygen tanks, since the surface area to be cleaned is very small in comparison to radiator panels (typically not more than about 0.03 m 2 vs. 5 m 2 or greater). In addition, the oxygen tank associated with a cryotelescope cleaner would be protected from micrometeorites by the spacecraft structure.
The invention is believed to operate on the helicon wave principal, with electromagnetic helicon waves launched on the plasma and propagating down the magnetic field lines to be absorbed through an electron damping process. This exchange of energy between the wave and electrons leads to energy transfer to the electrons, increasing their temperature and thereby sustaining the plasma.
Numerous conventional mechanisms can be employed to initiate the plasma. These include briefly turning up the power to generate an electric field high enough to break down the gas, waiting momentarily for a cosmic ray to excite electrons sufficiently, briefly increasing the gas pressure so that it breaks down more easily (with or without an increase in power), providing a sharp electrode source to initiate the plasma, and adding a radioactive component to the gas to produce a plasma-initiating radioactive decay.
The invention can also provide a spacecraft charging protection function. A spacecraft surface that is not exposed to the sun can acquire a high negative charge, on the order of -20 kV. This is illustrated by the negative charge symbol 108 on the spacecraft surface 110 in FIG. 4. The charge differential between the plasma and the negative surface charge produces an electric field 112, diverting positive ions from the plasma to neutralize the localized charge 108. This is accomplished with only a relatively small amount of charge diversion, so that the plasma which cleans surface 94 remains essentially charge neutral. A similar charge protection function is disclosed in U.S. Pat. No. 4,800,281 for a Penning-discharge plasma source.
While several illustrative embodiments of the invention have been shown and described, numerous variations and alternate embodiments will occur to those skilled in the art. Such variations and alternate embodiments are contemplated, and can be made without departing from the spirit and scope of the invention as defined in the appended claims.
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Contaminants are cleaned from the surface of a body in space by generating a substantially space-charge neutral reactive plasma, directing the plasma onto the contaminated surface at an energy below the surface sputtering energy (typically 20 eV), and reacting the plasma with the contaminants to remove them. A helicon wave plasma source is made light weight and compact enough for spacecraft use, with a plasma energy low enough to avoid damaging optical surfaces, by using permanent magnets to establish a static axial magnetic field, and a simple but novel rf antenna design. The antenna consists of a pair of spaced conductive rings which extend around the plasma tube, with conductive base and rf feed bars extending between the rings on diametrically opposite sides. The feed bar is interrupted to provide an rf input on opposite sides of the interruption. The antenna is preferably formed as an integral metal unit, with its rings rigidly supported by and integral with opposite ends of the base bar. The plasma source is also useful in neutralizing localized charges on the spacecraft.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention generally relates to circular saw blades, and more particularly, is concerned with split circular saw blades which are aligned and joined by self-interlocking projections and recesses.
2. Description of the Prior Art
In many lumber mill operations, a "gang saw" is used, wherein a number of circular saw blades are attached to a single rotating shaft or arbor, in order to make multiple cuts on a single pass of the wood being cut. As many as fifty or more circular saw blades could be used on a single arbor. In order to replace a single circular saw blade, it initially was necessary to remove any blades to the outside of that blade, so that the blade being replaced could be slipped off of the end of the arbor. This process was time consuming and created unnecessary wear on the arbor. Subsequently, quick change "split saws" were developed where the circular saw blade was cut in half. These blades were directly replaceable at any position on the gang arbor by loosening their means of attachment to the arbor and removing the two pieces constituting the split blade.
While the advent of the split saw blade improved efficiency due to the reduction in time required to replace individual saw blades, it also resulted in significantly increased costs for both the saw blades themselves and the means of attachment to the arbors. One system modified the blades with a machined collar which fit into a circular recess machined into the back plate affixed to the arbor. Another design provided for multiple holes in each blade section which fit over studs attached to the back plate. These systems were expensive because of the machining required and often lacked the accuracy necessary for precise alignment of the blades on the arbor. In order to gain a measure of universality, some blades were manufactured with both a collar and stud holes.
There remains a need for a saw blade design which can find universal use on standard arbors, but with the advantage of the quick change split saws. Needed is a design which removes the recess collars on the arbor back plate and the collar ribs on saw blades, and eliminates the need for holes in the blades and the special machining of arbors. Also needed are saw blades which can be used on either left or right hand arbors, and which are easier to maintain than the current blades. And, finally, a split saw blade system which cost less to manufacture is needed.
SUMMARY OF THE INVENTION
The present invention provides a self-interlocking split circular saw blade which is designed to satisfy the aforementioned needs. The invention embodies an improved circular split saw blade which interlocks with its own body by means of projections and recesses.
Accordingly, the present invention provides a circular saw blade which has been "split" into two sections in order to encircle the saw arbor for rapid emplacement and removal, and which is reconnected and self-interlocked to itself own body to provide an aligned and strong circular saw blade without the need for especially designed and machined collars or stud holes in the blades, or collar recesses and studs on the arbor back plates. The interlocking is accomplished by projections and corresponding recesses in the two sections of the split circular blade, which projections and recesses are designed to interlock accurately so as to provide needed strength and improved alignment for circular split saws at a reduced cost.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates prior art in split saw blades.
FIG. 2 is an elevation view of the preferred embodiment of the self-interlocking split saw blade.
FIG. 3 is an elevation view of alternative interlocking configurations of the saw blade of FIG. 2.
FIG. 4 are enlarged views of examples of interlocking projections and recesses used with the self-interlocking split saw blades shown in FIG. 2 and 3.
FIG. 5 illustrates the preferred embodiment of FIG. 2 in perspective, as assembled on an arbor.
FIG. 6 is a partial sectional view taken on line 6--6 of FIG. 5 looking in the direction indicated by the arrows.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, and more particularly to FIG. 1, there is shown prior art in split circular saw blades. FIG. 1a shows, in perspective, a split saw blade with a machined collar, the collar fitting into a machined collar recess in the arbor back plate (not shown) to provide alignment and to keep the split saw from detaching itself from the arbor due to centrifugal force. FIG. 1b shows, in perspective, a split saw blade with holes located for alignment with studs located on the arbor back plate, so as also to provide alignment and restraint against centrifugal force.
Referring to FIG. 2, there is shown the self-interlocking split saw blade, generally designated 10, which comprises the preferred embodiment of the invention. The saw blade 10 basically includes teeth 11, of varying design depending on the use of the blade, around the circular circumference thereof; the two halves 12 and 13 of the blade, which are of the same size and shape; a curved inner circumference 14 which fits about and encircles the saw's arbor; and interlocking projections 15, 17, 19, and 21, which, when the two sections of the split saw blade 12 and 13 are joined, fit and connect with the recesses 16, 18, 20, and 22 respectively. It should be noted that the split saw blade sections will only fit together, around the arbor, in a single manner, that is, projection 15 fits into recess 16, projection 17 fits into recess 18, projection 19 fits into recess 20 and projection 21 fits into recess 22. This is particularly important in saw blades which have directional teeth, such as blades for cutting wood, so as to prevent erroneous assembly wherein the teeth of the two sections would point in opposite directions. Such a feature is less important in cannery, masonary, meat blades or other circular saw blades where directional teeth are not of concern. It should be noted that while this invention is described primarily in terms of wood cutting saw blades, the scope thereof is intended to apply to all variations of circular saw blades, regardless of the intended use thereof or the material being cut.
FIG. 3 shows alternative configurations of the self-interlocking split saw blade. While the preferred embodiment in FIG. 2 shows, on a single split saw blade section, alternating projections and recesses, the alternative shown in FIG. 3a illustrates, on a single split saw blade section 23, two (2) projections 25 and 27 adjacent on one connecting edge and two recesses 30 and 32 adjacent on the the other connecting edge of that split saw blade section. As can be seen when split saw blade section 23 is interlocked with split saw blade section 24, projection 25 engages with recess 26, projection 27 engages recess 28, projection 29 engages recess 30 and projection 31 engages recess 32. As in the preferred embodiment, there is no possibility of misjoining the two split saw sections. The alternative specifically illustrated in FIG. 3a would be of advantage to a clockwise rotating saw blade wherein the projections would always trail the rotation, and thus be less likely to gouge the material being cut should misalignment occur. Of course, depending on the configuration used, if the back plate 46 and the face plate 47, as illustrated in FIG. 5 and FIG. 6, cover the projections, then no gouging could occur.
FIG. 3b shows a still different alternative for interlocking the split saw blades. In this figure, only a single interlocking projection and recess is provided for each saw blade section, so that, as illustrated, saw blade section 33 has projection 35 and recess 38, while saw blade section 34 has projection 37 and recess 36, wherein, upon assembly, projection 35 engages recess 36 and projection 37 engages recess 38. Again, in this alternative configuration, erroneous joining of the the blade sections has been eliminated by the positioning of the projections and recesses.
FIG. 3a and FIG. 3b illustrate that the specific number of projections and recesses utilized to interlock the split saw blade sections together is not critical to the invention. While four interlocking sets of projections and recesses are illustrated in the preferred embodiment in FIG. 2, this being believed to be an optimum trade-off between redundancy and simplicity of manufacture, clearly a greater number of sets of projection and recesses are within the scope of the invention, depending upon the particular saw configuration, as is evident to a person skilled in the art.
The interlocking of the various projections with their corresponding recesses, as noted above, provides the interlocked joining of two sections of split circular saw blades with each other to provide strength sufficient to restrain the saw sections from parting under the centrifugal movement of the rotating saw blade, and the accuracy of alignment necessary for true running of the saw.
Accuracy in the manufacture of interlocking split saw blade sections with projections and recesses, as appropriate, can be expected to approach a tolerance of two one-thousands of an inch (0.002 inch) through the use of current state-of-the-art laser cutting techniques. Such preciseness not only will allow the use of matched pairs of split saw blades, but also the free substituting of other split saw blade sections of the same type.
FIG. 4 illustrates enlarged views of examples of various individual projections and recesses which can be utilized with this invention. There are innumerable possible geometric designs for the interlocking members, and while the preferred embodiment of FIG. 2 and the alternatives of FIG. 3 show a single design of interlocking projections and recesses, the design of such projections and recesses are readily interchangeable. As described previously, the projections and recesses are located respectively on the split saw blade sections so as to eliminate the possibility of erroneous assembly of the blade sections. Similiarly, various designs of interlocking projections and recesses would have the purpose of preventing the assembly of different types of cutting blades sections together in the same circular saw blade. Thus, for example, as illustrated in FIG. 4, projection 39 and recess 40 could be reserved for general purpose saw blades, projection 41 and recess 42 could apply to cross-cut saw blades, while projection 43 and recess 44 might be appropriate for blades for ripping lumber. Other examples of individual projections and corresponding recesses which could be associated with particular applications of circular saw blades are within the scope of the person skilled in the art.
Finally, FIG. 5 and FIG. 6 illustrate the preferred embodiment of FIG. 2, as it could be assembled (other blades not shown) on a gang arbor 45. There are numerous methods of assembling a gang saw, this being only an example. Split saw blade sections 12 and 13 are interlocked through the joining of projections 15, 17, 19, and 21 with recesses 16, 18, 20, and 22, as illustrated. The self-interlocked split saw blade 10 is placed against the back plate 46 affixed to the arbor 45, and the face plate 47 is subsequently pressed against the saw blade 10 by a threaded nut 48 turned on the threads 49 until it is tight. Thus, blade 10, composed of the two interlocked split saw blade sections 12 and 13, is held accurately and securely for the rapid rotation and cutting action of the saw. It should be noted that no costly machining of collars and recesses, or studs and their holes, are required. In this example, similar assemblies of back plate 46, self-interlocking circular split saw blade sections 12 and 13, face plate 47 and threaded nut 48 would be found in sequence on the gang arbor 45. Back plate 46a illustrates the position of an adjacent back plate where another self-interlocking split saw blade could be mounted.
It is thought that the self-interlocking split saw of the present invention and many of it attendant advantages will be understood from the foregoing description and that it will be apparent that various changes may be made in form, construction and arrangement of the parts thereof without departing from the spirit and scope of the invention or sacrificing all of its material advantages, the form hereinbefore described being merely an exemplary embodiment thereof.
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A circular saw blade, having been divided into two sections to permit rapid replacement without having to be removed past the end of the saw arbor, is reconnected and self-interlocked to its own body, thus eliminating any requirement for machined collars or studs for retention or alignment. Interlocking is accomplished by the use of interlocking projections and corresponding recesses in various configurations on the two sections of the split saw blade.
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FIELD OF INVENTION
The present invention relates to knitting machines, and, more particularly, to an apparatus for collecting and removing fiber waste from a circular knitting machine while cooling the knitting unit thereof.
BACKGROUND OF INVENTION
Conventional knitting units of circular knitting machines are traditionally associated with more than 100 yarn supply bobbins. When certain yarns are employed for forming the knitted fabric, dust, lint and waste fibers (collectively referred to hereinafter as "fiber waste") are generated by engagement of the yarns with the machine's yarn feeding, guiding and/or other components of the knitting machine and creel. The amount of fiber waste set adrift in the ambient air is substantial. This amount of fiber waste tends to increase as the operating speed of the knitting machine increases. Once the fiber waste has become airborne, it tends to settle upon the yarn feeders, yarn guides and the knitting unit of the knitting machine, and even upon adjoining machines.
This fiber waste occasionally gets knitted into the fabric causing defects in the fabric and in some cases, damage to the needles and other components of the knitting unit. This accumulation of fiber waste necessitates frequent overalls of the knitting units on the machine which is both costly and time consuming.
Various kinds of devices have heretofore been proposed for removing fiber waste generated by the knitting unit. The majority of the prior devices employ either a motor driven fan or an air blower to blow the fiber waste away. It has also been proposed to provide a cover about each knitting machine, and to install an exhaust duct near the machine so that the machine operator may gather the fiber waste and introduce it into an exhaust duct. The large installation costs associated with such a method make it less desirable. In addition, this method requires shielding the machine body which negatively affects access to the machine and the surrounding work environment. Moreover, once lubricants, such as oil, etc., stick on the shielding member, fibers tend to adhere to the shielding member which is both unsightly and unsanitary.
As disclosed in U.S. Pat. No. 5,177,985, the assignee of the present invention has previously developed a system for the collection and removal of fiber waste which utilizes a fixed suction cylinder which cooperates with the suction/blowing means to direct fiber waste laden air from the knitting unit into a filter means. While this system constitutes a marked improvement in fiber waste removal and collection from circular knitting machines, the system does have limitations due to the fixed character of the suction cylinder.
As the operational speed of the knitting machines increases, the elements of the knitting unit begin to overheat, causing heat expansion which results in distortion of the cylinder and its surrounding components. This distortion in turn causes degradation in the accuracy of the knitting machine. However, such distorting and degradation could be prevented if the knitting machine was cooled during operation. Heretofore, no effective cooling of the knitting unit during operation has been made available.
SUMMARY OF THE INVENTION
In view of the foregoing background, it is an object of the present invention to provide an apparatus for use with a circular knitting machine which collects and removes fiber waste while also cooling the knitting unit thereof.
These and other objects, features and advantages of the present invention are provided by an apparatus for cooling a knitting unit of a circular knitting machine and collecting and removing fiber waste generated by the circular knitting machine in making knit fabric. The apparatus includes an air suction/blowing means located above the knitting unit of the circular knitting machine for generating air currents through the knitting unit and across the other elements of the knitting machine to remove fiber waste therefrom and entrain the same therein. A filter is provided above the air suction/blowing means for collecting fiber entrained in air currents blown thereto. An adjustable suction cylinder is located between the needle cylinder and the air suction/blowing means and assists the air suction/blowing means in creating a vacuum therein for drawing air upward through the knitting unit and for drawing air into the filter. Because the suction cylinder is adjustable relative to the air suction/blowing means and the knitting unit, the amount of air flow through the knitting unit may be increased or decreased.
To cool the knitting unit while fiber waste is removed therefrom, a cooling orifice is created between the inside of the needle cylinder of the knitting machine and the knit fabric being produced. This orifice is created by an orifice disk which controls and positions the knit fabric inside the needle cylinder in such a manner that the air currents are directed or channeled to and across the knitting unit.
It is preferable that the cooling orifice be a channel having a cross section which decreases as it approaches the knitting unit which causes air to speed up as it passes therethrough to cool the knitting unit. Increasing the air speed passing through the cooling orifice improves the cooling effect of the air.
BRIEF DESCRIPTION OF THE DRAWINGS
Some of the objects, features and advantages of the present invention having been stated, others will become apparent as the description proceeds, when taken in conjunction with the accompanying drawings in which:
FIG. 1 is a front elevational view of a circular knitting machine having a fiber waste collector, remover and cooling apparatus in accordance with a first embodiment of the invention;
FIG. 2 is an enlarged sectional view of a portion of the knitting unit shown in FIG. 1;
FIG. 3 is a partial sectional view of fiber waste collection and remover in accordance with the present invention;
FIG. 4 is an enlarged view of the knitting unit and the cooling device of the present invention;
FIG. 5 is a front elevational view of an alternative embodiment of the present invention;
FIG. 6 is a front elevational view of another alternative embodiment of the present invention; and
FIG. 7 is a top plan view of the alternative embodiment shown in FIG. 6.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention will now be described more fully hereinafter with reference to the accompanying drawings, in which a preferred embodiment of the invention is shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiment set forth herein. Rather, the illustrated embodiment is provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art to which it relates. Like numbers refer to like elements throughout.
A circular knitting machine 99 as shown in FIGS. 1 through 4, has a plurality of legs 1 supporting a bed or frame 2 that in turn supports a circular knitting unit 3. The knitting unit 3 as shown in FIGS. 1 and 2, includes a needle cylinder 4 rotatably supported on the frame 2, yarn feeders 5 and sinkers 6.
Located above the knitting unit 3, is a fiber waste collector/remover 7 for collecting and removing fiber waste generated during operation of circular knitting machine 99. As shown best in FIG. 3, the fiber waste collector/remover 7 includes an annular filter 8, a suction/blowing means 9, preferably a motor driven fan 9, and a filter cleaner 10. Rotative movement is imparted to either the filter cleaner 10 or the filter 8, so that they may rotate relative to each other, by a drive motor 11.
The filter 8 may be divided into two or more vertical sections, which are joined together in a conventional manner to create an integral unit. The filter 8 includes a first surface 8a and an opposite second surface 8b such that fiber waste may be collected on either surface 8a or 8b. In the embodiments shown, waste fibers are collected on first surface 8a. The filter 8 has a large number of perforations which are preferably between 20-40 meshes per inch. The preferred mesh number is 30 meshes per inch which allows fiber waste collected on either surface to be withdrawn by the filter cleaner 10 operating along the first surface 8a. Wire nets or similar filter substitutes with comparable perforations may be employed in accordance with this invention.
In the embodiment shown on FIG. 3, the filter 8 is fixed along its bottom portion to a circular bottom plate 13 which projects radially outward toward the upper portion of a yarn carrier 12 (shown in FIG. 1). The bottom plate 13 has a cup-shaped area which forms a center region 14. The center region 14 provides sufficient room for the air suction/blowing means 9, which in this embodiment is a motor fan, to be supported and centrally located above the knitting unit 3. The bottom plate 13, the filter 8 and the filter cleaner 10 are positioned above the knitting unit 3 by vertically extending posts 30 positioned on the frame 2 (as shown in FIG. 1).
Still referring to FIG. 3, the filter cleaner 10 includes a tip opening 10a which has a flared head sized to correspond to the width of the first surface 8a of the filter 8 so that one rotation of either the filter cleaner 10 or the filter 8 relative to each other cleans the entire filter. The tip opening 10a is attached at one end to a first horizontal portion 10b extending horizontally toward the center region 14. A vertical portion 10c extends vertically upward from the fan motor 9 generally transverse to the first horizontal portion 10b. An elbow portion 10e joins the first horizontal portion 10b and the vertical portion 10c. A T-shaped portion 10f extends vertically upward from vertical portion 10e such that second horizontal portion 10d is attached thereto and is located in parallel alignment above first horizontal portion 10b. In this embodiment, portions 10a, 10b, 10c, and 10e form an integral unit which is rotatably driven by driving means 11, enabling the filter cleaner to rotate around vertical portion 10c to clean along the first surface 8a of the filter 8. It is to be understood that in an alternative embodiment shown in FIG. 5, (described below in greater detail), the filter cleaner 10' remains stationary while the drive means 11' rotates the filter 8' relative thereto.
The drive means 11 includes a first spur gear 17 mounted on a shaft end of a gear motor 16. A second spur gear be is mounted on the periphery of the vertical portion 10c of the cleaning filter 10. A motor stand 19 surrounds the spur gears 17 and 18 and provides support for a center member 20 on which the gear motor 16 is mounted. This arrangement of the gear motor 16 allows the gear motor 16 to revolve at a slow speed, with the interval of operation predetermined by a timer (not shown). When activated, the gear motor 16 revolves the filter cleaner 10 around the inside of the filter 8 along the first surface 8a thereof to remove fiber waste collected on the first surface 8a of the filter 8.
An adjustable suction cylinder 21 is located below the motor fan 9. The suction cylinder 21, of the embodiment shown in FIGS. 1 and 4, is constructed of transparent plastic material that is vertically divided into several sections or pieces. The pieces are concentrically arranged to allow slidable vertical adjustment relative to one another. The suction cylinder 21 is located between the motor fan 9 and the knitting unit 3. The suction cylinder 21 has an external diameter at least equal to the external diameter of the knitting unit.
In this embodiment, the suction cylinder 21 is supported in position by a center shaft 22 extending vertically between the fan motor 9 and the frame 2. Radial supports 23 attached to the center shaft 22 and extending radially horizontally outward therefrom assist in supporting the suction cylinder 21 (see FIG. 4). Between the upper portion of the suction cylinder 21 and the motor fan 9 is an upper gap 24 (shown in FIG. 1). A lower gap 25 is located between the lower portion of the suction cylinder 21 and the needle cylinder 4. To ensure that an optimum vacuum is formed by the suction cylinder 21, while still allowing ambient air to flow into the suction cylinder 21, it is important to position the suction cylinder 21 as close to the needle cylinder 4 as possible, making the lower gap 25 as small as possible. The ability to vertically adjust the suction cylinder 21 by vertical movement of the concentrically arranged divided sections of the suction cylinder 21, relative to one another, allows for the adjustment of the size of the upper gap 24 and the lower gap 25 which in turn adjusts the amount of air intake in each of the gaps 24 and 25. This ability to vertically adjust the suction cylinder 21 has a further advantage of enabling easy repair to the knitting unit 3 and its related components without requiring disassembly of the suction cylinder 21.
As best shown in FIG. 4, an orifice disk 27 is mounted on the center shaft 22 in horizontal alignment with the bottom of the base portion 29 of the needle cylinder 4. The orifice disk 27 has a dual purpose. One purpose is to take the circular knit fabric N, which is cylindrical as it leaves the knitting unit 3, and spread or stretch it so that the knit fabric N can be wound flat on a take-up roll (not shown) located beneath the knitting unit 3. To assist in this function, the orifice disk 27 of this embodiment has a circular shape. It is to be understood that other shapes may also be utilized and remain within the spirit of the invention.
A second purpose of orifice disk 27 is to define a cooling orifice 26 located between the needle cylinder 4 of the knitting unit 3 and the fabric N. The cooling orifice 26 is a channel that runs the height of the needle cylinder 4, which has a cylinder portion 28 and a base portion 29 which supports the cylinder portion 28. The cooling orifice 26 cross section decreases as it approaches the knitting unit which causes the air passing therethrough to speed up to cool the hitting unit 3. In this embodiment, the preferred cross section of the cooling orifice 26 is between 2-5 cm. Increasing the air speed passing through the cooling orifice 26 improves the cooling effect of the air.
In operation, the fan motor 9 draws air from beneath the knitting unit 3 in the direction of the arrows which appear on FIGS. 1 and 4, as a result of the suction or vacuum created by the suction cylinder 21. Because of the cross sectional size of the cooling orifice 26, the air is forced to speed up, which improves its cooling effect, as it travels over the needles (not shown) on the needle cylinder 4, the sinkers 6 and the other moving parts of the knitting unit 3.
An experiment was conducted to compare how the temperature varied between the machines with and without an orifice and a suction cylinder. The comparison was done by measuring various parts, labeled A through F in FIG. 4 (which correspond to the temperatures appearing in the table below) after running the machines unloaded for 1,200 hours at a room temperature of 26° C. The results of the experiment are summarized in the table below.
______________________________________ Prior Art Invention (without a (with aLocation of cooling orifice cooling orificeTemperature or a suction and a suction TemperatureMeasurement cylinder) cylinder) Difference______________________________________A 73.4 C. 65.2 C. 8.2 C.B 66.7 C. 61.9 C. 4.8 C.C 61.4 C. 54.9 C. 6.5 C.D 65.4 C. 59.1 C. 6.3 C.E 57.2 C. 40.4 C. 16.8 C.F 72.8 C. 52.0 C. 20.8 C.______________________________________
As is evident from the results shown in the table, the inclusion of a cooling orifice and an adjustable suction cylinder in the present invention has significantly reduced the operating temperature of the knitting unit.
Continuing with the operation of the invention, the fiber waste which is generated by the knitting process at the knitting unit 3 is driven upward by cooperation between the motor fan 9 and the suction cylinder 21. The fiber waste is conducted upward into the suction cylinder 21 (as shown by the arrows in FIGS. 1 and 4), and then into the filter 8. The fiber waste is trapped and collected along the first surface 8a of the filter 8. The filter cleaner 10 is periodically activated by a timer (not shown) which activates the gear motor 16. The gear motor 16 rotates the integral portion of the filter cleaner 10 (elements 10a, 10b, 10c, and 10e) so that the tip opening 10a travels along the first surface 8a of the filter 8 to remove the fiber waste which has collected thereon since the previous pass-by of the tip opening 10a. The fiber waste then travels through the remaining portions of the filter cleaner 10 until it reaches a flexible tube 10g. The fiber waste travels through the flexible tube 10g to a suction device 15 where the fiber waste is stored until it is disposed of as desired.
FIG. 5 illustrates an alternative embodiment of the present invention. In this embodiment, the invention operates in a manner similar to that described with regard to FIGS. 1-4, except that rather than having a filter cleaner 10 rotate relative to a fixed filter 8, in this embodiment the filter 8' rotates relative to a fixed filter cleaner 10'. As is clearly shown in FIG. 5, the vertical portion 10c' of the filter cleaner 10' extends downward from the first horizontal portion 10b' rather than upward therefrom. In this embodiment the vertical portion 10c' and the first horizontal portion 10b' may be constructed of a single C-shaped piece and remain within the spirit of the invention. This new arrangement of the filter cleaner 10' allows the filter cleaner to remain stationary. The gear motor 16' in this embodiment is attached to the filter 10' in much the same manner as the filter cleaner 10 of the previous embodiment. The gear motor 16' rotates at a slow rate to revolve the filter 8' relative to the fixed filter cleaner 10' so that the first surface 8a' of the filter 8' passes in front of the tip opening 10a' to remove fiber waste from the filter 8'. An additional difference between the first embodiment shown in FIGS. 1-4 and the present embodiment illustrated in FIG. 5 is the location of the fan motor 9'. In this embodiment, the fan motor 9' is positioned farther from the filter 8' than before. The fan motor 9' is supported by the radial supports 23' attached to vertical extending posts 30' and the fan motor 9' is located closer to the knitting unit 3' of the circular knitting machines 99'. In all other respects, the embodiment shown in FIG. 5 functions in the same manner as previously described.
FIGS. 6 and 7 illustrate a third embodiment of the present invention. In FIGS. 6 and 7, rather than utilizing a flexible tube 10g to remove the fiber waste from the knitting machine 99, a series of ducts 35 are utilized to remove the fiber waste and transport it to the suction device 15".
In this embodiment, the ducts 35 are of rigid construction, however, it is to be understood that a more flexible construction may be utilized and still remain within the spirit of the invention. The duct 35 has a first vertical portion 10c" which extends upward from the motor fan 9". The first vertical portion 10c" has a suction opening 36. The suction opening 36 is supported by a frame 37. The fan motor 9" is in turn supported by the suction opening 36. A first horizontal portion 10b" extends radially outward from the knitting machine 99". A first elbow portion 10e" joins the first vertical portion 10c" and the first horizontal portion 10b". A second vertical portion 10g" extends downward from the first horizontal portion 10b" in generally parallel alignment with the knitting machine 99". A fiber waste-collection net 38 is located between the second vertical portion 10g" and the suction device 15". A second elbow portion 10h joins the first horizontal portion 10b " and the second vertical portion 10g". An exhaust opening 39 is located in the second vertical portion 10g" for allowing some of the air to exhaust to atmosphere. An acceptable alternative to the embodiment shown in FIG. 6 is to locate or mount the motor fan 9" within the first horizontal portion 10b" or on the bottom of exhaust opening 39. Movement of the motor fan in either of these locations will not affect the function or performance of the motor fan 9".
Many modifications and other embodiments of the invention will come to mind of one skilled in the art of the present invention having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the invention is not to be limited to the specific embodiments which have been disclosed, and that modifications and embodiments are intended to be included within the scope of the appended claims.
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Fiber waste generated during operation of a circular knitting machine is removed from components of the machine by an air suction/blowing fan motor which causes air currents that conduct the fiber waste to one or more filters. Air suction removes the fiber waste from the filters. An adjustable suction cylinder cooperates with the air suction/blowing fan motor to draw air from below the knitting cylinder through a cooling orifice to simultaneously cool the knitting unit.
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BACKGROUND OF THE INVENTION
This invention relates generally to scraper arrangements for conveyor belts and particularly is concerned with apparatus for biasing scrapers into contact with a conveyor belt surface at a location which is adjacent, near or on a head pulley.
A primary belt scraper or, more generally, a scraper at a head pulley of a conveyor belt, may be called upon to exert a substantial scraping action. To achieve this objective the scraper must be biased into scraping engagement with the conveyor belt surface which is to be cleaned, with a fair amount of force but in such a way that the scraper is deflectable, away from the belt, by significant obstructions on the belt.
The biasing arrangement which is adopted should be capable of being reset, from time to time, to compensate for wear on the scraper due to use. It is also desirable to be able to mount the scraper in different orientations to take account of different operative requirements
U.S. Pat. No. 5,992,614 relates to a tensioning device which enables an adjustable force to be exerted on a shaft which supports a scraper blade. A spring is used to provide a resilient force applying mechanism.
The spring is not self-dampening and is exposed and hence is subject to corrosion. Another factor is that a scraper blade is mounted directly to the shaft in a fixed orientation. A variation of this arrangement is shown in PCT/ZA98/19863.
EPO 583 731 shows a basic arrangement, which has a similar effect to the device of U.S. Pat. No. 5,992,614, but wherein the biasing force is generated by twisting a resilient tube about its axis. Different mounting configurations are shown, but there is no positional adjustment facility. EPO 497 324 shows a similar arrangement.
SUMMARY OF THE INVENTION
According to one aspect of the invention there is provided a scraper arrangement for use with a conveyor belt which includes an elongate member to which at least one scraper blade is mounted, a support for the elongate member which allows at least limited rotation of the elongate member relatively to the conveyor belt with the scraper blade in scraping engagement with the belt, a tubular component which is mounted for at least limited rotation relatively to the elongate member, at least one resiliently deformable torsion element, at least partly inside the tubular component, means for retaining the tubular component at a selected angular orientation with the torsion element in a deformed state characterised therein that the tubular component has an angular inner surface, an angular extension member is located at least partly inside the tubular component and the torsion element acts between the angular inner surface and the extension member.
The torsion element may be located at least partly inside the tubular component bearing against a surface or surfaces of the extension member which are within the tubular component.
The scraper arrangement may include four torsion elements respectively positioned at four inner corners of the tubular component, bearing respectively against four outer sides of the extension member.
In one form of the invention the scraper arrangement includes a clamp engaged with the elongate member, which permits at least limited rotational adjustment of the scraper blade relatively to the tubular component.
The scraper arrangement may include a mounting bracket whereto the tubular component is mounted for limited sliding adjusting movement relatively to the bracket.
The invention also provides a torsion unit for use with a conveyor belt scraper which includes a tubular component, an extension member which is located at least partly inside the tubular component, at least one resiliently deformable torsion element inside the tubular component, and a flange on the tubular component, characterised therein that the tubular component has an angular inner surface, the extension member is angular and the torsion element acts between opposed surfaces of the angular inner surface and the extension member.
The flange may be located at an end of the tubular component and the extension member may project from the tubular component at this end.
The torsion unit may be provided in combination with a scraper which has an elongate member, at least one scraper blade mounted to the elongate member, and mounting means to fix the elongate member to support structure so that the elongate member is rotatable at least to a limited extent relatively to the support structure, the extension member of the torsion unit being engaged with the elongate member and the combination including means for securing the flange of the torsion unit to the mounting means with the torsion element in a desired state of deformation.
The torsion unit may include a clamp which permits at least limited rotational adjustment of the scraper blade relatively to the torsion unit and the torsion unit may also include a bracket to which the tubular component is mounted so that the tubular component is slidably movable, to a limited extent, relatively to the bracket.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is further described by way of examples with reference to the accompanying drawings in which:
FIG. 1 is an end view of a scraper arrangement according to the invention,
FIG. 2 is a side view of the arrangement shown in FIG. 1,
FIG. 3 shows a different type of scraper arrangement, with a height adjustment mechanism,
FIGS. 4 and 5 show a scraper blade which is mounted to an arm, in different orientations,
FIG. 6 shows another scraper blade type, also on an arm, with height adjustment, and
FIG. 7 is a side view of a mounting or bias system which is particularly suited for the arrangements of FIGS. 4 to 6 wherein the scrapers are mounted to arms.
DESCRIPTION OF PREFERRED EMBODIMENTS
FIGS. 1 and 2 of the accompanying drawings illustrate a scraper arrangement 10 according to the invention which includes a conveyor belt scraper 12 and a torsion unit 14 .
The conveyor scraper 12 includes an elongate tubular support shaft 16 , which is square in cross-section, and which has a tapered channel section 18 secured to an upper surface. A plurality of scraper blades 20 are engaged with the channel section.
The shaft 16 is mounted to conventional fixed support structure 22 , shown in dotted outline in FIG. 1, adjacent a conveyor head pulley 24 . A conveyor belt 26 passes over the pulley.
At one end the shaft 16 is supported by a bearing 28 which is mounted to a support plate 30 which, in turn, is fixed to the structure 22 .
At an opposing end the scraper shaft 16 is supported by a bearing 32 which is fixed to a mounting bracket 34 . The mounting bracket is fixed to the support structure 22 in any suitable manner.
The torsion unit 14 includes an outer torsion tube 36 and an inner torsion bar 38 . The tube 36 is square in profile, see FIG. 2 . The torsion bar 38 is also square in profile but is angularly displaced relatively to the tube 36 through 45°. As is evident from FIG. 1 the torsion bar extends from the torsion tube 36 into the interior of the tubular support shaft 16 . The extended torsion bar has two relatively small pieces 40 of rectangular steel bar fixed to it on opposing sides. The pieces 40 fit snugly inside the tubular scraper shaft and effectively link the torsion bar to the scraper shaft in such a way that rotation of the scraper shaft imparts rotational movement to the torsion bar, and vice versa. On the other hand it is relatively easy to engage the torsion bar with the scraper shaft for this is effected merely by sliding the torsion bar and the steel pieces 40 into the tubular interior of the scraper shaft.
The bearing 32 is in a housing 42 which is directly fixed, on one side, by means of a flange 43 to the mounting bracket 34 . A flange 44 is fixed to an opposing side of the bearing housing.
A second flange 46 is fixed to the torsion tube 36 . The flange 46 has a number of holes 48 formed through it, at spaced intervals, see FIG. 2 . The flange 44 has a series of holes formed in it. If the flanges 46 and 44 are rotated relatively to one another then different holes 48 are progressively brought into alignment with one of the holes in the flange 44 . A bolt or pin can be passed through the holes which are in alignment and in this way the angular orientation of the flange 46 , relatively to the flange 44 , can be adjusted, within reason, and the flange 46 can then be locked in position. The holes 48 are spaced fairly close to one another and in practice permit the angular orientation of the flange 46 to be adjusted, relatively to the flange 44 , in increments of 2½°.
Four torsion elements 50 are positioned inside the torssion tube 36 . Each torsion element is made from round rubber and, when compressed, has a substantially triangular cross-section. As is shown in FIG. 2 each torsion element is located at an inner corner of the tube 36 and is in contact with a flat outer side of the torsion bar 38 .
The angular position of the torsion bar 38 relatively to the shaft 16 is fixed through the medium of the steel pieces 40 which prevent relative rotation of the torsion bar and the scraper shaft. The shaft 16 is however rotatable, at least to a limited extent, about the bearings 28 and 32 . The torsion tube 36 , apart from the flange 46 , is fixed to the torsion bar 38 only through the medium of the torsion elements 50 .
If a rotational force is exerted on the torsion tube 36 , using a suitable lever such as a spanner which is engaged with the torsion tube 36 , then the resulting force is transmitted to the torsion bar via the rubber torsion elements 50 . There is a tendency for the scraper a shaft 16 to rotate in the same direction and in this way the scraper blades 20 can be urged into scraping engagement with an outer surface of the conveyor belt 26 with a force which is dependent on the level of torque applied to the torsion tube 36 .
The scraper blades 20 can thus be urged into scraping contact with the conveyor belt with a scraping force which is controllable depending on the extent to which the torsion tube 36 is rotated relatively to the fixed structure 22 . When the torsion tube 36 is rotated the flange 46 rotates relatively to the adjacent flange 44 , which it is to be noted, is not movable relatively to the fixed structure 22 . A pin 45 is then inserted through the hole 48 which is in register with the locating hole in the flange 44 and the assembly can be locked in position.
If an obstruction on the belt 26 exerts substantial force on one or more of the scraper blades 20 then such blades are capable of deflecting in that the resulting force, generated by the obstruction, causes the scraper shaft 16 to rotate about its elongate axis X against the action of the torsion elements 50 which are further deformed to allow such deflecting movement to take place.
If scraping edges of the scraper blades become worn then the force which is exerted by the scraper blades on the conveyor belt surface is reduced. The force can be increased simply by rotating the torsion tube relatively to the fixed structure in a direction which compensates for the wear whereafter the two flanges 44 and 46 are again fixed to one another.
FIGS. 3 to 6 illustrate variations of the invention which is shown in FIGS. 1 and 2 and, where applicable, components which are the same in the various embodiments bear similar reference numerals.
FIG. 3 shows an arrangement wherein the support shaft 12 and the torsion unit 14 are mounted to brackets 60 an opposing sides of the conveyor belt 26 . The brackets are substantially identical and only one bracket is shown in FIG. 3 .
The bracket 60 includes two uprights 62 and 64 which are formed with respective elongate vertically extending slots 66 and 68 . The flange 43 of the torsion unit 14 is attached to the bracket by means of bolts which pass through holes 69 in the flange and which are engaged with the slots.
It is apparent from an inspection of FIG. 3 that the torsion unit and the belt scraper 12 are movable, in unison, upwards or downwards, according to requirement, in order to bring one or more scraper blades 20 A into engagement with an outer surface of the conveyor belt 26 . When the scraper arrangement is at a desired position the bolts are tightened thereby to lock the flange 43 to the bracket 60 .
The opposing side of the scraper arrangement, not shown in the drawing, is adjusted in a corresponding manner.
The scraper blade 20 A may be attached to a support shaft 16 A in a similar way to what has been described in connection with FIG. 2, or in any other way.
The arrangement of FIG. 3, viewed from the side, is generally as is shown in FIG. 7 . The construction is substantially the same as what is shown in FIG. 1 and, as before, if the torsion tube 36 is rotated relatively to the inner torsion bar 38 the torsion elements 50 between the tube and the torsion bar are distorted and thereby exert a resilient biassing force on the scraper blade 20 A which urges the blade into resilient engagement with the conveyor belt 26 .
In the arrangements of FIGS. 1, 2 and 3 the scraper blade or blades extend directly from the support shaft 16 which is co-axial with the torsion unit 14 . In the arrangement shown in FIGS. 4, 5 and 6 the torsion units are displaced from the support shafts. FIG. 4 illustrates an arrangement wherein the torsion unit 14 is mounted to a bracket 60 in a similar manner to what has been described in connection with FIG. 3 . An arm 70 (refer to FIG. 7 as well) extends from the torsion unit. The arm terminates in a clamp section 72 which has an inner semi-circular formation 74 . A similar clamp section 76 , also with an inner semi-circular formation 78 , is engageable with the clamp section 72 . The two sections can be fixed tightly together by means of bolts 80 .
The support shaft 16 , as before, has scraper blades 20 A attached to it. This is done in any appropriate way. A mounting bush 82 is fitted over the support shaft. The bush is round in outline and is formed with a square hole 84 which is complementary in size and shape to the outer surface of the support shaft 16 . Thus the bush can be threaded onto the shaft and moved to a desired position at which the bush is enclosed by the clamp sections 72 and 76 .
The arrangement is such that when the clamp sections 72 and 76 are loose the scraper blades and the support shaft 16 can be rotated, in unison, to a desired angular orientation relatively to the arm 70 . At this stage the bolts 80 are tightened and the scraper blades are then held in the desired orientation.
The configuration shown in FIG. 4 thus permits sliding adjustment of the torsion unit and rotational adjustment of the scraper blades relatively to the belt which is to be cleaned. This is in addition to the adjustable bias which is provided by the torsion unit which has already been described.
In FIG. 4 the scraper blades are at a leading outer surface of the conveyor belt directly opposite to the head pulley. FIG. 5 shows an arrangement, which uses similar components to what is shown in FIG. 4, wherein the torsion unit is lower than the position shown in FIG. 4 and the orientation is such that the scraper blades 20 A extend upwardly and outwardly with what may be referred to as inner surfaces 86 in scraping engagement with the conveyor belt. This is in contrast to what is shown in FIG. 4 which shows what is referred to as outer surfaces 88 of the blades in scraping engagement with the conveyor belt.
FIG. 6 shows another embodiment with scraper blades 20 B replacing the blades 20 A shown in FIGS. 4 and 5. The arm 70 is substantially horizontal and the scraper blades 20 B are positioned to extend vertically upwardly into engagement with an undersurface of the belt 26 . The blades can be adjusted vertically by sliding movement relatively to the bracket 60 , and rotationally by means of the clamp sections.
With each of the embodiments it is to be understood that, apart from the sliding and rotational adjustments of the scraper blades it is possible to vary the torsion force which is exerted by the torsion unit. The holes in the torsion unit flange are fairly close to one another and for example are spaced angularly apart by about 2½°. This makes it possible to vary the resilient torsion force in relatively small increments. Another possibility in this regard is to replace the torsion elements 50 with rubber of a different hardness. The lengths of the torsion elements which are inserted into the torsion tube 36 can also be altered. Another variable is the cross section of the torsion bar 38 and of the torsion tube 36 .
The torsion unit operates through the bearing 32 . The bearing is protected for it is fully enclosed and it is therefore not exposed to corrosive effects. The same applies to the torsion elements which are protected inside the torsion tube.
With the arrangement shown in FIGS. 2 and 3 only one torsion unit will be required. If the scraper arrangement includes an arm 70 of the kind shown in FIGS. 4, 5 and 6 then, due to the leverage which is exerted by the arm, it may be necessary to have more substantial support on opposed sides of the scraper blade. For example it may be necessary, depending on the requirements, to make use of two torsion units, on respective opposed sides of the conveyor belt, instead of making use of a single torsion unit, as is shown in FIG. 1 .
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A torsion unit ( 14 ) for use with a conveyor belt scraper ( 12 ) which includes a tubular component ( 36 ), an extension member ( 38 ) which is located at least partly inside the tubular component ( 36 ), at least one resiliently deformable torsion element inside the tubular component which acts between opposed surfaces of the tubular component and the extension member, and a flange on the tubular component.
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TECHNICAL FIELD
[0001] The present invention relates generally to user consent in a federation model and more particularly to the framework for obtaining cryptographically signed consent from a user on a host computer.
BACKGROUND OF THE INVENTION
[0002] User authentication is one of the most vexing issues in use and deployment of online services that require reliable knowledge of user identities. Any person who has used services from multiple web based service providers, e.g., online vendors, online banking, or online information providers, knows the difficulty in remembering the myriad of usemames and passwords that one can be required to use in online daily life.
[0003] One attempt to solve this issue and streamline the use of online services are Federated Identity Services. Federated identity-based services allow companies to connect their applications with applications of their partners or customers by granting trusted entities access to services and information based on successfully authenticating once with a shared identity management system. Federated identities offer businesses, governments, employees and consumers a more convenient and secure way to control identity information in the digital economy of today, and is a key component in driving the use of e-commerce, personalized data services. The identity management system described herein above is referred to as Identity provider (IDP).
[0004] The traditional approach to solving the problem of providing user authentication by allowing a user to authenticate once to an Identity provider for a group of services has been Single Sign On (SSO). In one form of SSO, centralization of access control information into one server requires a special plug-in installed into each Web server to retrieve the information. Every application needs to be “SSO enabled” by programming to the proprietary Application Program Interface (API), which is different for each competing vendor of SSO services. The coding task usually falls to the appropriate Information Technology (IT) organization. Overall, this technology has not been as successful as originally hoped, with many SSO implementations either failing to meet deployment schedules or experiencing scalability challenges. To address these needs, Liberty Alliance provides a framework based on a web services application model. (The Liberty Alliance, a consortium representing organizations from around the world, was created in 2001 to address the technical, business, and policy challenges around identity and identity-based Web services. www.projectlibert.org) Furthermore, Liberty Alliance provides a loosely coupled mechanism of exchanging messages between two incompatible systems by using XML or SOAP for identity providers to interact with web service providers.
[0005] In Liberty Alliance, the identity provider facilitates user authentication to a partner service provider and furthermore the identity provider stores user attributes. These user attributes may be needed to give user access to a resource or a service hosted by the service provider. An example of these user attributes is the home address of the user, which may be used by the service provider to send information to the user in response to user's request to access a resource. Furthermore, the identity provider may send the user attributes to the service provider without receiving consent of the user to share these user attributes with the service provider. The service providers generally request for more user attributes then required prior to granting access to a resource or a service. From the foregoing it is evident that user consent is needed before an identity provider shares user attributes with the service provider. Liberty Alliance, which provides a web services based framework for identity and service providers, addresses this need of a consent by providing a solution whereby a user consent is requested prior to sending the user attributes by the identity provider to the service provider. One example of acquiring such a consent from the user is displaying user attributes in a web page of a web browser and providing a check box for each attribute displayed for user to select that attribute and a submit button for user to give consent to share the selected attributes.
[0006] The Liberty Alliance solution uses the following methodology:
1. User enters the web address of a service provider in a web browser to access a resource. 2. The service provider requires specific attributes of the user prior to granting user access to the resource. The service provider knows an identity provider that can provide the information regarding user specific attribute. 3. Upon receipt of the request from the user to access a resource, the service provider redirects the user request from the web browser to the identity provider and furthermore in response the identity provider returns user attribute information which is displayed to the user in a web page of the web browser with a checkbox for each attribute displayed and a submit button for the user consent. 4. The user selects one or more attributes by selecting appropriate check boxes and selects the submit button to grant consent to the identity provider. Furthermore, the identity provider upon receiving the user consent to the attributes transmits these user consented attributes to the service provider.
[0011] While the Liberty Alliance solution provides a mechanism for obtaining the user's consent to share attributes with the service provider, there is still a risk that an impostor has provided that consent either by having obtained some way of authenticating as the user or by the introduction of malware along the network path between the user and the identity provider. Thus, neither the service provider nor the identity provider can be certain that the consent indeed came from the user.
[0012] From the foregoing it will be apparent to those skilled in the art that there is a need for an improved framework that provides an identity provider to share user attributes with a web service provider and furthermore, enabling the user on the host computer to provide consent to share the user attributes using cryptographically signed user consent in a manner that conveys to the web service provider and the identity provider a high level of confidence that it is the user that consented to the attributes being shared.
SUMMARY OF THE INVENTION
[0013] In a preferred embodiment, the present invention provides a framework for an identity provider to share user attributes with a web service provider wherein the user on the host computer consents to the user attributes to share with the web service provider using a cryptographically signed user consent.
[0014] In one embodiment for obtaining a cryptographically signed consent, the user requests access to a resource hosted by the web service provider. The web service provider, requiring additional user attributes before granting access to the user, makes a request to the identity provider for those attributes. The identity provider generates a random key (RK) and encrypts the user attributes using the random key RK. Furthermore, the identity provider encrypts the random key RK by using the public key (UPBK) of the user on the host computer to generate an encrypted random key (ERK). An encrypted XML message is produced by the identity provider by embedding the encrypted user attributes and encrypted random key ERK. The encrypted XML message is signed using XML signature thereby providing integrity to the encrypted message. In response to the request for user attributes from the web service provider, the identity provider sends the encrypted XML message to the web service provider.
[0015] In one embodiment, the web service provider sends the encrypted XML message received from the identity provider to the host computer and requests the user to cryptographically sign the attributes. A consent service on the host computer decrypts the encrypted XML message received from the web service provider by using a private key of the user (UPRK) on the host computer. The decrypted user attributes are displayed to the user in an interface, such as a web page in a browser or a windows user interface, on the host computer by the consent service. Furthermore, the attributes whose use have been consented to by the user in the interface, referred to herein above and displayed on the host computer by the consent service, are then encrypted by using the public key (WPBK) of the web service provider. The cryptographically signed consent of the user is generated using XML signature. An encrypted XML message is produced by the consent service by embedding the encrypted user consented attributes and the XML signature. In a response to the request to cryptographically sign user consent for the user attributes from the web service provider, the consent service sends the encrypted XML message to the host computer and furthermore, the host computer sends the encrypted XML message to the web service provider.
[0016] In one embodiment, the web service provider decrypts the encrypted XML message received from the host computer by using the private key (WPRK) of the web service provider to access user consented attributes and cryptographically signed user consent. The user consented attributes and cryptographically signed user consent are stored in the storage device of the web service provider and grants access to the user on the host computer to a requested resource of the web service provider. Furthermore, the web service provider shares user consented attributes with other web services providers, allowing access to the user on the host computer to federated services hosted by those web service providers.
[0017] Other aspects and advantages of the present invention will become apparent from the following detailed description, taken in conjunction with the accompanying drawings, illustrating by way of example the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 is a schematic illustration of the class of solutions to provide user consent to a web service provider.
[0019] FIG. 2 is a schematic illustration of the class of solutions to provide cryptographically signed user consent to a web service provider wherein the consent service is hosted on the host computer.
[0020] FIG. 3 is a timing sequence diagram illustrating the data flow in one embodiment of the invention and corresponding to the architecture of FIG. 2 .
[0021] FIG. 4 is a schematic illustration of an architecture and data flow to provide cryptographically signed user consent to a web service provider wherein the consent service on the host computer is operable of communicating with the identity provider according to one embodiment of the invention.
[0022] FIG. 5 is a timing sequence diagram illustrating the data flow in one embodiment of the invention and corresponding to the architecture of FIG. 4 .
[0023] FIG. 6 is a schematic illustration of an architecture and data flow to provide cryptographically signed user consent to a web service provider wherein the consent service is hosted on a security device such as a smart card and the smart card is a slave device of the host computer according to another embodiment of the invention.
[0024] FIG. 7 is a schematic of hardware architecture of a smart card illustrated in FIG. 6 .
DETAILED DESCRIPTION OF THE INVENTION
[0025] In the following detailed description, reference is made to the accompanying drawings that show, by way of illustration, specific embodiments in which the invention may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the invention. It is to be understood that the various embodiments of the invention, although different, are not necessarily mutually exclusive. For example, a particular feature, structure, or characteristic described herein in connection with one embodiment may be implemented within other embodiments without departing from the spirit and scope of the invention. In addition, it is to be understood that the location or arrangement of individual elements within each disclosed embodiment may be modified without departing from the spirit and scope of the invention. The following detailed description is, therefore, not to be taken in a limiting sense, and the scope of the present invention is defined only by the appended claims, appropriately interpreted, along with the full range of equivalents to which the claims are entitled. In the drawings, like numerals refer to the same or similar functionality throughout the several views.
[0026] I. Introduction
[0027] As shown in the drawings for purposes of illustration, the invention is embodied in a novel framework for an identity provider to share user attributes with a web service provider. The signed consent of the user on the host computer to share the user attributes with the web service provider conveys to the web service provider and the identity provider a high level of confidence that it is indeed the user who consented to the attributes being shared. A system according to the invention provides a method in which an identity provider encrypts user attributes to be transmitted via a web service provider to a host computer to obtain consent of the user attributes by the user on the host computer. The user attributes received from the web service provider are decrypted on the host computer and the decrypted attributes are displayed to the user in a user interface on the host computer such as a web page in a web browser or a windows user interface. The attributes consented-to by the user are encrypted and transmitted to the web service provider with cryptographically signed user consent. The web service provider shares these consented-to attributes of the user with other web service providers for the user on the host computer to access services provided by other web service providers.
[0028] FIG. 1 is a schematic illustration of an example of a conventional network connection between a client application such as a web browser 109 on a host computer 101 with a web service provider 103 . The host computer 101 communicates to the web service provider 103 via Network Address Translator 121 embedded in the network firewall 119 . The web browser 109 on the host computer sends a request from the user 107 to access a resource on the web service provider 103 in which the web service provider 103 makes a request for user attributes from an identity provider 105 holding user attributes on network 123 . The identity provider 105 acting as a proxy for a web service provider 103 transmits a page, for example, a browser web page containing the user attributes to a web browser 109 on the host computer 101 for display to the user 107 . The user 107 may then grant permission to share the user attributes with the web service provider 103 . A problem with the conventional approach is that the consumer of such an identity provider 105 , i.e., the web service provider 103 , must have great trust in the identity provider 105 as the web service provider 103 has no means of ascertaining that the response from the user 107 indeed is based upon input from the identity provider 105 . Record keeping by all parties will support resolution of any possible dispute about a breach of such trust. The user 107 has a risk that an identity provider 105 , or for that matter any web service provider 103 , may misrepresent the user 107 . The identity provider 105 should make efforts to induce trust in the user 107 , for example by offering transaction logs and deploying sufficiently strong authentication methods.
[0029] FIG. 2 is a schematic illustration illustrating an example of a high-level view in which a host computer 101 provides a consent service 201 according to the invention. In one embodiment of the invention the software service 205 of consent service 201 communicates to a client application a browser 109 on the host computer 101 . The host computer 101 communicates to the web service provider 103 via Network Address Translator 121 embedded in the network firewall 119 . In a federation model, the web service provider 103 requires user attributes that can be shared with other web service providers to allow the user 107 to access resources on other web service providers without requiring authentication with each such other web service provider. In this embodiment of the invention, a user 107 requests the web service provider 103 to access a resource in which the web service provider 103 is required to obtain user attributes from an identity provider 105 over network 123 . The web service provider 103 redirects the user request to the trusted identity provider 105 for the user attributes. A software service 117 of the identity provider 105 herein referred to as IPservice encrypts the user attributes and sends the encrypted information to the web service provider 103 . The web service provider 103 , not operable to decrypt this information, sends the encrypted user attributes to the host computer 101 to acquire consent of the user 107 . A software service 205 of the consent service 201 herein referred to as CSservice on the host computer 101 , decrypts the user attributes and displays the user attributes in a web page of the browser 109 . The user 107 consents to the user attributes displayed on the browser 109 and the consented-to user attributes are encrypted by CSservice 205 . Communicating with the web browser 109 , the CSservice 205 sends the encrypted attributes consented-to by the user with cryptographically signed user consent to the web service provider 103 . A software service 113 of the web service provider 103 herein referred to as WSPservice decrypts the user consented attributes and stores the user attributes and the cryptographic user consent in the storage device 111 of the web service provider 103 . The web service provider 103 , having received the user consented attributes, grants access to the resource requested by the user 107 . Furthermore, the web service provider 103 shares the user attributes with other web service providers, thus granting access to those providers' resources without the involvement of the identity provider 105 . However, that implementation must only be considered as an example and not as a restriction on the claims.
[0030] II. Flowchart
[0031] FIG. 3 is a timing sequence diagram illustrating the message flow in one embodiment of the invention and corresponding to the architecture of FIG. 2 in which the consent to share user attributes is cryptographically signed, thus providing the identity provider 105 and web service provider 103 a level of trust that the consent has been granted by the user and not by an interloper. In one embodiment of this invention, the web service provider 103 authenticates the user 107 to communicate with the web service provider 103 . The brief description provided immediately herein below is expanded upon in greater detail further below wherein the web service provider 103 requires the user 107 to grant consent to additional user attributes prior to web service provider 103 allowing access to resource on the web service provider 103 or services on other web service providers.
1. The user 107 opens a browser 109 on the host computer 101 and requests access to a resource on the web service provider 103 , using HTTP request message 301 . In one embodiment, the web service provider 103 requires consent of the user 107 for additional user attributes hosted at the identity provider 105 prior to granting access to the user 107 to the requested resource. 2. The WSPservice 113 having prior knowledge that the identity provider 105 on the network 123 can provide the user specific attribute information, establishes a communications link to the identity provider 105 and requests the user specific attributes, message 302 . The web service provider 103 request to the identity provider 105 is represented as a SOAP (Simple Object Access Protocol) request. SOAP is a lightweight protocol for exchange of information in a decentralized, distributed environment. It is an XML based protocol that consists of three parts: an envelope that defines a framework for describing what is in a message and how to process it, a set of encoding rules for expressing instances of application-defined datatypes, and a convention for representing remote procedure calls and responses.
[0034] 3. In one embodiment, the IPservice 117 generates a random key RK, step 303 , e.g., a key conforming to Advanced Encryption Standard (AES). AES, also known as Rijndael, is a block cipher adopted as an encryption standard by National Institute of Standards and Technology (NIST) as US FIPS PUB 197. The IPservice 117 encrypts the user specific attributes using the random key RK, step 304 . An example of user attributes stored in the storage device 115 of the identity provider 105 is illustrated below in Table I.
TABLE I An example of user attributes stored by the identity provider. 1 <UserAttrInfo xmlns=‘http://exampleuser1.org/attribute v2’> 2 <Name>John Smith</Name> 3 <PhoneNumber>800 876 5432</PhoneNumber> 4 <MobilNumber>866 766 1234</MobilNumber> 5 <FaxNumber>866 987 6543</FaxNumber> 6 </UserAttrInfo>
[0035] 4. The IPservice 117 operable of knowing the public key UPBK of the user 107 encrypts the random key RK using the user public key UPBK, generating encrypted random key ERK, step 305 . The IPservice 117 generates a message embedding the encrypted user attributes of step 304 and the encrypted random key ERK of step 305 using XML encryption, step 306 . The IPservice 117 generates a SOAP response with the encrypted XML message of step 306 , step 307 . An example of encrypted XML message of step 306 generated by IPservice 117 is illustrated below in Table II.
TABLE II An example of the identity provider generated XML encryption message. 1 <?xml version=‘1.0’?> 2 <UserAttrInfo xmlns=‘http://exampleuser1.org/attribute v2’> 3 <EncryptedData Type=‘http://www.w3.org/2001/04/xmlenc#Element ‘xmlns=’http://www.w3.org/2001/04/ xmlenc#’> 4 <EncryptionMethod Algorithm=‘http://www.w3.org/2001/04/xml enc#aes128-cbc’/> 5 <ds:KeyInfo xmlns:ds=‘http://www.w3.org/2000/09/xmld sig#’> 6 <ds:RetrievalMethod URI=‘#EK’ Type=“http://www.w3.org/2001/04/xmlenc#Encrypted Key”> 7 <ds:KeyName>Sally Mae</ds:KeyName> 8 </ds:KeyInfo> 9 <CipherData> 10 <CipherValue>MYUSERATTRIBUTES </CipherValue> 11 </CipherData> 12 </EncryptedData> 13 </UserAttrInfo>
The AES- 128 -CBC in item 4 herein is a symmetric key cipher. The random key RK in item 6 of Table II herein is located at a memory location address ‘#EK’. The ds:KeyName in item 7 of Table II herein provides an alternative method of identifying the key needed to decrypt the CipherData. Either or both the ds:KeyName in item 7 of Table II herein and ds:KeyRetrievalMethod in item 6 of Table II herein could be used to identify the same random key RK. 5. The IPservice 117 in a response to the SOAP request, message 302 from the WSPservice 113 , sends a SOAP response generated in step 307 to the web service provider 103 , message 308 . The message 308 received by the web service provider from the identity provider 105 is encrypted using the public key UPBK of the user 107 and furthermore cannot be decrypted by the WSPservice 113 . The WSPservice 113 redirects the message 308 received from the identity provider 105 to the browser 109 on the host computer 101 , message 309 . 6. The browser 109 on the host computer 101 sends the SOAP request containing the encrypted XML message from the web service provider 103 to the CSservice 205 , message 310 . The CSservice 205 validates the XML signed message received from the web service provider 103 , step 311 . Furthermore, the CSservice 205 , which has the private key UPRK of the user 107 , decrypts the encrypted random key ERK to retrieve the random key RK, step 312 . The CSservice 205 decrypts the user attributes using the random key RK, step 313 . The decrypted user attributes are displayed in a web page of the browser 109 by the CSService 205 to obtain the consent of the user 107 , message 314 . In one embodiment, the web page displayed to the user 107 comprises each user attribute with a selection checkbox and a submit button to obtain user's consent to use selected attributes. The user 107 selects one or more user attributes displayed in the web page of the browser 109 and activates the submit button in the web page of the browser 109 . The browser 109 then conveys the selected user attributes to the CSservice 205 , message 315 . 7. The CSservice 205 having received the user consented attributes from the browser 109 on the host computer, generates a random key RK 2 , step 317 , e.g., a key conforming to Advanced Encryption Standard (AES). The CSService 205 encrypts the user consented attributes using the random key RK 2 , step 318 . The CSservice 205 operable of knowing the public key WPBK of the web service provider 103 encrypts the random key RK 2 using the web service provider public key WPBK, generating encrypted random key ERK 2 , step 318 . Furthermore, in one embodiment, the CSservice 205 generates cryptographically signed consent of the user on the host computer using XML Signature, step 319 . (The XML Signature is a method of associating a key with referenced data; it does not normally specify how keys are associated with persons or institutions, nor the meaning of the data being referenced and signed. XML Signatures provide integrity, message authentication, and signer authentication services for data of any type, whether located within the XML that includes the signature or elsewhere.) The CSservice 205 generates a message embedding the encrypted user consented attributes of step 317 , the encrypted random key ERK 2 of step 318 and the XML signature of step 319 using XML encryption, step 320 . The CSservice 205 generates a SOAP response with the encrypted XML message of step 320 , step 321 . The CSservice 205 , in a response to the SOAP request message 310 from the web service provider 103 , sends the SOAP response generated in step 321 to the browser 109 on the host computer, message 322 . Furthermore, the browser 109 on the host computer 101 sends the SOAP response containing encrypted XML message from the CSservice 205 to the web service provider 103 , message 323 . 8. The web service provider 103 having received the SOAP response containing encrypted XML message 323 from the browser 109 on the host computer 101 , sends the message 323 to WSPservice 113 . The WSPservice 113 having the private key WPRK of the web service provider 103 decrypts the encrypted random key ERK 2 to retrieve the random key RK 2 , step 324 . The WSPservice 113 decrypts the user consented attributes using the random key RK 2 , step 325 . Furthermore, the web service provider 103 logs the cryptographically signed consent of the user 107 in the storage device 111 of the web service provider 103 , step 326 and stores the user consented attributes in the storage device 111 of the web service provider 103 , step 327 .
[0041] The framework of this invention to obtain the cryptographically signed consent of user 107 on host computer 101 , as described in the above message flow, is constituted by CSservice 205 and the web service provider 103 communicating to the identity provider 105 on the network 123 . Furthermore, the web service provider 103 using the user consented attributes provides to the user 107 access to the requested resource or access to the resources on other web service providers in a federation model without any further involvement of the identity provider 105 .
[0042] III. Alternate Embodiment
[0043] As described herein-above, illustrated in FIG. 4 is an alternate embodiment of the invention in which a host computer 101 provides a consent service 401 wherein the consent service is operable to communicate to the identity provider 105 via Network Address Translator 125 embedded in the network firewall 119 . In one embodiment of the invention the software service 405 of consent service 401 communicates to a client application, e.g., a browser 109 on the host computer 101 . The host computer 101 communicates to the web service provider 103 via Network Address Translator 121 embedded in the network firewall 119 . In a federation model, the web service provider 103 requires user attributes that can be shared with other web service providers to allow the user 107 to access resources on other web service providers without requiring authentication with each such other provider. In this embodiment of the invention, a user 107 requests the web service provider 103 to access a resource for which the web service provider 103 is required to obtain user attributes from an identity provider 105 . The web service provider 103 , which is not operable to communicate directly to the identity provider 105 , sends a request to the browser 109 for user 107 to consent to user attributes. The web service provider request for user consent to user attributes is displayed in a web page of the browser 109 . The user's consent to permit the web service to provide the requested user attributes is sent to the CSservice 405 . Next, the CSservice 105 transmits the request to the identity provider 105 by communicating via Network Address Translator 125 embedded in the network firewall 119 . The IPservice 117 encrypts the user attributes and sends the encrypted information to the CSservice 405 . The CSservice 405 decrypts the user attributes. The user attributes are re-encrypted by the CSservice 405 with a request for user's cryptographic signature. The CSservice 405 communicating with the web browser 109 sends the encrypted user attributes with a cryptographically signed user consent to the web service provider 103 . The WSPservice 113 decrypts the user consented attributes and stores the user attributes and the cryptographically signed user consent in the storage device 111 of the web service provider 103 . The web service provider 103 , having received the user attributes, grants user 107 access to the resource requested. Furthermore, in one embodiment, the web service provider 103 may share the user attributes with other web service providers to which the user 107 may have access, thereby permitting the user to access these resources without the involvement of the identity provider 105 . However, that implementation must only be considered as an example and not as a restriction on the claims.
[0044] III.A. Flowchart
[0045] FIG. 5 is a timing sequence diagram illustrating the message flow in one embodiment of the invention and corresponding to the architecture of FIG. 4 . In one embodiment of this invention, the web service provider 103 authenticates the user 107 to communicate with the web service provider 103 . As described in greater detail immediately below, the web service provider 103 requires the user 107 to grant consent to additional user attributes prior to web service provider 103 allowing access to a resource on the web service provider 103 or services on other web service providers.
1. The user 107 opens a browser 109 on the host computer 101 and requests access to a resource on the web service provider 103 , message 501 . Message 501 is an HTTP request. In one embodiment, the web service provider 103 requires consent of the user 107 for additional user attributes hosted at the identity provider 105 prior to granting access to the user 107 to the requested resource. 2. The WSPservice 113 , having prior knowledge that the identity provider 105 can provide the user specific attribute information and because the web service provider cannot communicate to the identity provider 105 , WSPservice 113 sends a request to the browser 109 for user consent to specific user attributes, message 502 .
[0048] 3. The user attributes requested by the web service provider 103 in message 502 are displayed in a web page of the browser 109 for obtaining the consent of the user 107 , step 503 . The browser 109 , after recording consent of the user to the user attributes requested by the web service provider 103 , sends the now user-approved web service provider 103 request for the specific user attributes to the CSservice 405 , message 504 . The CSService 405 operable of communicating with the identity provider 105 via Network Address Translator 125 embedded in the network firewall 119 (as shown in FIG. 4 ), sends the request of web service provider 103 for user attributes to identity provider 105 with the user consent to request for user attributes by the web service provider 103 , message 505 .
4. In one embodiment, the IPservice 117 generates a random key RK 1 , step 506 , e.g., a key conforming to Advanced Encryption Standard (AES). The IPservice 117 encrypts the user specific attributes using the random key RK 1 , step 507 . An example of user attributes stored in the storage device 115 of the identity provider 105 is illustrated herein above in Table I. 5. The IPservice 117 operable of knowing the public key UPBK of the user 107 encrypts the random key RK 1 using the user public key UPBK, generating encrypted random key ERK 1 , step 508 . The IPservice 117 generates a message embedding the encrypted user attributes of step 507 and the encrypted random key ERK 1 of step 508 using XML encryption, step 509 . The IPservice 117 generates a SOAP response with the encrypted XML message of step 509 , step 510 . An example of encrypted XML message of step 509 generated by IPservice 117 is illustrated herein above in Table II. 6. The IPservice 117 in a response to the SOAP request message 505 from the CSservice 405 sends a SOAP response generated in step 510 to the CSService 405 , message 511 . The CSservice 405 wherein having the private key UPRK of the user 107 decrypts the encrypted random key ERK 1 to retrieve the random key RK 1 , step 512 . The CSservice 405 decrypts the user attributes using the random key RK 1 , step 513 . 7. The CSservice 405 having decrypted the user consented attributes received from the identity provider 105 , generates a random key RK 3 , step 514 , e.g., a key conforming to Advanced Encryption Standard (AES). The CSservice 405 encrypts the user consented attributes using the random key RK 3 , step 515 . An example of user attributes stored in the storage device 115 of the identity provider 105 is illustrated herein above in Table I. The CSservice 405 operable of knowing the public key WPBK of the web service provider 103 encrypts the random key RK 3 using the web service provider public key WPBK, generating encrypted random key ERK 3 , step 516 . Furthermore, in one embodiment, the CSservice 405 generates cryptographically signed consent of the user on the host computer using XML Signature, step 517 . The CSservice 405 generates a message embedding the encrypted user consented attributes of step 515 , the encrypted random key ERK 3 of step 516 and the XML signature of step 517 using XML encryption, step 518 . The CSservice 405 generates a SOAP response with the encrypted XML message of step 518 , step 519 . The CSservice 405 in a response to the SOAP request, message 502 from the web service provider 103 , sends the SOAP response generated in step 519 to the browser 109 on the host computer, message 520 . Furthermore, the browser 109 on the host computer 101 sends the SOAP response containing encrypted XML message 520 from the CSservice 405 to the web service provider 103 , message 521 . 8. The web service provider 103 having received the SOAP response containing encrypted XML message 521 from the browser 109 on the host computer 101 , sends the message 521 to WSPservice 113 . The WSPservice 113 having the private key WPRK of the web service provider 103 decrypts the encrypted random key ERK 3 to retrieve the random key RK 3 , step 522 . The WSPservice 113 decrypts the user consented attributes using the random key RK 3 , step 523 . Furthermore, the web service provider 103 logs the cryptographically signed consent of the user 107 in the storage device 111 of the web service provider 103 , step 524 and stores the user consented attributes in the storage device 111 of the web service provider 103 , step 525 .
[0054] The above-described message flow describes the CSservice 405 hosted on the host computer 101 communicating to the identity provider 105 on the Network Address Translator 125 embedded in the network firewall 119 and the web service provider 103 , which constitutes the framework of this invention to obtain the cryptographically signed consent of the user 107 on the host computer 101 . Furthermore, the web service provider 103 using the user consented attributes provides access to requested resource to the user 107 and further to resources on other web service providers in a federation model without any further involvement of the identity provider 105 .
[0055] IV. Another Alternate Embodiment
[0056] As described herein-above in an another alternate embodiment of the invention, the consent service 603 is hosted on a security device such as a smart card 601 wherein the smart card 601 is a slave device of the host computer 101 as illustrated in FIG. 6 . Furthermore, the host computer provides the smart card 601 connectivity and communication to the web service provider 103 . The workflow outlined in FIG. 3 applies in its entirety in reference to all the message flow to obtain the cryptographically signed consent of the user 107 on the host computer 101 by the web service provider 103 in conjunction with the identity provider 105 .
[0057] FIG. 7 is a schematic illustration of an exemplary architecture of the hardware of a smart card 601 that may be used in conjunction with the invention. The smart card 601 is a smart card having a central processing unit 703 , a read-only memory (ROM) 705 , a random access memory (RAM) 707 , a non-volatile memory (NVM) 709 , and a communications interface 711 for receiving input and placing output to a host computer 101 , particularly the electronics of the host computer 101 , to which the smart card device 601 is connected. These various components are connected to one another, for example, by bus 713 . In one embodiment of the invention, the consent service module 603 illustrated in FIG. 6 would be stored on the resource-constrained device 601 in the NVM 709 . The framework for obtaining cryptographically signed consent of a user on a host computer by a web service provider using an identity provider of the present invention as described herein may be implemented as a software program or a collection of software programs having instructions for controlling the CPU 703 of the smart card device 601 . These software programs would normally be stored in the NVM 709 and loaded as needed for execution into the RAM 707 .
[0058] From the foregoing it will be appreciated that the framework for obtaining cryptographically signed consent of a user on a host computer by a web service provider using an identity provider as outlined herein by the present invention represents a significant advance in the art. The present invention provides assurance to the web service provider that no interloper or malicious software that may have been deployed on the host computer could have displayed the web page on the browser to get the consent to user attributes by the user on the host computer. In addition, the web service provider is assured that no interloper or malicious software that may have been deployed on the host computer could have consented to the user attributes on the host computer and have generated the cryptographically signed user consent on the host computer.
[0059] Although specific embodiments of the invention have been described and illustrated, the invention is not to be limited to the specific forms or arrangements of parts so described and illustrated. The invention is limited only by the claims.
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A consent service on a host computer providing cryptographically signed consent for user attributes by a user on a host computer to a web service provider. The consent service is operable to provide decryption of the user attributes acquired by the web service provider from an identity provider. The consent service displaying and acquiring user consent to one or more user attributes displayed in a browser web page to the user on the host computer. The consent service is operable to provide encryption of the user consented attributes and to generate cryptographically signed consent of the user. The consent service conveying and transmitting the user consented attribute and cryptographically signed user consent to the web service provider. The web service provider is operable to provide decryption of the user consented attributes and storing the user consented attributes and signed user consent. The web service provider sharing user consented attributes and user signed consent with other web service providers so the user on the host computer can access resources on the other web service providers without multiple authentication or any further interaction with the identity provider.
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TECHNICAL FIELD
[0001] The present invention relates to electronic article surveillance (EAS) systems, and more specifically, to EAS systems with a self-supporting single turn transmit loop.
BACKGROUND
[0002] EAS systems can be used to prevent unauthorized removal of merchandise from stores or retail settings, and prevent removal of books or other lending media from libraries without the item first being checked out. EAS systems typically include a detection system, often made of two side gates between which an individual must pass to exit a store or library. The gates generate an electromagnetic field that is used to excite a response from a security tag attached to the merchandise, book or media. A variety of tags are used in EAS systems and include magnetomechanical (also known as acousto-magnetic), radio frequency identification (RFID) and magnetic (also known as magneto-harmonic) tags.
[0003] EAS systems present a variety of challenges, including providing gates that generate sufficient magnetic drive fields to fully cover the area between two gates; designing or placing tags that are not easily shielded from a magnetic drive field generated by the EAS gates; and providing cost-effective EAS gates and tags that are proportional in value to the merchandise or media they are being used to track.
SUMMARY
[0004] The present invention provides an elegant solution for an EAS gate where the transmit loop is made of a single turn loop. This construction provides several advantages over existing EAS gates. For example, the single turn loop construction provides a light-weight solution, allowing the gate to be more easily supported. The single turn loop construction allows for manufacturing options that are lower-cost than current EAS gate constructions due to both reduced material and labor costs. A simpler construction can also result in reduced likelihood of gate failure. The present invention also allows for construction of an EAS gate without the need for a molded exterior, providing for a narrower gate with improved aesthetics.
[0005] In one embodiment, the present invention provides a single turn loop electronic article surveillance gate. The gate includes a closed magnetic core; a multi-turn primary winding wound around the core; and a secondary loop passing through the core once. The secondary loop is a self-supporting single turn loop, and the secondary loop is a transmit loop that generates a magnetic drive field for the gate.
[0006] In another embodiment, the present invention provides an electronic article surveillance system. The electronic article surveillance system includes a gate including a receive coil and a transmit loop. The transmit loop is a rigid loop forming a secondary loop of a transformer. The transformer further includes a closed magnetic core and a primary winding wound around the core. The receive coil is comprised of two symmetrical loops.
BRIEF DESCRIPTION OF DRAWINGS
[0007] The invention may be more completely understood in consideration of the following detailed description in connection with the accompanying drawings, in which:
[0008] FIG. 1 shows a single loop turn EAS gate.
[0009] FIG. 2 shows an exemplary closed magnetic core.
[0010] FIG. 3 shows an illustration of the magnetic drive field generated by a transmit loop of an EAS gate.
[0011] FIG. 4 shows an EAS gate system including a transmit loop and a receive coil.
[0012] FIGS. 5A-5K show exemplary cross section shapes for a transmit loop.
[0013] FIG. 6 is a chart illustrating resistance associated with various cross sections for a transmit loop.
[0014] FIG. 7 shows a circuit diagram illustrating a single loop turn EAS gate.
[0015] In the following description of illustrated embodiments, reference is made to the accompanying drawings, in which are shown by way of illustration various embodiments in which the invention may be practiced. It is understood that the embodiments may be utilized and structural changes may be made without departing from the scope of the present invention. The figures are not necessarily to scale. Like numbers used in the figures refer to like components. However, it will be understood that the use of a number to refer to a component in a given figure is not intended to limit the component in another figure labeled with the same number.
DETAILED DESCRIPTION
[0016] The following description provides more detailed information about the present invention, including illustrations of various embodiments of the present invention. Magnetic EAS systems are typically formed with pairs of gates. Each gate may include both a winding or loop for transmitting a signal to generate a magnetic field and a second winding or loop to receive or detect signals created by tags responding to the generated magnetic field.
[0017] The transmit loop of an EAS gate typically produces a magnetic field of magnitude greater than 50 microTesla (μT) over much of an area large enough to create a portal so that a human can easily walk between a pair of such EAS gates. Such a portal often has a cross section sized in the range of 1 square meter. The magnetic field is generated by driving current through a loop or coil of wire. The magnitude of the magnetic field is directly proportional to the product of the current times the number of coil turns (units of Amp-turns). To produce a 50 μT or greater magnetic field over the desired volume, something like 200 Amp-turns must be generated in the drive winding. Such a magnetic field can be created, for example, by driving 10 Amps through a coil of 20 turns.
[0018] Multi-turn transmit coils can have several costs associated with them. For example, such coils typically require some type of mechanical support, which increases manufacturing costs. Multi-turn transmit coils can also generate acoustic noise via the Lorentz force which tends to cause mutual attraction of adjacent turns of a coil when current is driven through the turns of the coil, often resulting in an audible vibration that can be objectionable.
[0019] Multi-turn transmit coils can require higher voltages than those required in the current invention. For example, some multi-turn transmit coils may have voltages as high as 100 V on their transmit coils. Such voltage levels may require that the multi-turn loop be electrically insulated to prevent human exposure to high voltages. Such insulation may be in the form of a large molded structure, further increasing manufacturing cost.
[0020] In contrast to a transmit coil made with several (or even many) turns, a single turn loop as described in the present disclosure can generate a sufficient magnetic field by driving about 200 Amp-turns in a single turn loop. Such a construction can provide the appropriate Amp-turns with lower voltages, such as voltages in the range of 1 V to 5 V. Such a loop can be self supporting and have several other advantages as discussed throughout the present disclosure.
[0021] FIG. 1 shows a diagram of a single turn loop EAS gate 10 . Gate 10 includes transmit loop 12 , magnetic core 14 and multi-turn winding 16 , which together function as a transformer to produce a magnetic field surrounding the gate. Gate 10 functions to drive sufficient Amp-turns (often in the range of about 200 Amp-turns) through transmit loop 12 to generate a magnetic field for detecting security tags attached to items that may be carried between a pair of gates.
[0022] The transformer can have a range of configurations. For example, multi-turn winding 16 may have a variety of turns for example, between 50 and 100 turns. The current driven through multi-turn winding may vary inversely with the number of turns in the multi-turn winding 16 . For example, in an embodiment with 84 turns of multi-turn winding 16 , the current level may be in the range of 2.25 to 2.75 amps. The Amp-turns driven by transmit loop 12 can be calculated by multiplying the current driven through multi-turn winding 16 by the number of turns in multi-turn winding 16 . For example, to drive 200 Amp-turns through transmit loop 12 , 2.38 amps could be driven through an 84-turn winding. Alternatively, 4 Amps could be driven through a 50-turn winding.
[0023] Physically, transmit loop 12 , closed magnetic core 14 and multi-turn winding 16 can be constructed from a variety of materials. In one embodiment, transmit loop 12 can be made, for example, in one embodiment, of round, solid copper with a 0.375 inch diameter or copper pipe with an outer diameter of 0.625 inches and a wall thickness of 0.62 inches. While a variety of sizes and configurations can be used for transmit loop 12 , a structure with a smaller diameter can often result in lower loss when transmitting a signal and can be more aesthetically pleasing. Transmit loop 12 may also be made from aluminum. Transmit loop 12 may also be made from a mixed composition comprising primarily aluminum or copper. Transmit loop 12 may have a variety of shapes, covering a range of area. In one embodiment, transmit loop 12 encloses an area in the range of 0.8 m 2 to 1.0 m 2 . In some embodiments, transmit loop 12 may be self-supporting such that it holds its vertical structure when mounted at the base.
[0024] Closed magnetic core 14 , as discussed in further detail with respect to FIG. 2 , may be formed from a molded, wrapped or otherwise fashioned magnetic material, such as silicon iron, ferrite or any other appropriate materials as may be apparent to one of skill in the art. A closed core is one that is continuous or substantially continuous. An example of a closed form is a toroid.
[0025] Multi-turn winding 16 is wrapped around closed magnetic core 14 and may be made of any appropriate conductive material, such as stranded copper, aluminum or another type of wire. The wire could additionally be insulated. The number of turns for multi-turn winding 16 may vary based on the specific design.
[0026] FIG. 2 shows an exemplary closed magnetic core 24 . In this embodiment, magnetic core 24 is formed of a thin magnetic strap 22 wrapped or coiled about a center form 26 . In some embodiments, center form 26 may be temporary and used only for forming closed magnetic core 24 . Magnetic strap 22 may be made of a variety of materials, for example, silicon iron, ferrite or any other appropriate materials as may be apparent to one of skill in the art.
[0027] Magnetic core 24 may also be a variety of shapes. In one embodiment, magnetic core 24 may be cylindrical. Magnetic core 24 may also be toroidal, have a square circumference, or be any other appropriate shape.
[0028] The size of magnetic core 24 may vary based on a variety of factors. Saturation of the core can limit how small the magnetic core 24 may be and other factors such as cost and cosmetics can serve as upper size limiting factors for magnetic core 24 . In some embodiments, the cross section of magnetic core 24 may be in the range of 500 to 1,500 mm 2 . Additionally, the diameter of magnetic core 24 should be large enough to allow the turns of winding 16 and loop 12 ( FIG. 1 ) to pass through the center hole of magnetic core 24 .
[0029] After the multi-turn winding is wrapped about magnetic core 24 , the construction, including both magnetic core 24 and multi-turn winding 16 may be potted to prevent mechanical motion generated by current driven through the multi-turn winding 16 . Potting often includes filling the voids with a material that hardens. The hardening material is often non-conductive, can prevent moisture or motion and therefore acoustic noise, and can increase durability and improve insulation resistance.
[0030] FIG. 3 shows an illustration of the magnetic field flux 38 generated by a transmit loop 32 of an EAS gate 30 . Arrows 33 indicate the direction of current in transmit loop 32 . Resulting magnetic field flux 38 follows the Right Hand Rule with respect to transmit loop 32 . The magnitude of magnetic drive field is dependent on the number of Amp-turns being driven via transmit loop 32 .
[0031] The frequency of magnetic drive field can range significantly, but typically is a lower frequency. For example, the frequency of magnetic drive field may be about 400 Hz, about 500 Hz, or in the range of 200 Hz to 1,000 Hz. There are a number of factors to consider in determining the frequency of magnetic drive field. As the frequency of the magnetic drive field increases, the transmit loop 32 experiences greater loss due to increased transmit loop AC resistance. However, a higher frequency magnetic drive field increases the amplitude of the output of the receive coil for a security tag passing through the field.
[0032] One important challenge in designing an EAS gate is to ensure there are no “dead zones” between a pair of EAS gates 30 such that a tag passing through that zone would not be detected. One way to shift the coverage of the magnetic drive field to change the shape of transmit loop 32 . For example, FIG. 4 shows an EAS gate with a varied transmit loop shape to provide improved magnetic field coverage. EAS gate 30 may be configured such that the transmit loop 32 is capable of generating a magnetic drive field extending at least 0.4 meters, 0.5 meters or more from EAS gate 30 .
[0033] FIG. 4 shows an EAS gate pair 40 including a transmit loop 42 and a receive coil 48 . In this configuration, individual EAS gates 41 are spaced about 1 meter from each other. The distance between EAS gates 41 can be determined by accessibility requirements of the respective jurisdiction. Each EAS gate 41 includes a potted magnetic core 44 with a multi-turn winding through which current is driven to transmit loops 42 . Transmit loop 42 generates a magnetic drive field, with each magnetic drive field extending approximately half-way between the EAS gate pair 40 .
[0034] Each EAS gate 41 further includes a receive coil 48 . Receive coil 48 may have a variety of configurations. In this configuration, receive coil 48 wound on area filler 49 and is co-planar with transmit loop. Receive coil 48 may be contained in the same housing, lattice or gate as transmit loop 42 , and may or may not be co-planar with transmit loop 42 .
[0035] In one configuration, receive coil 48 can be formed of two symmetrical loops 48 A and 48 B. The respective loops 48 A and 48 B are wound oppositely, i.e., one clockwise and the other counterclockwise. One benefit of using two symmetrical loops is that the two loops 48 A and 48 B cancel out the induced voltage from the drive circuit flux from the transmit loop 42 so that loops 48 A and 48 B can adequately detect disturbances in the field by tags. Receive coil 48 may enclose a relatively large area. For example, in some embodiments, receive coil 48 or receive coils 48 A and 48 B cumulatively may enclose 75% or more of the area enclosed by transmit loop 42 .
[0036] In the configuration illustrated in FIG. 4 , transmit loops 42 each include four horizontal segments 42 A- 42 D. Horizontal segments 42 A- 42 D can prove advantageous as they provide variation in the direction of the magnetic drive field generated by transmit loops 42 , to allow for more complete field coverage of an area between the EAS gate pair 40 .
[0037] In some configurations, transmit loop 42 may be made of several pieces of material joined together or may be constructed of a single piece of material joined in one location. Because of the low voltage possible as described in the present disclosure, transmit loop 42 may form the outer structure for EAS gate 41 , and the surface of transmit loop 42 may be exposed so that an individual walking through or near EAS gate pair 40 may touch transmit loop 42 .
[0038] EAS gate pair 40 is configured to work collectively so that the cumulative magnetic drive field emitted by transmit loops 42 covers the majority of the area between EAS gate pair 40 . When a soft magnetic material, RF tag, or other tag or security item passes between EAS gate pair 40 , the item disturbs the magnetic field, and receive coils A and/or B may then detect the presence of such item or soft magnetic material and trigger an alarm.
[0039] While FIG. 4 illustrates one embodiment for an EAS gate pair 40 , an EAS gate pair consistent with the present disclosure may take a variety of configurations, with changes in distance between EAS gates 41 , configuration of transmit loops 42 and associated receive coils 48 , difference in mounting, area filler 49 and other items.
[0040] FIGS. 5A-5K show exemplary cross section shapes for a transmit loop. While transmit loop 42 in FIG. 4 is illustrated as a round copper pipe, various shapes for the cross section of the transmit loop will impact the resistance of the transmit loop 42 acting as a conductor. The shape of a cross section of transmit loop 42 also affects the aesthetic appeal of an EAS gate incorporating transmit loop 42 .
[0041] FIGS. 5A-5K show exemplary cross-sectional shapes for a transmit loop conductor including round cross-section 51 , rectangular cross-section 52 , square cross-section 53 , flat cross-section 54 , U-shaped cross-section 55 , V-shaped cross-section 56 , T-shaped cross-section 57 , D-shaped cross-section 58 , solid round cross-section 51 A, solid rectangular cross-section 52 A and solid square cross-section 53 A. In these various cross-sectional shapes, corners may be rounded consistent with the cross-sectional shapes. Additionally, some cross-sections are closed, such as round cross-section 51 , rectangular cross-section 52 , square cross-section 53 , and D-shaped cross-section 58 . Others are open, such as flat cross-section 54 , U-shaped cross-section 55 , V-shaped cross-section 56 , and T-shaped cross-section 57 . Cross sections may be solid or hollow. A transmit loop consistent with the present invention may have either a close or an open cross-section.
Example 1
Cross-Sectional Shape Variation
[0042] The AC resistance of a variety of cross-sections that could be used in copper transmit loops consistent with the present disclosure was modeled with respect to changing frequency. The results of such modeling are shown in FIG. 6 .
[0043] The various types of cross-sections modeled and the corresponding result identifier are shown in Table 1 below.
[0000]
TABLE 1
Cross Sections Modeled in FIG. 6
Dimensions
Cross-Section
Shape
(in inches)
61
Flat
0.1250 × 1
62
Tubular
0.072 wall thickness ×
0.625 outer diameter
63
Solid round
0.375 diameter
64
Solid round
0.4375 diameter
65
Square
0.375 × 0.375
[0044] The various types of cross-sections modeled and the identifying number are shown in Table 1 above. Providing modeling of AC resistance allows one to intelligently choose a cross section for a transmit loop based on the other design features.
[0045] For example, in a configuration where the transmit loop may be operated at a variety of frequencies, a cross-section with relatively flat AC resistance may be desirable for the purpose of consistent performance. For example, the resistance of cross-section 62 is relatively flat across the shown frequency range and may be a good option for such a design scenario.
[0046] In another scenario, for a gate designed to operate at a particular frequency, for example, 400 Hz, it may be desirable to choose a cross section for transmit loop that is the lowest at that particular frequency. Therefore, cross-section 64 would provide a good option for a gate designed to operate at 400 Hz.
Example 2
Exemplary Drive Circuit for Transmit Loop
[0047] FIG. 7 shows a circuit diagram for an exemplary gate 70 . Gate 70 includes transmit loop 72 and receive coils 74 A and 74 B. Receive coils 74 A and 74 B are similar receiver sub-coils wound in opposite directions and connected in series. The receive coils 74 A and 74 B are connected to a differential amplifier 75 . The amplified signal from receive coils 74 A and 74 B is passed to the remainder of the receive circuitry 76 where the received signal is further processed.
[0048] A signal source 77 generates a sinusoidal signal which is passed to a driver circuit 78 . In this example, the RMS value of the signal generated by signal source 77 is 0.59 V. The driver circuit 78 provides the current and voltage required to generate the desired magnetic field via the single turn loop. In this instance, the drive current and voltage generated by driver circuit 78 is 2.5 Amps and 22.1 V. The inductance presented by the primary of the toroidal transformer is resonated with capacitor 79 , with a value of 5.5 μF so that the driver circuit 78 drives a purely resistive load. The toroidal transformer 80 and capacitor 79 provide an impedance match between the driver circuit 78 and the single turn loop 72 . The current driven through the single loop turn 200 Amps and the voltage across it is 1.6 V. The magnetic field is generated by single turn loop's 72 200 Amp-turns.
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A single turn loop electronic article surveillance (EAS) gate. The gate includes a closed magnetic core, a multi-turn primary winding wound around the core, and a secondary loop passing through the core once. The secondary loop is a self-supporting single turn loop, and the secondary loop is a transmit loop that generates a magnetic drive field for the article detection gate system.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is based on and hereby claims priority to PCT Application No. PCT/EP2004/052148 filed on Sep. 13, 2004 and German Application No. 10345638.4 filed on Sep. 29, 2003, the contents of which are hereby incorporated by reference.
BACKGROUND OF THE INVENTION
The invention relates to a data transmission method in a communication network, especially cellular radio network, in which data, especially data packets of a packet-oriented data service, are transmitted over a data channel jointly used by several terminals and several jointly used control channels are used for signaling the specific mobile station(s) for which the data is intended.
In UMTS (Universal Mobile Telecommunication System) data packets are sent to User Equipment (UE) over the High-Speed Downlink Shared Channel (HS_DSCH). The associated control information is transmitted in parallel over the High-Speed Shared Control Channel (HS_SCCH). A maximum of four of these HS_SCCHs are assigned to a mobile station. So that the receiving mobile station can recognize that the information on the HS_SCCH and the data on the HS_DSCH is intended for it, the control information is linked to identification information specific to a mobile station. For a more precise definition of terms the reader is referred to the description of the Figures below.
In UMTS the HS_DSCH is shifted in relation to the HS_SCCH by two time slots and three time slots of both the HS_SCCH and of the HS_DSCH correspond to one information unit of the physical layer (the length of an information unit is referred to as a subframe).
As well as the mobile station-specific identification information a unit of the HS_SCCH also contains information about
the HS_DSCH spreading codes or channelization codes used, the modulation scheme, for example QPSK (Quadrature Phase Shift Keying) or 16 QAM (16 Quadrature Amplitude Modulation), the number of the data bits which are transferred from the physical layer to the next higher layer, the indication as to whether this is a first data transmission or a retransmission of the data, the HARQ process number, the information relating to the mapping specification of the data bits to the 16 QAM modulation used and regarding the rate adaptation pattern.
The information relates in each case to the HS_DSCH information unit transmitted 2 time slots later.
In UMTS a mobile station must monitor up to four HS_SCCHs if it has not already received data intended for it in the immediately preceding HS_SCCH unit. An example with 4 HS_SCCHs is selected below, but a different number is similarly possible, such as 2 or 3. Conversely, in the UMTS standard it is true to say that a mobile station which receives the control information intended for it on one of the HS_SCCHs, in the subsequent interval of the length of three time slots only monitors one HS_SCCH, this being the HS_SCCH on which the control information was previously received. The reason for this is that it allows parts of the receiver hardware which will be needed for HS_SCCH receiving, in the event of data transmission on the HS_DSCH, to be able to be used for HS_DSCH receiving and thereby fewer resources are needed overall. This is referred to as the consecutive scheduling rule.
Furthermore different categories of mobile stations, i.e. mobile stations with different service features, are used in UMTS. As regards packet-oriented high-speed data transmission a mobile station is identified in accordance with its category, especially in the following capabilities
the maximum number of HS_DSCH channelization codes which it can simultaneously receive and process in an HS_DSCH unit, the minimum period of time between two consecutive data transmissions on the HS_DSCH which it can process, the modulation scheme (QPSK, 16 QAM) which it can process,
and further parameters.
In addition the physical layer is informed via signaling by higher layers of the OSI (Open system Interconnection) models about the number of Hybrid Automatic Repeat Request (HARQ) process and the maximum transport block size or packet size.
An example of inconsistent information in the case of UMTS is if the number of HS_DSCH channelization codes used transmitted in the HS_SCCH unit is greater than the maximum number of HS_DSCH channelization codes which the mobile station must be able to process in accordance with its category or/and if the number of the HARQ process is higher than the number of HARQ processes configured for this mobile station.
If a mobile station establishes that the information in an HS_SCCH unit which it evaluates in accordance with its identification as intended for it does not contain consistent information, the physical layer can in this case reject the information and not forward it. The advantage of this method is that the likelihood of a transfer of erroneous packets from the physical layer to higher layers is reduced by those packets which appear to contain inconsistent information being filtered out. Since the inconsistent control information itself is not passed on to higher layers since it is only needed in the physical layer, such filtering can only be performed in the physical layer. Inconsistent data can under some circumstances lead to serious malfunctions at higher layers, thus great importance has been placed in the UMTS specification on avoiding such errors as far as possible. In addition to further methods such as checksum tests, the consistency checking described is a method for avoiding such erroneous behavior.
It can now be the case that data which could actually have been correctly received is also rejected by such consistency checking: For example it can be the case that a mobile station is requested to used 5 HS_DSCH spreading codes or channelization codes which corresponds to its maximum capability. Errors in transmission can now mean that the mobile station incorrectly believes that it has to receive 15 codes. If, instead of this, it now receives the maximum possible number of codes, namely 5, it would have corrected the incorrect transmission of the control information using this method. The mobile station should not attempt however to correct errors in control information but instead should detect errors and reject the entire data frame.
The disadvantage of this is that data can be rejected incorrectly.
SUMMARY OF THE INVENTION
Using this related art as its starting point, one possible object of the present invention is to create a simple option for reducing the erroneous rejection of data in a communication network.
The inventors propose a communication network in which data is transmitted between a terminal and a base station over a data channel which can be used by one or more, i.e. at least two, terminals. The data is subdivided into individual time segments in such cases. Furthermore a number, i.e. at least two control channels, are provided on which the terminal listens in, and on one of these control channels the terminal will be informed via control information if a data transmission is to be undertaken later, i.e. in a subsequent time slot over the data channel.
If the terminal receives the control information on one of the control channels, it analyzes its contents, especially as to whether the control information is actually directed to it. The control information has a plurality of parts, that is at least one first control information component and one second control information component. In this case the first control information component can be received in a first time segment and the second control information component in a subsequent second time segment.
Each of these pieces of control information is analyzed, and on the basis of this analysis, a decision parameter is generated for each of these pieces of control information. An overall decision parameter for the control information is determined by these individual decision parameters, which is then used to determine whether the data received on the data channel is to be rejected, i.e. not processed further, especially not forwarded to higher layers of the OSI model. This rejection can for example be undertaken in a third time segment following the first or the second time segment.
The fact that the overall decision parameter is composed of a plurality of individual decision parameters reduces the probability of an incorrect decision.
The method is especially advantageous if the overall decision parameter is also used to define the control channel or control channels on which the terminal is to listen in in one or more subsequent time segments, e.g. the third time segment. This has the advantage that the computing effort in the terminal is reduced if the latter no longer has to listen in on all control channels but only on one or more specific control channels.
In particular the terminal can continue to listen on the at least two above-mentioned control channels, for example if a piece of control information is classified as not relating to the terminal (for example because the data is not able to be processed by the terminal).
In a further development there is provision for the overall decision parameter to be able to assume two values, for example a positive value if the control information relates to the terminal and a negative value if the control information does not relate the terminal. Thus for example the decision can be made as to whether the terminal listens in on all control channels or only on the control channel on which it has received control information.
The overall decision parameter can especially be composed of the individual decision parameters such that it only then assumes a positive value if all the individual decision parameters are also positive.
The communication system involved can for example be a UMTS system.
In relation to the situation depicted at the start in UMTS the probability is thus reduced of the transmission immediately following the transmission of an inconsistent piece of information (an HSDPA frame) being missed by a terminal or a mobile station. The starting point for this is the consecutive scheduling rule described above and the fact that it is highly probable that there is an HS_SCCH false alarm if the decoding of the HS_SCCH information unit supplies inconsistent information. Thus the situation is prevented in which a false alarm on detection of the control channel prevents data of the next frame from being able to be received. Furthermore in a UMTS system as described at the start, the probability of detecting a false alarm is increased by the inclusion of further criteria for consistency checking. (A mobile station which only supports QPSK modulation with HSDPA can, by additionally performing a consistency check in relation to the modulation scheme in the HS_SCCH information unit directed to it, reduce the probability of a false alarm). A false alarm in this context occurs if a mobile station, on decoding the identification information, incorrectly assumes that the identification information matches its identification although no transmission has actually been performed by the base station for this mobile station, but instead a transmission can have been performed for another mobile station or even no transmission at all.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other objects and advantages of the present invention will become more apparent and more readily appreciated from the following description of the preferred embodiments, taken in conjunction with the accompanying drawings of which:
FIG. 1 : a communication system with a base station and a terminal; and
FIG. 2 : a subdivision of control channels and data channels into 4 time slots
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Reference will now be made in detail to the preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings, wherein like reference numerals refer to like elements throughout.
Before the figures are presented in detail an initial explanation will be provided for a plurality of terms used:
A communications system or communication network is to be seen as a structure for the exchange of data. This can for example involve a cellular mobile radio network, such as the GSM (Global System of Mobile Communications) or the UMTS (Universal Mobile Telecommunications System) network. A communication network comprises at least two connection nodes, which means that this term also covers point-to-point connections.
Terminals and base stations are generally provided in a communication system, these being connected to each other via a radio interface. In UMTS the communication system or radio transmission network at least features base stations, also referred to here as NodeBs, as well as Radio Network Controllers (RNC) for connecting the individual base stations. The Universal Terrestrial Radio Access Network UTRAN is the radio part of an UMTS network in which the radio interface is also made available for example. A radio interface is always standardized and defines the totality of the physical and protocol definitions for data exchange, for example the modulation method, the bandwidth, the frequency range, access methods, security procedures and also switching techniques. The UTRAN thus comprises at least base stations as well as at least one RNC.
A base station is a central unit in a communications network, which in the case of a cellular mobile radio network, serves terminals within a cell of the mobile radio network via one or more radio channels. The base station provides the air interface between base station and terminal. It takes over the handling of radio operation with the mobile subscribers and monitors the physical radio connection. In addition it transfers payload and status messages to the terminals. The base station does not have a switching function but merely a service provision function. A base station comprises at least one transceiver unit.
A terminal can be any communication terminal via which a user communicates in a communication system. This includes for example mobile radio terminals such as mobile telephones or portable computers with a radio module. A terminal is often also referred to as a “mobile station” (MS) or as User Equipment (UE) in UMTS.
In mobile radio a distinction is made between two connection directions. The downlink (DL) direction identifies the direction of transmission from the base station to the terminal. The uplink (UL) direction identifies the opposite direction of transmission from terminal to base station.
In broadband transmission systems, for example a UMTS mobile radio network, a channel is one part of an overall transmission capacity available. Within the context of this application a wireless communication path is referred to as a radio channel.
In a mobile radio system, for example UMTS, there are two types of physical channels available for transmission of data: Dedicated channels and common channels. With dedicated channels a physical resource is reserved only for the transmission of information for a specific terminal. With common channels information can be transmitted which is intended for all terminals, for example the Primary Common Control Physical Channel (P-CCPCH) in the downlink or all terminals share a physical resource. This is the case with HS_PDSCH over which data is sent to a terminal depending on the connection quality at the terminal.
In mobile radio systems in accordance with UMTS for example, as well as circuit switched services, in which a connection is permanently allocated for its duration, packet switched services are also provided.
To co-ordinate the timing of the data transmission or of signaling procedures, a transmission is subdivided into timeslots or slots. A time slot in the UMTS system lasts for 0.666 ms.
A further time segment in UMTS, especially in connection with HSDPA, is a subframe containing 3 time slots. A frame as a further time segment in UMTS contains 15 time slots
FIG. 1 shows a communication network CN. A base station sends data over the High-Speed Downlink Shared Channel (HS_DSCH) as data channel to a terminal or user equipment UE. It indicates a transmission on the first High-Speed Shared Control Channel HS_SCCH 1 or on the second High-Speed Shared Control Channel HS_SCCH 2 as its control channel. Two control channels are typically selected in the Figure but any number greater than two can also be selected. The terminal features at least one transceiver unit and a processor unit for processing the data.
Control information which can include a plurality of pieces of control information is sent out via the control channels.
FIG. 2 shows a typical timing structure of control channels HS_SCCH 1 to HS_SCCH 4 and a data channel HS_DSCH.
The four control channels are transmitted in parallel from the base station. Each of the four control channels HS_SCCH 1 to HS_SCCH 4 features a first part P 1 on which a first piece of control information is transmitted and a second part P 2 on which a second piece of control information is transmitted. Identifying information to identify the terminal can be accommodated in a first part P 1 , for example the identification number of the terminal. Only one data channel HS_DSCH is listed for example. Each of the channels is subdivided into subframes of which the first subframe R 1 and a second subframe R 2 are shown in the example. These subframes are further subdivided each into three timeslots ZS 1 , ZS 2 and ZS 3 .
The data channel HS_DSCH is offset in relation to the control channel by 2 timeslots. The first part of a control channel (HS_SCCH 1 -HSCCH 4 ) is sent before the associated data channel HS_DSCH, with a gap of one time slot between the end of the control channel (HS_SCCH 1 - 4 ) and the beginning of the data channel HS_DSCH. The second part P 2 of the control channel HS_SCCH overlaps with the associated data channel HS_DSCH and does this by the length of one time slot. The exemplary embodiments depicted below relate to the UMTS standard, that is to a UMTS mobile radio network. In the labels the abbreviations already used above are used directly to identify the channels. The corresponding method can however also be applied to other standards for which the corresponding transmission methods are provided. The reader is also referred to the introductory explanations especially relating to consistency checking and to the following abbreviations:
HSDPA: High Speed Downlink Packet Access
HS_DSCH: High-Speed Downlink Shared Channel (HSDPA DL data channel)
HS_SCCH: High-Speed Shared Control Channel (HSDPA DL control channel).
A mobile station which only supports QPSK modulation with HSDPA can, by additionally performing a consistency check, as described at the beginning in relation to the modulation schemes, reduce the probability of false alarms in the HS_SCCH information unit directed to it.
A mobile station which receives an HS_SCCH Information Unit directed to it especially performs one or more of the consistency checks listed below:
The mobile station is to check whether the information “pber”, that is the number of channelization codes used on the HS_DSCH, is less than or equal to the maximum number of codes which it can process. The mobile station is to check whether the decoded modulation scheme is allowed in accordance with its capabilities.
If at least one of the above-mentioned consistency checks fails, the mobile station is to reject the data on the physical layer and behave as though no HS_SCCH information unit directed to it had been received, i.e. the monitoring of all four HS_SCCHs in the following HS_SCCH subframe is continued. This is also possible in time since the consistency checks described can be performed after the decoding of the first HS_SCCH time slot. This is still possible before the time at which the receive devices must be switched to receive the following HS_SCCH subframe. Furthermore the receive devices can only be switched to receive the HS_DSCH if this information is present since the receive devices can only then be switched to receive the correct channelization codes or channel coding information. Furthermore the mobile station should check whether the decoded HARQ process number and the decoded variable of the specified transport block is less than or equal to the maximum values transmitted from the higher layers via signaling. By contrast with the checks discussed in the previous paragraph, this check can only be made after the receipt of third time slot of the HS_SCCH subframe. At this point in time the receive devices and have already been switched to receive the HS_DSCH, so that in this case it is no longer possible, instead of the HS_DSCH, to monitor all four HS_SCCHs in the following HS_SCCH subframe. If at least one of the consistency checks fails the mobile station (physical layer) should reject the data, even if data has already been received on the HS_DSCH (at least partly).
The following methods are provided in particular:
a) A method for data transmission in a cellular radio network in which data packets of a packet-oriented data service are transmitted via a data channel shared by a plurality of mobile stations (HS_DSCH) and in which a plurality of shared control channels (HS_SCCH) are used to signal for which specific mobile station(s) the data is intended (and further parameters), with the data channel being delayed in time in relation to the control channels. b) Furthermore a method as previously described, in which, after detection of the receipt of an HS_SCCH information unit on one of the shared control channels, receipt is only on the control channel (HS_SCCH) on which the immediately preceding information unit was received for a receiver unit in the immediately following subframe.
An information unit can especially be regarded here as a piece of control information.
c) Furthermore a method as previously described in which at least one part of the received HS_SCCH information unit is subjected to a consistency check, and in the event that at least one inconsistency is established, the data is not passed on from the physical layer to higher layers. Inconsistency means especially that the information concerned cannot be processed by the terminal. d) Furthermore a method as previously described in which at least one part of a detected HS_SCCH information unit is subjected to a consistency check, and if an inconsistency is present, in the immediately following subframe data is received on a plurality of control channels (HS_SCCH), if an inconsistency is not present in the immediately following subframe, receiving is merely on the control channel (HS_SCCH) on which the HS_SCCH information unit was detected in the current subframe. d1) A further development of this is especially a method as previously described in which at least two parts (first part, second part) of a detected HS_SCCH information unit are subjected to a consistency check and, if an inconsistency is present in one part (first part), the data is not passed on from the physical layer to higher layers, and in the immediately following subframe receiving is on a plurality of control channels (HS_SCCH), and if an inconsistency is present in the other part (second part) only the data is not passed on from the physical layer to higher layers. d11) This method can be developed to the extent that if an inconsistency is not present, receiving in the directly following subframe is merely on the control channel (HS_SCCH) on which the HS_SCCH information unit was detected in the current subframe. d2) The method as illustrated under d) can be developed to the extent that the one part (first part) is sent before the data (HS_DSCH) and the other part (second part) overlaps at least partly in time with the data (HS_DSCH) or is sent after it in time. e) Each of the methods can be developed so that the consistency check relates to the number of HS_DSCH channelization codes. f) Furthermore the method can be modified so that a consistency check relates to the modulation scheme. g) Furthermore a consistency check can be performed on the decoded information on the HS_SCCH relating to the number of data bits transferred from the physical layer to the next higher layer and/or the HARQ process number. HARQ process number is taken in this case to mean the process number for a specific transmission if a plurality of HARQ processes are running simultaneously.
The invention has been described in detail with particular reference to preferred embodiments thereof and examples, but it will be understood that variations and modifications can be effected within the spirit and scope of the invention covered by the claims which may include the phrase “at least one of A, B and C” as an alternative expression that means one or more of A, B and C may be used, contrary to the holding in Superguide v. DIRECTV, 69 USPQ2d 1865 (Fed. Cir. 2004).
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A method transmits data between a base station and a terminal in a communication system. According to said method, data is transmitted subdivided into time segments (Zs,R) from the base station (HS-DSCH) that is jointly used by several terminals via the base station informs the terminals, and the base station informs the terminal via one of at least two control channels method encompasses the following: the at least two control channels (HS-SCCH 1, HS-SCCH 2 ) are monitored by the terminal; the terminal receives the piece of control information on a first of the at least two control channels (HS-SCCH 1 ) within a first time segment (ZS 1, R 1 ); an individual decision parameter is generated for each of the parts (P 1, P 2 ) of control information based on the content of the respective part (P 1, P 2 ) of control information: an overall decision parameter is determined based on the individual decision parameters; data received on the data channel (HS-DSCH) and the piece of information received on the control channel (HS-SCCH 1 ) are rejected in accordance with the overall decision parameter.
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BACKGROUND OF THE INVENTION
This invention relates to an improvement in devices for intermittent delivery of fluid under pressure. In a more specific embodiment, it relates to improvements in such devices for delivery of water to pools; and in its most pertinent application it relates to the use of pop-up heads to deliver water for cleaning and scrubbing purposes in swimming pools.
In the prior art, various devices have been invented for the purpose of delivering water to swimming pools for the specific purpose of scrubbing the interior walls and floors thereof, or simply to agitate the water and put the fine solids in suspension to facilitate their removal by the filtering system of the swimming pool. Such devices progressed from stationary protrusions from the walls of the swimming pool which direct a continuous stream of water in one direction only to rotary heads which deliver a constant stream of water from either stationary or pop-up heads to pop-up heads which deliver a stream of water which changes in angular direction on successive intermittent uses of the head.
An example of the fixed protruding type which introduced a steady flow of fluid into a swimming pool may be found in U.S. Pat. No. 3,045,829 to Rule. An example of a fixed protruding head that delivers water from a constantly rotating head may be found in U.S. Pat. No. 3,247,969 to Miller. An example of a head which is rotated constantly to deliver fluid jets may be found in U.S. Pat. No. 3,675,252 to Ghiz and in U.S. Pat. No. 3,770,203 to Dyar. An example in the prior art of a swimming pool head adapted to intermittent delivery of a jet of water in a general direction may be found in U.S. Pat. No. 3,506,489 to Baker and in U.S. Pat. No. 3,408,006 to Stanwood. The fundamental purposes of all of these devices is to stir up the sediment and debris deposited on the walls and floor of the swimming pool so that it may be put into suspension in the water and removed from the water by the pool filter system.
An inspection of the references cited will show that for esthetic reasons the ideal water delivery head will be of the pop-up nature which is flush with the walls of the pool when not in use and which pops up for delivery of a stream of water. Functionally, to avoid the swirl effect, ideally the stream should be ejected from the head in a straight line, and the action should be intermittent in view of limited pressure values of the pool system.
In the prior art the latter objective has been accomplished by seriatim, intermittent routing of a supply of fluid under pressure to a plurality of lines, each of which has a head at the end. This is accomplished by means of a valving arrangement that distributes water seriatim to the various lines and their associated heads.
However, there are a number of problems with the prior art devices remaining to be solved. One of the problems is the complexity of the mechanism used to advance the heads. Another problem is the susceptibility of complicated mechanisms to disablement due to small bits of sediment suspended in the water and drawn into the mechanism. Yet another problem is the difficulty of servicing the prior art devices once installed, instances of which are the necessity of servicing the heads while submerged in the swimming pool in which they are installed. Yet another problem is the increased cost which necessarily goes along with making a complex mechanical structure.
BRIEF SUMMARY OF THE INVENTION
For the purpose of overcoming the defects of prior art devices, solving a significant portion of the prior art problems such as making the devices less complicated to manufacture, more reliable, and less complicated and expensive to service once installed, I have invented an apparatus for delivering a stream of fluid under pressure from a source thereof which is responsive to intermittent pressure from said source of fluid and rotates a selected number of degrees between deliveries.
Briefly, my apparatus for intermittent delivery of a fluid under pressure has a hollow, cylindrical housing and a cylindrical plunger fitted for rotatable, reciprocal motion within the housing. The plunger has a body, means defining a delivery head at one end of the body, and means defining a valve head or piston at the other end of the body. Operatively associated with the cylinder and plunger are means defining an axial fluid conduit communicating between the two ends of the body and defining an intake orifice in the piston end and a delivery orifice adapted to direct the flow of fluid under pressure in a selected direction from the delivery head. There are also operatively associated with the foregoing elements means for reciprocating and incrementally rotating the plunger body within the housing between a ready position, wherein the head is flush with an end of the housing and a pool wall, and a fluid delivery position wherein the head is extended out of the housing.
Means are provided for incrementally rotating and axially advancing the body responsive to pressure from the source of fluid wherein at least one bore is disposed in the body at an angle to the direction of fluid flow whereby the fluid pressure will rotate the plunger by exerting force against the inclined plane of the bore.
Also provided are means for simultaneously limiting the axial travel of the body to establish a delivery position and a ready position, and means for returning the body to the ready position.
The presently contemplated best use of the apparatus is as a water delivery head for swimming pools. Conveniently the piston is in the form of a flange carried at an end of the body and the bore is a plurality of bores in and through the piston communicating between the high pressure side of the piston and the low pressure side, with the addition of relief ports in the body downstream of the piston communicating between the low side of the flange and the interior of the conduit. In another embodiment the bore communicates with and extends radially outward from the axial conduit, but offset from the axial center thereof to the exterior, and may be tapered to the exit point. The bore may also define a dog leg path between the axial center and the perimeter of the head. In yet another embodiment the bore may be a combination of the bores in the piston and the angled bore in the delivery head.
Conveniently, the means for limiting the outward axial and rotary travel of the plunger toward the delivery position is a removable internal rim extending radially inward from the interior walls of the housing, and cooperating with means carried by the plunger for frictionally engaging the rim, such that when the two contact the rotary motion is halted in addition to the axial motion.
For example, the plunger body has an elongate narrowed waist portion or rod which is received within axially disposed circular guide means for keeping the plunger axially centered. Stop means for engaging the larger portion of the body as it advances to the delivery position is a removable plate having an axial aperture, or a split ring, carried in a groove in the interior wall of the housing and, optionally, a plug removably retained in place by the protruding rim of the split ring and a shoulder provided by relieving a portion of the housing's inner wall. The contacting surfaces are provided with at least one friction layer conveniently made of rubber or other elastomeric material.
Means for adjusting the stroke of the plunger are provided, conveniently an adjustable washer disposed on the waist between the tab and the head.
Conveniently, the means for returning the plunger to the ready position may be a helical spring disposed around the plunger and which is compressed when the plunger is advanced from the ready to the delivery position by the pressure of the fluids, thus, overcoming the force of the spring. When the pressure is removed the spring returns the plunger to the ready position.
To prevent interior fouling of the conduit and the relief ports the bores, when provided in the piston flange, should be made smaller in diameter than the relief ports.
All parts of the mechanism within the housing are removable for servicing at a more convenient place.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A more detailed and complete understanding of the invention may be gained from consideration of the attached drawing in which:
FIG. 1 is an exploded perspective view of a presently preferred embodiment of the device;
FIG. 2 is an integrated elevation view of the device of FIG. 1, taken in cross-section;
FIG. 3 is an enlarged view of a portion of the body shown in FIG. 2 including the piston flange (and shoulder), partly in cross-section, taken along the lines 3--3;
FIG. 4 is a plan view of the delivery head, in cross-section, taken along the lines 4--4;
FIG. 5 is an elevation view of an alternative embodiment of the delivery head, in cross-section;
FIG. 6 is a plan view of the delivery head of FIG. 5, in section, taken along the lines 6--6;
FIG. 7 is an elevation view, in section, of the delivery head of FIG. 5 rotated ninety degrees;
FIG. 8 is a view of another preferred alternative embodiment of the split ring and plunger stop feature in place in the housing, which is shown in cross-section;
FIG. 9 is a perspective view of the split ring of FIG. 8;
FIG. 10 is a view of yet another preferred embodiment of this invention wherein the housing is depicted in section and the interior workings are depicted partly in section;
FIG. 11 is a perspective view, partly exploded, of yet another preferred embodiment of the delivery head of this invention;
FIG. 12 is a view in section, taken along the lines 12--12, of the insert to the head depicted in FIG. 11;
FIG. 13 is an exploded view, in perspective, of an alternative preferred embodiment of the invention wherein the housing is partially cut away to show interior details;
FIG. 14 is a view of an assembled apparatus made according to the teachings of this invention, partly in section, illustrated as it appears in place in a pool environment.
FIG. 15 is a plan view of the embodiment illustrated in FIG. 13.
Referring to FIGS. 1 and 14 in which preferred embodiments of the invention are shown, the housing 1 is PVC pipe machined or injection molded to fit into a two-inch inside diameter water conduit (in general use for swimming pool filter systems) into which the housing is fitted and glued for use. The lip 2 covers and finishes the end of the outer conduit 50 (not a part of the invention).
As seen in FIGS. 1 and 2 the inner wall 7 of the housing is relieved from the lip end through part of its length, creating shoulder 5 whose purpose will be explained presently. Formed in the relieved portion of the inner wall 7 is a circumferential groove 3 provided for the reception of split ring 8.
The flange 12 of plug 11 rests on the shoulder 5 and is retained securely between split ring 8 and shoulder 5. Plug 11 is provided with an axially centered aperture 15 for the reception of the waist 21 of the lower body 19 as will be presently explained. The shank 14 of the plug 11 is fitted with an O-ring 16 which provides an essentially water-tight seal between the plug 11 and the inner wall 7 of the housing 1.
Somewhat loosely fitted within the cylindrical housing 1 is a plunger 10 which has a head 25, a waist 21 and a lower body 19. The latter has a piston flange 18 the perimeter of which loosely fits the inside diameter of the housing. As illustrated in FIG. 3 the flange 18 carries rotator bores 13 annularly disposed on the axis of the body.
The plunger body rotates when the force of water moving into the housing in the direction of the arrow 28 impinges on the plane of the bores 13. The angular degree of the turn is controlled by adjusting two cooperating functions: (1) the angle of the bores 13 relative the longitudinal axis of the plunger and (2) the length of the plunger stroke. The required values may be determined for a particular purpose without undue experimentation.
Relief ports 17 are provided to permit water going through bore 13 to enter axial bore 23 to relieve pressure between flange 18 and plug 11. A spring 29 is coiled around the lower body and waist and bears on the flange 18 and the plug 11. The waist 21 is provided with external threads 22 which mate with internal threads 30 in head 25. In the head 25 axial bore 23 branches off into radial bore 26 which is in turn connected to angular bore 27 which may impart angular rotation along or in cooperation with bores 13.
An alternative presently most preferred embodiment of the delivery head 25 is shown in FIGS. 5 through 7 inclusive wherein the radial bore 26a is offset such that its outer perimeter 33 is tangent to the perimeter 34 of the circle described by a cross-section of axial bore 23a. The force of the fluid current impinging on the offset radial bore is in itself sufficient to impart rotational movement to the plunger 10.
In another most preferred embodiment the axial bore is larger in relation to the head than appears in these figures. For example, the axial bore 23a diameter is 3/4 inch and the depending portion of the head 25a is one-inch in diameter. The radial bore 26a diameter is about one-half inch at axial bore 23a tapering to three-sixteenths inch at the head perimeter exit point.
In FIGS. 8 and 9 a preferred alternative embodiment of the invention features a split ring 8a which incorporates a guide ring 32a held in place by spokes 31. When used in conjunction with means for applying rotational movement of the plunger embodied in the delivery head such as shown in radial bores 26 and 26a, ring 8a may be used in lieu of the two-piece combination comprising split ring 8 and plug 11, inasmuch as it is not required that the plug be solid in order to channel the water into the axial bore 23 through relief ports 17. In that case there are no ports 13 in flange 12 which accordingly serves the usual function of a piston head.
Yet another preferred alternative to the features shown in FIGS. 5 through 7 is illustrated in FIGS. 11 and 12 wherein the head is provided with an insert (for ease of manufacture). A radial bore 26b is tapered from its communication with axial bore 23a to the perimeter of the head 25a, and a stream straightener 35 is placed in the insert 36 at the end communicating with the axial bore. The stream straightener 35 has a series of webs 37 extending between the perimeter and the axis of the stream straightener. Their function is to break up the rotational momentum of the water stream as it rounds the bend connecting the axial bore and the radial bore. As the water is forced from the wide end of the radial bore 26 through the smaller radial bore 26b it straightens and increases in velocity, resulting in greater pressure and less dispersion of the stream as it leaves the delivery head.
Another highly preferred feature is shown in FIG. 10 wherein the means for adjusting the stroke of the plunger is found in the use of adjustable washer 50. Whereas in other embodiments shown the stroke is established in the manufacturing process by the length of the stroke (subject to some adjustment capability in the field by moving the head 25) in cooperation with the angle and size of apertures 13, the feature depicted in FIG. 10 permits a wide range of adjustments in the field because the length of the stroke governs the degree of angular rotation, all other factors being equal. Conceivably, variations from specifications of fluid pressure, or desired angular rotation per cycle, may occur that will make field adjustments necessary. Washer 50 facilitates delicate and precise adjustment.
It also serves a dual purpose in preventing the dropping of the plunger into a vertical pipe when the head 25 is removed, and makes the use of pin 6 unnecessary.
Referring now to FIGS. 13, 14 and 15 in which an alternative preferred embodiment of the guide and stop member combination is depicted, guide plate 41 replaces the combination of plug 11 and split ring 8 and as a one piece element duplicates the function of both. Housing 1 is provided with opposed slots 40 having vertical legs 43 and horizontal legs 44, the slots 40 being disposed on opposite sides of the housing wall with the horizontal legs 44 turned in opposite directions to provide a bayonet type joint for the reception of the fingers 45 on guide plate 41. The plate 41 is inserted in the vertical slot 43 and lowered to horizontal slot 44 where the fingers 45 are secured with a twist. They are removed by the opposite procedure.
An axial aperture 46 is provided in the guide plate 41 for the reception of waist 21 of the plunger 10. The sizes of the waist 21 and cooperating axial aperture 46 may be larger than shown in various embodiments. The one side of guide plate 41 also serves as a stop means to limit the axial and rotational travel of the plunger body as explained previously in other embodiments.
Referring to FIG. 14, the apparatus of this invention is shown in its pool environment. Numeral 51 indicates the gunited area of a cross-section of a swimming pool wall. The plaster layer is indicated at 52. The pool manufacturer lays in a conduit 50a connected to a remote supply of water under pressure, typically controlled by a valve (not shown). Enough space between the end of the conduit 50a and the pool surface 53 is left to accommodate the lip 2 of housing 1. The housing is inserted into the conduit and cemented in place. As explained before, the plunger 10 and associated elements may be easily inserted and removed from the housing.
The manufacture of the apparatus may be carried out with methods and materials well known to persons ordinarily skilled in the art. The housing, for example, is made of polyvinylchloride plastic (PVC) and may be molded by any suitable standard procedure. The internal working parts are made of Delryn brand plastic, excepting O-ring and spring.
It is possible to deliver thirty to forty gallons per minute by means of this invention compared to three gallons per minute in a prior model which did not incorporate all of the present features. This makes it possible to clean a greater area of swimming pool surface with fewer heads, as will be appreciated by those skilled in the art.
OPERATION OF THE DEVICE
The apparatus is installed in a swimming pool with the delivery head end of the housing flush with the pool wall; typically, in a two-inch inside diameter pipe as above explained. It is contemplated that the apparatus be used in conjunction with a remote valve which will direct intermittent streams of water to successive ones of conduits communicating with individual embodiments of this invention. Considering only one such apparatus for the purpose of discussion and illustration, when the remote valve sends a flow of water under pressure in the conduit associated with the apparatus, the water impinges upon and exerts pressure upon flange 18 which compresses spring 29 and advances the plunger body axially causing delivery head 25 to pop-up from the housing and simultaneously rotating the plunger until both the axial and rotary movement of the plunger are halted by frictional engagement of plug 11 and rubber washer 20. When the delivery cycle programmed into the valve is completed the spring 29 will return the plunger to the retracted position (flush with the end of housing 1).
To service the apparatus the repairman will first unscrew delivery head 25 and remove split ring 8 by engaging bosses 9 with needle-nose pliers and squeezing and pulling the ring to disengage it from groove 3. At this point the pin 6 prevents the remainder of the plunger body from falling out of reach in a vertical conduit such as might be found at the bottom of a swimming pool. The pin thus keeps the plunger body accessible for service.
The plug 11 with its associated O-ring is removed after the split ring, then the lower body and spring can be removed.
After the necessary services are accomplished the component parts can be replaced in reverse order to the order of removal.
Although the invention is taught with reference to certain specified embodiments, it will be apparent to those skilled in the art from a consideration of the above disclosure that various changes in form and arrangement of parts may be made to suit requirements without departing from the spirit and scope of the invention.
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Apparatus for intermittent delivery of a fluid under pressure wherein a plunger having a conduit is disposed in a housing for reciprocal, rotary motion and responsive to fluid pressure at the intake end, by means provided in the plunger pops out of the housing and rotates a pre-selected number of degrees. Means are provided to stop both rotary and axial movement simultaneously.
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This invention relates to an infant carrier which is useful for protecting an infant in a motor vehicle.
BACKGROUND OF THE INVENTION
One of the problems which is encountered is finding adequate protection for a young baby up to six months old when carried in a motor vehicle, and various proposals have been put forward for carrying a young baby under safe conditions. However, serious injury can occur in the case of vehicle impact if a young baby is held in position by a seat belt, and one of the objects of this invention is to provide an infant carrier wherein there is less hazard of serious injury to a young baby in the case of a vehicle impact.
BRIEF SUMMARY OF THE INVENTION
In this invention a container, for carrying an infant in a supine position, has an open top which is covered by a flexible cover of resilient perforate material. The container is provided with seat belt retention means such that it can be retained to the rear seat of a vehicle having seat belts therein. In the event of vehicle impact, an infant is supported over a large area of its body.
More specifically, in this invention an infant carrier comprises a wall structure defining a container for carrying an infant in a supine position, and having an open top, means on the walls enabling the container to be anchored with respect to a vehicle seat, sheet retention means on the container wall structure, and a flexible cover of resilient perforate material arranged to be retained to said container walls over said open top.
For example the perforate cover may be a sheet of rubber or other flexible elastomeric material and may be retained to retention lugs by a plurality of retention straps, so arranged that upon impact of a vehicle a baby within the container will be displaced only the distance from the container walls to the perforate sheet before deceleration occurs, and the deceleration will be applied as uniformly as possible over a much larger area of the baby's body than would be the case if restraining straps or harness were used.
Another difficulty which is encountered by parents and children is that heretofore they have required an infant carrier of one size and type to carry a baby, and of another size and type to support a small child. Further in this invention the infant carrier container comprises a seat and seat back portion and a seat frame extension, and means securing the seat frame extension to the seat and seat back portion to thereby complete the wall structure so as to form the container for containing a baby, said securing means being releasable so that the seat frame extension can be removed and the container walls can then constitute the side walls, base wall and back for a seat for an older child.
When a child reaches the age of from, say six months to three years, the child frequently expresses a wish to sit upright in a vehicle and to see out of the window. Still further in this invention, there are provided securing means on the wall structure of the infant carrier to secure the seat frame extension to the seat wall in a locality whereby the seat level is raised from the vehicle seat thereby enabling the child to be supported at a higher level than if it is strapped to the seat of a vehicle.
BRIEF DESCRIPTION OF THE DRAWINGS
An embodiment of the invention is described hereunder in some detail with reference to and is illustrated in the accompanying drawings, in which:
FIG. 1 is a perspective view of an infant carrier when in the seating mode,
FIG. 2 is a section on plane 2-2-2 of FIG. 1, and
FIG. 3 is a perspective view of the infant carrier when in the supine mode.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
In this embodiment FIGS. 1 and 2 illustrate the infant carrier in a seating mode, and FIG. 3 illustrates the carrier in a supine mode, that is, capable of use as a container for supporting a small body in the supine position.
In the seating mode, a seat and seat back portion 10 of an infant carrier comprise a short limb 11 and a long limb 12. An end of the long limb is provided with securing clasps 13, and a seat frame extension 14 is secured to that end by complementary securing clasp receivers. Alternatively, the securing means comprise screws and nuts, and when interengaged extend the long limb of the seat frame. The extension 14 has an upstanding end wall 15 and converts the carrier into an open top container-like structure for use in a bassinet type supine mode. The container walls are all lined with (or formed integrally with) ribs 17 and apertures 18, of resilient energy absorbing material in this embodiment polyurethane foam, to allow breathing and drainage. The frame and extension walls comprise securing lugs 19 which are engaged by enlarged ends of retaining straps 20 which extend outwardly from the periphery of a perforate rubber sheet 21 (FIG. 3). The seat frame extension 14 and the seat frame itself are provided with seat belt recesses 23 arranged to receive an existing seat belt adjacent a vehicle seat and retain an infant carrier with respect to the vehicle seat.
When it is desired to use the infant carrier for a larger child, say a child beyond the age of six months, the seat frame extension 14 is removed from the end of the long limb 12, the infant carrier is rotated so that the long limb is upright, and screw threaded means 25 interconnect the seat frame extension to the underside of the short limb, so that the seat and seat back portion are elevated by the extension, for use in a seating mode. Again a seat belt recess 23 is available for retaining the seat frame with respect to the vehicle seat by passing the vehicle seat belt over the seat belt recess walls. In this case the short limb becomes the seating portion of the carrier, and the long limb becomes the seat back portion. In order to be of convenient shape in both instances, the edge side walls are so shaped that they provide arm rests in each one of the two positions, and the arm rests are themselves padded.
When used in the seating mode, the lower part of the device is restrained within the vehicle by passing an adult seat belt (not shown) around the base of the device through appropriate seat belt guide recesses 23. The top of the device may also be restrained by passing the upper strap of the adult seat belt through an appropriate guide, or by use of an independent strap attached to the vehicle frame. A suitable harness (not shown) is attached to the seat and the seat back to restrain the child within the device. In the supine mode the device is restrained within the vehicle by passing an adult seat belt around each end of the device through appropriate webbing guide recesses 23, and being joined together with suitable catches, preferably attached to the body of the device.
The invention has a number of advantages over prior art. The example the risk to a young baby is much reduced by use of a perforate sheet. The carrier, being convertible from supine to seating mode, is useful for supporting a child over several years of his life, and in many instances until he is ready to use the vehicle seat belts with some degree of safety, that is, he is of sufficient size to not "submarine" beneath the seat belt on vehicle impact. If desired, use may be made of extending lugs in addition to the seat belt recesses defined above, so that for example the infant carrier can be supported by both lap and sash belts. The walls of the seat frame can conveniently be formed from thermoplastics and/or thermoset material by injection or other moulding.
In another embodiment not illustrated, links join the extension to the seat frame (in the seating mode), providing crank means which upon rotation allows the seat portion to translate relative to the base portion, from an upright seating attitude to a reclined seating attitude.
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A container, for carrying an infant in a supine position, having an open top which is covered by a flexible cover of resilient perforate material, provided with seat belt retention means such that it can be retained to the rear seat of a vehicle having seat belts therein, and in the event of vehicle impact, an infant is supported over a large area of its body.
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BACKGROUND OF THE INVENTION
The invention relates to a refrigeration system having a plurality of cooling surfaces, each of which is connected by way of a series-connected controlled valve to a common refrigerant supply device, and having a control arrangement connected to the valves.
The refrigerant supply device can here be formed by a heat-exchanger in which heat is extracted from brine. The heat is given up to a coolant which is cooled in a customary cooling circuit having one or more compressors, a condenser and a collector, the heat exchanger being provided with an expansion valve. The brine then flows through the cooling surfaces and absorbs heat there in order to cool the environment around the cooling surfaces. In another practical form, the cooling surfaces can also have refrigerant flowing directly through them, the refrigerant being channelled through a circuit containing one or more compressors, a condenser and a collector.
A refrigeration system of the kind mentioned in the introduction is known from EP 0 410 330 A2. The refrigeration system in that case has at least two compressors arranged in parallel in the refrigerant circuit, which compressors can be operated jointly or alternately individually to satisfy the cooling requirement at the various cooling points simultaneously. In this connection it is desirable for the frequency of switching-on of the individual compressors to be reduced in order to prolong their service life. A control arrangement which is connected to thermostatic valves is provided for controlling the compressors. The thermostatic valves relay only the necessary temperature information to the control unit, however, so that this controls the compressors accordingly. The control unit can also switch off individual cooling surfaces when their actual value falls below a predetermined reference value.
SUMMARY OF THE INVENTION
The invention is based on the problem of rendering loading on the refrigerant supply device more uniform.
In a refrigeration system of the kind mentioned in the introduction, this problem is solved in that the control arrangement generates for each valve a pulse-width modulated signal for operation of the valve, all signals having the same period, and in that the valves of the individual cooling surfaces open at staggered intervals with respect to one another.
There is a more uniform call upon the output of the refrigeration supply device with this construction. Since the individual valves open at staggered intervals, refrigerant is channelled through the cooling surfaces also at correspondingly staggered intervals. The control arrangement controls only the start of "refrigerant consumption", however. The end is determined for each cooling surface in dependence on its demand for refrigeration. The control arrangement controls the valve accordingly, that is, it closes it when sufficient refrigerant has flowed into the cooling surface. Viewed statistically, with a sufficiently large number of cooling surfaces a state will then be reached in which always a few cooling surfaces are being supplied with refrigerant, whilst other cooling surfaces are switched off. The larger is the number of cooling surfaces, the more uniform can one keep the loading on the refrigerant supply device. Useful results have also already been obtained in practice when only three or four cooling surfaces are operated in parallel with one another. Since all signals have the same period, that is, all valves open similarly but at staggered intervals, the refrigerating capacity can be distributed very uniformly via the distribution of the refrigerant, so that the loading on the refrigerant supply device is correspondingly uniform.
In a preferred construction, the period is constant. Not only are the periods for the individual valves the same, but also successive periods are the same. Control is therefore simplified. It is easier to define the parallelism of the individual valves during operation in that they are able to open at staggered intervals.
The valves are advantageously ON-OFF valves. Such valves can be operated, for example, under clocked control. The ratio of the open time to the sum of open and closed time then provides the opening degree which in turn determines the through-flow. At any rate, the valve is fully opened in the open time, so that is lets through the maximum possible flow of refrigerant. In the closed time, on the other hand, the valve is completely blocked. For that reason such a valve is especially suitable for the refrigeration system in question, because when it is open, it introduces the maximum possible flow of refrigerant into the cooling surface, that is, it takes away refrigerant from the compressors quickly but briefly, but in the closed state the refrigerant is available for other cooling surfaces.
In this connection, it is especially preferred for the control arrangement to have for each valve a controller which determines a pulse duty factor for the valve in dependence on the demand for refrigeration and supplies a corresponding signal. The control is effected therefore autonomously for each valve or for each cooling surface. The controller can be in the form of a separate component which is housed in the vicinity of each cooling surface. Alternatively, it can be part of the control arrangement. In particular, it can be realized in software or by programmed control. The controller receives temperature data from the cooling surface and adjusts the pulse duty factor so that this actual temperature approximates as closely as possible to a predetermined reference temperature. The reference value or reference temperature can be entered in the controller in known manner.
The control arrangement preferably produces for each controller a synchronizing pulse which is staggered with respect to other synchronizing pulses. Each controller responds identically to the synchronizing pulse allocated to it. In the simplest case, on receiving this synchronizing pulse, it opens the valve and holds it open for the proportion of the period which is needed based on the pulse duty factor. Alternatively, it is possible for the synchronizing pulse first to initiate a computation algorithm, the length of which is the same for all controllers, that is, which has the same number of processing steps for all controllers, and by means of which the controller determines the pulse duty factor from the temperature difference between reference and actual temperature and then opens the valve. What matters here is merely that all controllers operate identically, that is, open the valve always with the same delay after the appearance of the synchronizing pulse.
In an alternative construction, provision can be made for the control arrangement to generate a common synchronizing pulse for all controllers and for each controller to have a time-delay element, the delay time of which differs from other delay times. Whereas a synchronizing pulse for each controller requires each controller to be addressed or requires a separate lead for each controller, with a common synchronizing pulse for all controllers a relatively simple transfer of data can be achieved. The time offset between the different valves is then achieved by the fact that the individual controllers respond to the synchronizing pulse with different delays. The time offset can also be realized in this way as the individual valves are triggered.
Each controller preferably has a timer which determines the period. This timer is admittedly required as an extra element for each controller, but in return there is no longer any need to transfer the period additionally from the control arrangement to the controllers. The controller still requires the time information in order to determine the pulse duty factor.
In this connection it is especially preferred for the timers to be activated by the synchronizing pulses only under predetermined operating conditions. Such an operating condition can occur, for example, when switching on the refrigeration system. After that, the individual controllers can operate autonomously for a relatively long period of time. Currently available timers are accurate enough to maintain parallel operation of the controllers also over a relatively long period of time. Other operating conditions can be, for example, the change-over from day-time operation to night-time operation, when the refrigerating capacity is increased and reduced respectively. Finally, such a synchronizing pulse can be generated at predetermined longer periods of time, for example, every eight hours.
Preferably, several cooling surfaces are combined in groups. When there are many cooling surfaces, the delay time for an individual cooling surface may possibly be too short, because the delay time equals the period divided by the number of cooling surfaces. If several cooling surfaces are combined to form a group, the principle of shifted control can be transferred to the individual groups, that is, the cooling surfaces of one group are supplied jointly, by triggering all valves of that group simultaneously, but the valves of different groups are triggered at different times. The delay times become adequately long again.
In parallel with the cooling surfaces there is preferably provided an overflow path containing an overflow valve. Since it is possible for all cooling surfaces to be blocked by their valves, the overflow path provides an opportunity for refrigerant to circulate even when temporarily there is no flow through the cooling surfaces. Such an arrangement is especially advantageous when a secondary circuit is being used for the refrigerant, in which the refrigerant is formed, for example, by brine. The overflow valve can optionally be replaced by a simple throttle.
It is also advantageous for the refrigerant supply device to have a buffered supply. This enables high and low load peaks to be catered for, without the compressors having to be reversed.
Each cooling surface is preferably additionally connected in series with a thermostatic expansion valve. The functions of the expansion valve and the valve that is controlled by the control arrangement can therefore be isolated. The thermostatic expansion valve is chiefly responsible for filling the cooling surface, whilst the other valve regulates the amount of coolant that is taken from the circuit to charge the cooling surface.
Additionally, an adjusting valve can also be provided in series with the cooling surface. Such an adjusting valve can, for example, limit the flow-through in cases in which dissimilar cooling surfaces are used in parallel with one another.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is described hereinafter with reference to preferred embodiments in conjunction with the drawings, in which
FIG. 1 shows a refrigeration system operated with brine,
FIG. 2 shows a different embodiment of a refrigeration system,
FIG. 3 is a diagrammatic representation of signal waveforms in a first embodiment and
FIG. 4 is a diagrammatic representation of signal waveforms in a second embodiment.
DETAILED DESCRIPTION OF THE INVENTION
A refrigeration system 1 in FIG. 1 comprises a brine circuit 2. Here, the brine passes through the secondary side of a heat exchanger 3, that is, an evaporator. The primary side of the heat exchanger 3 is supplied from a refrigerant circuit 4. The refrigerant circuit 4 has a compressor group 5 comprising several compressors 5a, 5b, 5c, a condenser 6, a collector 7 and a thermostatic expansion valve 8, which is arranged upstream of the heat exchanger 3. The compressor group 5 is controlled by a central unit 9 which is connected to a temperature sensor 10 which determines the temperature of the brine in the brine circuit 2 downstream of the heat exchanger 3. Depending on the temperature, the compressors 5 are operated with a lower or higher output or individual compressors are switched on or off.
Several cooling surfaces 11 are arranged in parallel with one another in the brine circuit 2. Cooling surface shall be understood in this application to mean any device which operates as heat exchanger between a refrigerant or the brine and an ambient medium. This applies even when the cooling surfaces 11 are not of planar construction but have a different form.
Each cooling surface 11 is in series with a valve 12, which is connected to a controller 13. From a temperature sensor 14 the controller 12 receives information about the temperature of the cooling surface 11 associated with the controller. Arranged in series with the cooling surface 11 there is furthermore an adjusting valve 15, with which the maximum flow-through can be adjusted. This is especially advantageous when cooling surfaces of different sizes or having different flow resistances are used.
In parallel with the cooling surfaces 14 there is arranged an overflow valve 16 in an overflow path 17.
All controllers 13 are connected to a common control unit. The control unit 18 and the controllers 13 together form a control arrangement.
The central unit 9 can optionally also be part of the control arrangement.
An alternative configuration, in which identical and corresponding parts have been given the same reference numbers, is illustrated in FIG. 2. The cooling surfaces 11 are here no longer supplied by a secondary circuit which is fed with brine, but directly by the refrigerant from the refrigerant circuit 4. A thermostatic expansion valve 19 is accordingly arranged upstream of each cooling surface 11, and receives the necessary temperature information by way of a temperature sensor 20.
The valves 12 are in the form of ON-OFF valves in both embodiments. They therefore have only two operating positions. In the ON position they are fully open and unblock a path for the refrigerant, which is then able to flow either directly or by way of the expansion valves 19 into the cooling surface 11. In the closed state the flow of refrigerant into the cooling surface 11 is blocked.
When the valves are controlled so that always a few valves 12 are open and other valves 12 are closed, a relatively uniform loading of the refrigerant supply device that is arranged in the refrigerant circuit 4 can be achieved.
In order to embody this principle, the individual valves 12 are triggered at staggered intervals, which will be explained with reference to FIGS. 3 and 4.
In FIG. 3, the lines a, b, c, d each indicate signals for different valves 12. In the lines with the index 1 a respective synchronizing signal 21, 22, 23, 24 generated by the control unit 18 is illustrated. The individual synchronizing signals 21-24 are staggered with respect to one another. Identical synchronizing signals, for example, the signal 21, are generated at intervals with a period Tper. With four valves 12, different synchronizing signals are expediently staggered by a quarter period Tper/4 with respect to one another.
Further, in the lines that are provided with the index 2, control pulses 25 for the valves 12 are illustrated. These control pulses 25 are generated by the respective controllers 13 for the associated valve 12, namely, in dependence on the temperature at the cooling surface 11 determined by means of the temperature sensor 14. As long as the control signal 25 is present, that is, in the hatched time zones, the particular valve 12 is open. In line a the open time is about 38% of the period. In line b the opening degree is about 65% of the period. In line C the opening degree is about 55% of the period and in line d the open time is about 14% of the period. The period can be, for example, five minutes. The percentage open time corresponds exactly to the mean opening degree of the valve 12.
One can see that in this manner a relatively uniform loading of the refrigerant supply device can be effected. Certain fluctuations in the refrigerant requirement do occur, but these are restricted to relatively small portions of time. Such small portions of time can be catered for by the refrigerant supply in the collector 7.
Whereas in the embodiment of FIG. 3 a synchronizing pulse 21-24 is needed for each valve, and has to be sent either by way of its own line or with a corresponding address to the controller 13, in the embodiment according to FIG. 4 a single synchronizing pulse 26 is sufficient. For that purpose, all that is needed is for each controller 12 to be provided with a delay element which triggers the control pulse 25 a predetermined duration after the start of the synchronizing pulse 26. The delay times Td are different for the four controllers. In this case they change in increments of 1/4 period (Td=Tper/4). The pulse duty factor, that is, the ratio between the open time of the valve and the period Tper is similar to that in FIG. 3.
As one can see from FIG. 4, the synchronizing pulse 26 is supplied just once by the control unit 18, for example, at the start of operation of the refrigeration system. Thereafter, each controller 13 is operated autonomously. For that purpose it has another timer which provides clocked control of it at intervals corresponding to the period Tper. Each controller therefore has a periodic operation with the same period. Since inexpensive timers of acceptable accuracy are currently available, this option suffices to achieve a corresponding parallel operation of the controllers.
If instead of the illustrated four cooling surfaces a larger number of cooling surfaces is used, for example, more than 10, the last cooling surface may lag behind the first cooling surface by ten times the delay time of the first valve. As a result, the behaviour of the refrigeration system could be too sluggish. In order to shorten the total response time, individual cooling surfaces can then be combined in groups, for example, the first with the eleventh, twenty-first, thirty-first, the second with the twelfth, twenty-second, thirty-second etc.. The loading for the refrigerant supply device nevertheless remains relatively uniform. The delay times remain long enough even with relatively short periods.
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A refrigeration system having a plurality of cooled surfaces, each of which has a thermostatically controlled refrigerant supply valve. The valves are pulse-width modulated, each having the same period and being so controlled so they have staggered openings relative to one another thus providing a more uniform load on the system.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to dispensers for the delivery of materials in liquid or solution form, and more particularly to such dispensers as are useful in fluid reservoirs having cylic variation in fluid level.
2. Description of the Prior Art
Numerous dispensers are known, that are capable of storing and discharging their contents when placed within fluid reservoirs having cyclic change in fluid level. An example of such a fluid reservoir, is the water tank that is normally associated with the toilet boil of a domestic bathroom toilet apparatus. In such instance, it has long been desirable to dispense a quantity of a cleanser, deodorant or the like, to circulate through the toilet apparatus, to disinfect and clean the walls of the toilet bowl, to maintain the apparatus in hygienic condition.
Representative dispensing devices known in the prior art include the device shown in U.S. Pat. No. 1,002,974 to Dunkley, which shows a reservoir containing a quantity of disinfectant, which is positioned within a larger fluid container or cistern. The disinfectant container has a trough hingeably associated with it, and adapted to alternately scoop up a portion of the fluid in the cistern and transfer it into the disinfectant container. By this means, the disinfectant container is mixed with a quantity of the fluid ambient and, when the total fluid capacity of the disinfectant container is exceeded, a solution containing disinfectant is discharged at the spout.
U.S. Pat. No. 1,227,997 to Clifford discloses a pivoting dispenser adapted to reside within a tank containing a body of fluid, to alternately dispense a quantity of an antiseptic thereinto. The Clifford device utilizes a float such as indicated at 22, which controls the angle and frequency of the tilt of the antiseptic dispenser, and thereby the quantity of fluid released through the nozzle orifice when the dispenser tilts toward the vertical. The Clifford device, however, does not offer the uniform discharge of a premeasured amount of antiseptic, as the amount of discharge will vary with the angle and residence time of the dispenser.
U.S. Pat. No. 2,888,685 to Giangrosso et al discloses a dispenser device for use with a toilet bowl tank that is mountable on the float arm and dispenses a quantity of deodorant when the float arm lowers as the fluid in the tank is drained. This device uses a ball and check valve to permit discharge, which may introduce inaccuracies and nonuniformities in operation. Similarly then, this device cannot assure that a predetermined quantity of deodorant is always dispensed.
Finally, U.S. Pat. No. 4,296,503 to Leardi discloses a dispenser that is mountable within a toilet bowl tank and is adapted to pivot from a floating position to an essentially veritical, dispensing position to discharge a quantity of a deodorant or detergent composition. The Leardi device has an essentially open upper surface that permits unlimited contact with the fluid in the toilet bowl tank with the solid cake of material positioned within the container. The Leardi device shows no means for metering the amount of deodorant or cleaner that will be discharged into the water tank. The consequence of this inability is that the device may discharge an excess of deodorant or cleanser initially, and may thereafter discharge inadequate amounts and ultimately will be totally expended prematurely. As a consequence, the efficiency of operation of the device of Leardi is relatively low.
In similar fashion, those devices in the prior art that appear to offer some metering capability are complex in construction and operation and are correspondingly unreliable. A need therefore exists for the development of a dispensing device that offers simplicity in construction and operation, and reliability of uniformity in the metering of the active ingredient contained therein.
SUMMARY OF THE INVENTION
In accordance with the present invention a buoyant dispenser is disclosed for suspension in a fluid reservoir having a cyclically variable fluid level, for the periodic delivery of a metered quantity of a dispensable material. The dispenser comprises a container having a central receptacle for holding the dispensable material, buoyancy means communicating with the container and straddling the receptacle, a cover in fluid tight engagement with the receptacle, attitude guide means attached to the container and adapted to be anchored to the wall of the fluid reservoir and a metering means in fluid registry with the receptacle to permit the controlled ingress and egress of the fluid.
More particularly, the central receptacle of the container has a mouth which in turn, is attached to an extended rim or lip. The receptacle may have a greater longitudinal dimension and may in one embodiment be essentially rectangular. The buoyancy means may comprise pontoon-like structures such as sealed air chambers, foamed resinous strips or other floatation devices, and may in one embodiment be attached to the rim of the container. The cover extends over the mouth of the receptacle, and may further be coextensive with the rim. In such instance, the buoyancy means may be attached to the peripheral portions of the cover.
The attitude guide means includes a connector hingably attached to one end to the container, and having an anchor means such as one or more clips attached to its free end. The connector may be a flexible sheet, a wire or a chain attached to the peripheral edge of the rim of the container, which by limiting the vertical movement of the container, would cause it to rotate into an essentially vertical attitude when the fluid is draining from the reservoir falls below a level offering horizontal support to the dispenser. In this attitude, and as described later on herein, the dispensable material may either be discharged, or appropriately mixed in solution with the fluid to be treated, whereupon discharge of the resulting solution would take place after the fluid level in the reservoir rises, and the container resumes its fully buoyant disposition.
The metering means preferably comprises two centrally positioned holes that, in one embodiment, are both positioned in said cover in spaced apart relation to each other. In an alternate embodiment, each of the holes is positioned respectively in the cover and the corresponding wall of the receptacle, and may further be in substantial axial alignment with each other.
In an alternate embodiment of the invention, the container having the receptacle with a greater longitudinal dimension may be divided by a partition extending transverse to this greater longitudinal dimension, and having a height less than the depth of the receptacle. In this embodiment the transverse partition divides the receptacle into a larger volume compartment and a smaller volume compartment. The hole defined by the container passes through the smaller volume compartment, and a corresponding hole is disposed on the portion of the cover extending thereover. In this embodiment, the container fills with a quantity of fluid when the fluid level of the reservoir is at its maximum, and this quantity is thereafter mixed with the dispensable material when the container assumes the changed attitude as the fluid drains from the reservoir. Upon the refilling of the reservoir, the container resumes its original attitude and the prepared solution of fluid and dispensable material is discharged into the ambient fluid body.
The present dispenser confers the advantages of simplicity of design and corresponding manufacture, while providing for the desired isolation and regulated metering of the dispensable material. The container may be constructed as a throw-away item, or may be refillable, in the instance where the cover is snap fittably engaged to the container. The absence of complex parts reduces manufacturing costs and corresponding maintenance in use. Moreover, the design of the present dispenser makes it possible to dispense either solid or liquid material, without concern that premature discharge of excessive dispensable material will take place.
The present dispenser finds use in a variety of environments, including cattle feed stations and other fluid reservoirs with cyclical fluid variation. A particularly pertinent domestic use for the present dispenser, is in the tank of a domestic toilet apparatus.
Accordingly, it is a principal object of the present invention to provide a buoyant dispenser which may be suspended in a reservoir having a cyclically variable fluid level, that is capable of releasing a metered quantity of a dispensable material thereto.
It is a further object of the present invention to provide a buoyant dispenser as aforesaid that is of simple and inexpensive construction and operation.
It is a yet further object of the present invention to provide a buoyant dispenser as aforesaid that is capable of the isolated storage of said dispensible material.
It is a still further object of the present invention to provide a buoyant dispenser as aforesaid that is capable of releasing a uniform quantity of dispensable material on a regular basis.
Other objects and advantages will become apparent to those skilled in the art from a review of the ensuing description which proceeds with reference to the following illustrative drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view partly in phantom of a dispenser in accordance with a first embodiment of the present invention.
FIG. 2 is a side sectional view of the dispenser of FIG. 1, taken through line 2--2 thereof.
FIG. 3 is a side sectional view similar to FIG. 2, showing the dispenser in the tilted position.
FIG. 4 is a side sectional view similar to FIG. 2, showing the dispenser fully rotated into the vertical position.
FIG. 5 is a side sectional view partly in phantom of a dispenser in accordance with an alternate embodiment of the present invention.
FIG. 6 is a top view of the dispenser of FIG. 5.
FIG. 7 is a side sectional view similar to FIG. 5, showing the dispenser in the tilted position.
FIG. 8 is a side sectional view similar to FIG. 5, showing the dispenser in the fully rotated, vertical position.
DETAILED DESCRIPTION
Referring now to the drawings wherein like numerals designate like parts, and generally to FIG. 1, dispenser 2 in accordance with the present invention is shown in perspective and comprises a container 4, with a central receptacle 6 provided to hold a quantity of a dispensable material. As mentioned earlier herein, the dispensable material may be in solid or liquid form, and may comprise a chemical compound or composition having specific activity depending upon the environment of the fluid contained by the reservoir in which the present dispenser is to be placed. In the instance where the reservoir is a toilet tank, the dispensable material may comprise one of many well known disinfectants, scale-removing agents and the like. As the present invention relates primarily to the dispenser, and not to the contents dispensed, further details regarding the exact compositions of the dispensable material are not provided herein.
Referring further to FIG. 1, dispenser 2 includes buoyancy means such as pontoons 8 which as shown, communicate with container 4 and straddle receptacle 6. In the embodiment shown in the FIGURES, the pontoons 8 appear to be attached to container 4. As explained later on herein, pontoons 8 may be attached to the cover 10 instead.
Buoyancy means or pontoons 8 may comprise fluid-tight receptacles containing ambient air, such as suggested in the FIGURES. Alternately, pontoons 8 may comprise strips of buoyant material such as foamed resinous materials, sponge or the like. In this latter event, strips of foamed resinous material may be glued to either container 4 or cover 10, in the general straddling position illustrated in the FIGURES, to provide the desired buoyant support to the dispenser 2 when it is disposed in a floating position on a body of fluid.
As shown in phantom in FIG. 1, receptacle 6 has an open end defining a mouth 20 which, when dispenser 2 is in the essentially horizontal, floating position, constitutes the upper most extent of the fluid capacity of receptacle 6. Mouth 20 is attached to an extended rim 22 which defines the full horizontal perimeter of container 4, and as illustrated, may serve as the points of attachment of pontoons 8. For example, in the instance where pontoons 8 are fluid-tight air receptacles, container 4 may be formed as one piece with the primary receptacle 6 and the air receptacles positioned along rim 22 as shown. Thereafter, the cover 10 may be sealingly applied to container 4 and by this procedure will render the pontoons fluid-tight and thereby operable.
Cover 10 is disposed in fluid-tight engagement with receptacle 6 as shown, and more particularly, may extend into engagement with mouth 20. In one embodiment, not shown, mouth 20 may provide a rim for the removable engagement of a suitable cover 10, and the latter may be snap fittably attached, and thereafter detached for recharging with dispensable material.
In the more common instance where dispenser 2 is not intended for re-use, cover 10 may be coextensive with rim 22 and may be sealingly bonded thereto by a variety of methods known in the art. Thus, for example, cover 10 may be glued to the mating surfaces of rim 22, which as indicated earlier, may be configured to define pockets or receptacles that will contain or themselves become pontoons 8. In this connection, the receptacles designated by the numeral 8 may also contain appropriate foamed material that itself would lend sufficient buoyancy to the dispenser 2.
Attitude guide means 12 comprises a connector 14 which as illustrated in FIG. 1 may comprise a flexible sheet. Connector 14 extends from attachment to a peripheral margin of rim 22, and is provided with a length sufficient to permit the container to rotate from the essentially horizontal, buoyant position shown in FIG. 1 to the vertical, suspended position illustrated in FIG. 4. As will be described later on herein with regard to the operation of the present dispenser, this capability for change in attitude or rotation, in cooperation with the metering means of the present invention, facilitates the uniform repeated release of a predetermined quantity of dispensable material to the fluid ambient of the reservoir on a regulated basis, while storing and isolating the remainder of the dispensable material from the external fluid ambient.
Connector 14 as illustrated comprises a flexible sheet, however it is to be understood that a plurality of wires, cables or similar filamentry material may be utilized instead. For example, two wires or filaments may be connected to corners of the peripheral margin of container 4, in approximately the position of the lateral margins of the sheet illustrated in FIG. 1, and as actually illustrated in FIG. 5. In such instance where a flexible connector is utilized, there is no need for specific flexible hinge means disposed between the connector 14 and the margin of container 4. However when connector 14 is rigid, some form of hinge means, such as a flexible connector sheet, formal hinge, etc., not illustrated herein, may be necessary. The present invention is intended to encompass this modification within its spirit and scope.
Connector 14 terminates at its free end in anchor means 16 which, as illustrated, may comprise a generally U-shaped clip in the instance where the dispenser 2 is suspended from the wall of a water tank such as that used in conjunction with domestic toilet fixtures. Naturally, while anchor means 16 as illustrated is a single clip, in the instance where multiple filaments are used as connector 14, a comparable number of clips may serve as anchor means 16. The present invention is intended to encompass multiple connectors 14 and anchor means 16 within its scope. Likewise, variant anchor means not illustrated herein, such as permanently attachable brackets, hook and eyelet arrangements, removably attachable adhesive strips and the like may serve as the anchoring means within the scope of the invention.
The metering means of the dispenser of the present invention is illustrated at 18 and is in fluid registry with the receptacle 6 to permit the controlled ingress and egress of the ambient fluid, and the corresponding release of dispensable material from the dispenser 2. Metering means 18 comprise paired holes that are centrally positioned and spaced apart from each other. In the embodiment illustrated in FIGS. 1-4, holes 18 are positioned centrally along cover 10 as best illustrated in FIG. 1. In the instance the receptacle has a greater longitudinal dimension, as in the embodiments illustrated herein, the holes 18 are disposed in substantial alignment with the longitudinal dimension.
In the embodiment illustrated in FIGS. 1-4, and as will be described with respect to the operation thereof, the hole 18 proximate to connector 14 serves primarily to equalize the air pressure between the external ambient and the interior of receptacle 6, to permit unimpeded ingress and egress of fluid and dispensable material. The hole 18 distal with respect to connector 14 is the port through which fluid passes in operation. This hole is positioned in relation to the quantity of fluid that it is desired to periodically dispense, as will be seen with reference to FIGS. 2-4 discussed hereinafter with respect to the operation of dispenser 2.
Thus, and referring briefly to FIGS. 3 and 4, the exact location of hole 18 in relation to the unsupported end of container 4, governs the quantity of fluid that will be released as the container tilts toward the vertical, as well as the quantity of fluid that will be taken in as the fluid level in the reservoir rises and the container tips back toward the floating, horizontal position. The exact location of this distal hole 18 may vary within the scope of the present invention, depending upon the size of receptacle 6 and the quantity of dispensable material that it is desired to release.
The operation of the device of FIG. 1 is illustrated with reference FIGS. 2-4. As mentioned above, the device of FIG. 1 is designed to release dispensable material labeled 24 herein into the fluid ambient 26 as the level of the ambient 26 in the reservoir drops. Thus, FIG. 2 illustrates dispenser 2 at rest and represents the position of dispenser when the reservoir, not shown herein, contains a maximum quantity of fluid 26. It can be seen from FIGS. 2-4 that the length of connector 14 governs the level at which dispenser 2 assumes a horizontal attitude in fluid 26. As mentioned earlier, the exact length of connector 14 may vary to suit the specific fluid environment and application of the dispenser.
Referring now to FIG. 3, it can be seen that fluid 26 is at a lower level than illustrated in FIG. 2, and accordingly that dispenser 2 has rotated about the pivot axis defined between connector 14 and the peripheral margin of container 6, in a downward direction toward a vertical attitude. The draining cycle of fluid 26 is represented by the solid line, and it can be seen that the quantity of dispensable material 24 that exceeded the level illustrated in FIG. 3 has escaped through distal hole 18 and has thereby mixed with fluid ambient 26 during its draining cycle.
As mentioned earlier, dispensable material 24 may comprise either a solid, a liquid, or a mixture of the two. In any event, the movement of dispensable fluid includes the formation of a mixture with the fluid ambient 26, which mixture is thereafter discharged into the remainder of the fluid body. Thus, the discharge of dispensable material 24 through distal hole 18, comprises the discharge of a mixture of ambient 26 and dispensable material 24.
Referring now to FIG. 4, the container 2 has rotated into the fully vertical position as shown, due to the maximum drainage of fluid 26 below the furthest level of extent capable by dispenser 2. In such instance, dispensable material 24 (or a solution thereof) has been fully discharged so that the remainder of dispensable material 24 resides at a level corresponding to the distance between distal hole 18 and the unsupported end of container 4. As mentioned earlier, the positioning of this distal hole 18 in conjunction with the operation of dispenser 2 to form a mixture of dispensable material 24 and fluid ambient 26 and to discharge a quantity of the same on each cycle of rotation, accomplishes the objectives of storing and isolating the majority of the dispensable material 24 while uniformly releasing a premeasured quantity thereof on a regulated, continuous basis.
Referring again to FIG. 3, and with respect to fluid 26 illustrated by the dotted line, the refilling of the reservoir and the raising of the fluid level results in the commencement of the rotation of dispenser 2 toward the horizontal position. During this rotation, and as illustrated in FIG. 3, a quantity of fluid ambient 26 now enters receptacle 6 through distal hole 18 and is thereby available to mix with a further quantity of dispensable material 24. The size of distal hole 18 and its position along cover 10 in relation to the quantity of dispensable fluid 24 remaining in dispenser 2, governs the quantity of fluid ambient 26 that now enters dispenser 2, so that careful control of the foregoing parameters assures corresponding control of the volumetric ratio of fluid ambient 26 to dispensable material 24 during each fluid refilling cycle.
Referring again to FIG. 2, the refilling of the reservoir is now complete and it can be seen that the dispensable material 24 has been increased in volume by a quantity of fluid 26, so that the resulting dispensable material 24 is equal in volume to that contained prior to the discharge cycle. As such, dispenser 2 is now ready for a further discharge sequence as fluid ambient 26 commences a further cycle of level variation.
The device illustrated in FIGS. 1-4 represents a first embodiment of the invention, wherein discharge of the dispensable material takes place as the level of the fluid ambient 26 in the reservoir drops. This sequence of discharge and refill is suitable in certain dispensing applications, however, may be undesirable in instances where it is desired that the material dispensed remain in the reservoir and become uniformly dispersed and active therein. In such instance, a dispenser in accordance with an alternate embodiment of the invention may be more suitable, and such dispenser is illustrated and designated 28 in FIGS. 5-8 herein.
Referring now to FIG. 5, dispenser 28 is in general respects similar to dispenser 2 of FIGS. 1-4. Thus, a container 30 is disclosed with a receptacle 32 and buoyancy means such as pontoons 8 positioned in straddling relationship, as shown in phantom in the top view of dispenser 28, presented in FIG. 6. Likewise, a rim 22 is provided, to which pontoons 8 may be attached or within which they may be formed, all as described earlier herein. Similarly, receptacle 32 defines a mouth 20 that is positioned adjacent rim 22 and may in one embodiment be continuous and integral therewith.
Dispenser 28 also utilizes an attitude guide means 12 which as illustrated herein may comprise paired filaments, wires or strings as connectors 14. It is to be understood, however, that connectors 14 may comprise sheet materials, adhesive tape, and the like, as stated earlier herein.
Dispenser 28 differs from dispenser 2 in the provision of a transverse partition 34 within receptacle 32. Receptacle 32 as illustrated, in similar fashion to receptacle 6 of FIGS. 1-4, has a greater longitudinal dimension and, in one embodiment, may be rectangular. In the instance, of the embodiment of FIGS. 5-8, and as illustrated in FIG. 6, partition 34 extends transversely to the greater longitudinal dimension of receptacle 32 and accordingly divides receptacle 32 into a first larger volumetric capacity compartment 36 and a second smaller volumetric capacity compartment 38. Partition 34 furthermore has a height that is less than the depth of receptacle 32 so that the dispensable material 24 within receptacle 32 may rise and flow over partition 34 as will be seen with reference to FIGS. 7 and 8 described later on herein.
A further structural distinction in dispenser 28 resides with the cover and metering means. Specifically, cover 40 while otherwise similar to cover 10, defines a single upper hole 42 as shown, while a second lower hole 44 is defined by container 30 and is preferably in substantial axial alignment with upper hole 42. Both holes are located in communication with second smaller volumetric capacity compartment 38 to facilitate the operation of the metering means of the present invention in the manner described later on herein. Upper hole 42 serves in similar capacity to the proximal hole 18 of the embodiment of FIGS. 1-4, in that it equalizes the pressure between the external atmosphere and the interior of container 30, to permit dispensable material 24 and ambient fluid 26 to flow regularly through lower hole 44 as will be described.
The operation of the dispenser 28 will now be described with reference to FIGS. 5, 7 and 8. Referring first to FIG. 5, dispenser 28 is shown in the fully floating, horizontal position, supported by ambient fluid 26. In this position, second compartment 38 contains a quantity of dispensable material 24 which is able to mix with the fluid ambient 26 and to disperse throughout the fluid contained in the reservoir. The buoyancy of dispenser 28 is such that it remains at the level shown in FIG. 5, which is lower than the level of fluid maintained within first compartment 36. Partition 34 thus rises to height greater than the level of the external fluid 26, and retains and thereby isolates the bulk of dispensable material 24. The exact quantity of dispensable material 24 released by dispenser 28 is governed by the size of the respective compartments 36 and 38, holes 42 and 44 and the height of partition 34. All of these dimensions may vary to assure that a specific quantity of dispensable material 24 is released during a given cycle.
The release and diffusion of dispensable material 24 at the highest fluid level in the reservoir, permits the dispensable material to reside in the reservoir for a period of time which in most instances is sufficient for any active ingredients in the dispensable material to perform their intended functions within the reservoir. Thereafter, when the reservoir is drained, so that the fluid level begins to decrease, dispenser 28 ultimately rotates toward the vertical attitude, as shown in FIG. 7, in similar fashion to dispenser 2 described above.
Referring now to FIG. 7 the rotation of dispenser 28 to the vertical attitude permits a portion of the dispensable material 24 contained within first compartment 36 to travel over the upper edge of partition 34, and to transfer into second compartment 38. In this way, a select quantity of dispensable material 24 is positioned for later release. The full cycle of rotation is completely illustrated when review of FIG. 8 is made, as complete vertical suspension of dispenser 28 occurs when fluid level 26 sinks below the free end of container 30 and out of contact with dispenser 28. The refilling of second compartment 38 takes place as dispenser 28 begins to resume its horizontal attitude, with the rise in the level of fluid 26, as described with reference to FIG. 7. As soon as dispenser 28 resumes its full horizontal attitude as illustrated in FIG. 5, the dispensable material 24 is released into the fluid ambient 26.
The dispensers of the present invention may be prepared from a variety of well known materials, depending upon end use. Thus, in the instance where usable dispensers are contemplated, certain synthetic resins, metals and glass many be employed; in the instance where a throw-away dispenser is contemplated, less expensive plastics, including foam plastics, paper or cardboard, or other easily disposable materials may be utilized.
The dispenser provides the desired metering function in contrast to the prior art devices, and is thereby suitable for the continuous metered discharge of a variety of active ingredients into bodies of water having cyclical fluid level variations. As mentioned earlier, a particularly useful application of the present dispenser, is in the water tank of a toilet apparatus, where a variety of active ingredients such as detergents, perfumes, disinfectants, rust and stain removers, bleaches and the like may be dispensed. Also, the exact ingredients comprising the dispensable material, as well as the state of such material i.e., solid, liquid or mixed solid and liquid, may vary and would all be operable and useful in accordance with the dispensers of the present invention.
It is understood that the invention is not limited to the illustrations described and shown herein, which are deemed to be merely illustrative of the best modes of carrying out the invention, and which are suitable of modification of form, size, arrangement of parts and details of operation. The invention rather is intended to encompass all such modifications which are within the spirit and scope and defined by the claims.
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A buoyant dispenser for periodic delivery of a metered quantity of a dispensable material comprises a container having a central receptacle to hold the dispensable material, buoyancy means such as pontoons straddling the receptacle, a cover in fluid-tight engagement with the receptacle, an attitude guide means attached to the container that is adapted to be anchored to a wall of the fluid reservoir and a metering means in fluid registry with the receptacle to permit controlled ingress and egress of the fluid and dispensable material. Preferably, the metering means comprises a pair of holes disposed in spaced apart relation to each other, and positioned to allow a predetermined quantity of dispensable material to escape from the receptacle. In one embodiment, the receptacle is divided into two compartments by a transverse partition, and the metering means comprises holes communicating with one of the compartments, so that the dispensable material in that compartment is discharged when the dispenser in the fully floating position. The present dispenser finds particular utility in fluid reservoirs having cyclically variable fluid levels, and is particularly suited for use in the water tank of a domestic toilet apparatus.
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CROSS REFERENCE TO RELATED APPLICATIONS
The present application is a continuation of international patent application No. PCT/EP00/07101, filed Jul. 25, 2000, designating the United States of America, the entire disclosure of which is incorporated herein by reference. Priority is claimed based on Federal Republic of Germany patent application no. DE 199 36 521.0, filed Aug. 6, 1999.
BACKGROUND AND SUMMARY OF THE INVENTION
The invention relates to substituted pyrrolidine-2,3,4-trione 3-oxime derivatives, processes for their preparation, pharmaceutical compositions comprising these compounds, and methods for using these compounds for the preparation of pharmaceutical compositions and for the treatment of various diseases or conditions.
The treatment of chronic and non-chronic states of pain is of great importance in medicine. There is a worldwide demand for pain treatments which have a good efficacy. The urgent need for action in respect of patient-relevant and target-orientated treatment of chronic and non-chronic states of pain, this being understood as meaning successful and satisfactory pain treatment for the patient, is documented in the large number of scientific works which have recently appeared in the field of applied analgesia and fundamental research on nociception.
Conventional opioids, such as morphine, have a good action in the treatment of severe to very severe pain. However, their use is limited due to the known side effects, e.g. respiratory depression, vomiting, sedation, constipation, addiction, dependency and development of tolerance. They can therefore be administered over a relatively long period of time or in relatively high dosages only with particular safety precautions, such as specific prescription instructions (Goodman, Gilman, The Pharmacological Basis of Therapeutics, Pergamon Press, New York 1990). Furthermore, they have a relatively low efficacy for some states of pain, in particular neuropathic and incidental pain.
Opioids display their analgesic action by binding to receptors on the membrane which belong to the family of so-called G protein-coupled receptors. In addition, there are further receptors and ion channels which are considerably involved in the system of pain formation and pain conduction, such as the N-methyl-D-aspartate (NMDA) ion channel, via which a considerable part of the communication of synapses proceeds and through which the calcium ion exchange between a neuronal cell and its environment is controlled.
Knowledge of the physiological importance of ion channel-selective substances has been acquired by the development of the patch clamp technique, with which the action of NMDA antagonists on the calcium balance inside the cell can be demonstrated.
An object on which the invention is based was to provide new compounds which are suitable for pain treatment or for anxiolysis. Furthermore, these compounds should have as few as possible of the side effects of opioid analgesics, e.g. nausea, vomiting, dependency, respiratory depression or constipation. Further objects were to provide new active compounds for treatment of inflammatory and/or allergic reactions, depressions, drug and/or alcohol abuse, gastritis, diarrhoea, urinary incontinence, cardiovascular diseases, respiratory tract diseases, coughing, mental illnesses, epilepsy, schizophrenia, Alzheimer's disease, Huntington's disease, Parkinson's disease, cerebral ischaemias, cerebral infarctions, psychoses caused by increased amino acid levels, apoplexies, cerebral oedemas, hypoxia, anoxia, AIDS dementia, encephalomyelitis, Tourette's syndrome or perinatal asphyxia.
DETAILED DESCRIPTION OF THE INVENTION
It has now been found that substituted pyrrolidine-2,3,4-trione 3-oxime derivatives of the following general formula I, as NMDA antagonists, selectively attack the glycine binding site and are suitable for treatment of inflammatory and/or allergic reactions, depressions, drug and/or alcohol abuse, gastritis, diarrhoea, urinary incontinence, cardiovascular diseases, respiratory tract diseases, coughing, mental illnesses, epilepsy, schizophrenia, Alzheimer's disease, Huntington's disease, Parkinson's disease, cerebral ischaemias, cerebral infarctions, psychoses caused by increased amino acid levels, apoplexies, cerebral oedemas, hypoxia, anoxia, AIDS dementia, encephalomyelitis, Tourette's syndrome or perinatal asphyxia, and which moreover have a pronounced analgesic or anxiolytic action.
The present invention therefore provides compounds of the general formula I
wherein
the radical R 1 represents H, OR 8 , COR 5 , CSR 5 , NR 6 R 7 , COOR 5 , CONR 6 R 7 , CSNR 6 R 7 , a C 1-10 -alkyl, preferably a C 1-6 -alkyl, an aryl or a heteroaryl radical or represents an aryl radical bonded via a C 1-6 -alkylene group, preferably an aryl radical bonded via a C 1-3 -alkylene group,
the radicals R 2 , R 3 , which are identical or different, represent H, F, Cl, Br, CF 3 , OR 8 , SR 8 , a C 1-10 -alkyl, preferably a C 1-6 -alkyl, an aryl or a heteroaryl radical or represent an aryl radical bonded via a C 1-6 -alkylene group, preferably an aryl radical bonded via a C 1-3 -alkylene group,
the radical R 4 represents H, OH, OR 8 , SR 8 , COR 5 , COOR 5 , COCOR 5 , CONR 6 R 7 , CSNR 6 R 7 , preferably OH or OR 8 , a C 1-10 -alkyl, preferably a C 1-6 -alkyl, an aryl or a heteroaryl radical or represents an aryl radical bonded via a C 1-6 -alkylene group, preferably an aryl radical bonded via a C 1-3 -alkylene group,
the radical R 5 represents H, a C 1-10 -alkyl, preferably a C 1-6 -alkyl, an aryl or a heteroaryl radical or represents an aryl radical bonded via a C 1-6 -alkylene group, preferably an aryl radical bonded via a C 1-3 -alkylene group,
the radicals R 6 , R 7 , which are identical or different, represent H, OR 8 , COR 5 , COOR 5 , a C 1-10 -alkyl, preferably a C 1-6 -alkyl, an aryl or a heteroaryl radical or represent an aryl radical bonded via a C 1-6 -alkylene group, preferably an aryl radical bonded via a C 1-3 -alkylene group,
the radical R 8 represents a C 1-10 -alkyl, preferably a C 1-6 -alkyl, an aryl or a heteroaryl radical or represents an aryl radical bonded via a C 1-6 -alkylene group, preferably an aryl radical bonded via a C 1-3 -alkylene group,
in the form of their racemates, enantiomers, diastereomers or a corresponding base or a corresponding physiologically tolerated salt.
Alkyl radicals are also understood as meaning branched, unbranched or cyclic hydrocarbons which are unsubstituted or at least monosubstituted, preferably by F, Cl, Br, CN, NO 2 , CHO, SO 2 C 1-6 -alkyl, SO 2 CF 3 , OR 5 , NR 6 R 7 , COR 5 , COOR 5 , COCOR 5 , CONR 6 R 7 or CSNR 6 R 7 , where the radicals R 5 to R 7 have the meaning according to the general formula I. If these alkyl radicals contain more than one substituent, these can be identical or different. The alkyl radicals are preferably methyl, ethyl, propyl, isopropyl, n-butyl, sec-butyl, tert-butyl, neopentyl, n-hexyl, cyclopropyl, cyclobutyl, cyclopentyl or cyclohexyl.
An aryl radical is also understood as meaning phenyl radicals which are unsubstituted or at least monosubstituted by OH, F, Cl, Br, CF 3 , CN, NO 2 , CHO, SO 2 C 1-6 -alkyl, SO 2 CF 3 , OR 5 , NR 6 R 7 , COR 5 , COOR 5 , COCOR 5 , CONR 6 R 7 , CSNR 6 R 7 , a C 1-6 -alkyl radical, a C 1-6 -alkoxy radical, a C 2-6 -alkylene radical, a heterocyclyl radical and/or a phenyl radical, wherein the radicals R 5 to R 7 have the meaning according to the general formula I. The term can also denote an optionally substituted naphthyl radical. The phenyl radicals can also be fused with further rings.
A heteroaryl radical is also understood as meaning 5- or 6-membered unsaturated heterocyclic compounds which are optionally provided with a fused-on aryl radical and contain at least one heteroatom, preferably nitrogen and/or oxygen and/or sulfur.
The heteroaryl radical is preferably furan, thiophene, pyrrole, pyridine, pyrimidine, quinoline, isoquinoline, phthalazine or quinazoline.
The following substituted pyrrolidine-2,3,4-trione 3-oxime derivatives are particularly preferred:
5-(methoxyphenylmethylene)-pyrrolidine-2,3,4-trione 3-oxime
5-(bromophenylmethylene)-pyrrolidine-2,3,4-trione 3-oxime
5-benzylidene-pyrrolidine-2,3,4-trione 3-oxime,
5-(2-chlorobenzylidene)-pyrrolidine-2,3,4-trione 3-oxime
5-(4-chlorobenzylidene)-pyrrolidine-2,3,4-trione 3-oxime
5-(2,3-dichlorobenzylidene)-pyrrolidine-2,3,4-trione 3-oxime
5-(2,4-dichlorobenzylidene)-pyrrolidine-2,3,4-trione 3-oxime
5-(2,6-dichlorobenzylidene)-pyrrolidine-2,3,4-trione 3-oxime and
5-(3-chlorobenzylidene)-pyrrolidine-2,3,4-trione 3-oxime.
The present invention also provides processes for the preparation of substituted pyrrolidine-2,3,4-trione 3-oxime derivatives of the general formula I, in which tetramic acids of the general formula II
wherein the radicals R 1 to R 3 have the meaning according to the general formula I, are reacted with an aqueous solution of sodium nitrite in an ice-cooled solution, preferably in an ice-cooled solution of glacial acetic acid, to give compounds of the general formula I wherein the radical R 4 represents OH and the radicals R 1 to R 3 have the meaning according to the general formula I, and these are preferably purified by recrystallization, preferably from ethanol, and isolated.
The synthesis of the starting compounds, the tetramic acids of the general formula II, can be carried out in accordance with H. Poschenrieder et al. (Arch. Pharm. Pharm. Med. Chem. 1998, vol. 331, pages 389-394) and Stachel et al. (J. Heterocycl. Chem. 1980, vol. 17, pages 1195-1199 and Liebigs Ann. Chem. 1985, pages 1692-1696) and the literature references cited therein. They are included herewith as reference and are therefore part of the disclosure.
The compounds of the general formula I wherein the radical R 4 represents OH and the radicals R 1 to R 3 have the meaning according to the general formula I are reacted with C 1-10 -alkyl halides, preferably with C 1-6 -alkyl halides, with aryl halides, heteroaryl halides or with aryl-C 1-6 -alkyl halides, preferably with aryl-C 1-3 -alkyl halides, preferably under an inert gas atmosphere in absolute solvents, preferably in open-chain and/or cyclic ethers, at low temperatures in the presence of strong bases, preferably alkali metal hydroxides and/or alkaline earth metal hydroxides and/or organometallic bases, to give compounds of the general formula I wherein the radical R 4 represents OR 8 and the radicals R 1 to R 3 and R 8 have the meaning according to the general formula I.
The compounds of the general formula I wherein the radical R 4 represents OR 8 and the radicals R 1 to R 3 and R 8 have the meaning according to the general formula I can be derivatized still further in that they are reacted with acid chlorides of the general formula R 5 —(C═O)—Cl and/or acid bromides of the general formula R 5 —(C═O)—Br or chloroformic acid esters of the general formula Cl—(C═O)—O—R 5 or fluoroformic acid esters of the general formula F—(C═O)—O—R 5 or with open-chain carbonates of the general formula R 5 —O—(C═O)—O—R 5 or with correspondingly substituted cyclic carbonates, preferably with correspondingly substituted cyclic carbonates which contain 5 or 6 atoms in the ring, wherein in each case the radical R 5 has the meaning according to the general formula I, preferably under an inert gas atmosphere in an absolute solvent, preferably in open-chain and/or cyclic ethers, to give compounds of the general formula I wherein the radical R 4 represents COR 5 and COOR 5 and the radicals R 1 to R 3 and the radical R 5 have the meaning according to the general formula I, are purified and isolated by conventional processes.
The compounds of the general formula I wherein the radical R 4 represents OH and the radicals R 1 to R 3 have the meaning according to the general formula I can also be reacted with aliphatic, aromatic and heteroaromatic isocyanates or isothiocyanates at low temperatures in aprotic, polar solvents to give compounds of the general formula I wherein the radical R 4 represents CONR 6 R 7 or CSNR 6 R 7 , the radical R 6 or R 7 denotes H and the radicals R 1 to R 3 and R 6 and R 7 have the meaning according to the general formula I, are purified and isolated by conventional processes.
The preparation of the compounds of the general formula I in which the radical R 4 represents a C 1-10 -alkyl radical, an aryl radical or a heteroaryl radical or represents an aryl radical bonded via a C 1-6 -alkylene group can be carried out by the method described in Maruoka and Yamamoto, Angew. Chem., vol. 97, pp. 670-683, 1985, Maruoka et al. J. Am. Chem. Soc., vol. 105, p. 2831, 1985 or Maruoka et al. Org. Synth., vol. 66, p. 185. The corresponding disclosures are included herewith as reference.
The preparation of the compounds of the general formula I wherein the radical R 4 represents H, SR 8 or COCOR 5 and the radicals R 5 and R 8 have the meaning according to the general formula I can be carried out by the various methods known to the expert. The preparation of the compounds of the general formula I wherein the radical R 4 represents CONR 6 R 7 or CSNR 6 R 7 and the radicals R 6 and R 7 either each denote H or each have the meaning of the general formula I but are not H can also be carried out by the various methods known to the expert.
Analyses by means of 1 H-NMR spectroscopy show that the pyrrolidine-2,3,4-trione 3-oxime derivatives of the general formula I obtained by the abovementioned processes can be present as a mixture of syn and anti isomers, which it has not been possible to separate further.
The compounds of the general formula I according to the invention can be converted with acids, such as, for example, hydrochloric acid, hydrobromic acid, sulfuric acid, methanesulfonic acid, formic acid, acetic acid, oxalic acid, succinic acid, tartaric acid, mandelic acid, fumaric acid, lactic acid, citric acid, glutamic acid, aspartic acid or a mixture of at least two of these acids into the corresponding physiologically tolerated salts in the manner known per se. The salt formation is preferably carried out in a solvent, such as, for example, diethyl ether, diisopropyl ether, acetic acid alkyl esters, acetone, 2-butanone or a mixture of at least two of these solvents. Trimethylchlorosilane in aqueous solution is moreover suitable for preparation of the corresponding hydrochlorides.
The substituted pyrrolidine-2,3,4-trione 3-oxime derivatives of the general formula I according to the invention are toxicologically acceptable and therefore represent suitable pharmaceutical active compounds.
The invention therefore also provides medicaments which comprise, as the active compound, at least one substituted pyrrolidine-2,3,4-trione 3-oxime derivative of the general formula I and/or a corresponding base and/or a corresponding physiologically tolerated salt, and optionally further active compounds and/or auxiliary substances. The medicament can also comprise a mixture of at least two enantiomers and/or the corresponding bases and/or the corresponding physiologically tolerated salts of a compound of the general formula I according to the invention, wherein the enantiomers are not present in equimolar amounts.
The medicaments are preferably employed for treatment or control of pain, inflammatory and/or allergic reactions, depressions, drug and/or alcohol abuse, gastritis, diarrhoea, urinary incontinence, cardiovascular diseases, respiratory tract diseases, coughing, mental illnesses, neurodegenerative diseases, epilepsy, schizophrenia, Alzheimer's disease, Huntington's disease, Parkinson's disease, cerebral ischaemias, cerebral infarctions, psychoses caused by increased amino acid levels, apoplexies, cerebral oedemas, deficiency states of the central nervous system, hypoxia, anoxia, AIDS dementia, encephalomyelitis, Tourette's syndrome, perinatal asphyxia or for anxiolysis.
The invention also provides the use of at least one substituted pyrrolidine-2,3,4-trione 3-oxime derivative of the general formula I and/or a corresponding base and/or a corresponding physiologically tolerated salt for the preparation of a medicament for treatment/control for/of pain, inflammatory and/or allergic reactions, depressions, drug and/or alcohol abuse, gastritis, diarrhoea, urinary incontinence, cardiovascular diseases, respiratory tract diseases, coughing, mental illnesses, neurodegenerative diseases, epilepsy, schizophrenia, Alzheimer's disease, Huntington's disease, Parkinson's disease, cerebral ischaemias, cerebral infarctions, psychoses caused by increased amino acid levels, apoplexies, cerebral oedemas, deficiency states of the central nervous system, hypoxia, anoxia, AIDS dementia, encephalomyelitis, Tourette's syndrome, perinatal asphyxia or for anxiolysis.
To prepare corresponding pharmaceutical formulations, in addition to at least one substituted pyrrolidine-2,3,4-trione 3-oxime derivative of the general formula I, conventional auxiliary substances, or excipients, such as carrier materials, fillers, solvents, diluents, dyestuffs or binders, are additionally employed. The choice of auxiliary substances and the amounts thereof to be employed depends on the mode of administration, such as oral, intravenous, intraperitoneal, intradermal, intramuscular, intranasal, buccal or local, for example on infections on the skin, the mucous membranes and on the eyes, and is known to the expert. Formulations in the form of tablets, coated tablets, capsules, granules, drops, juices and syrups and multiparticulate formulations, for example pellets or granules, which can optionally also be filled in capsules or pressed to tablets, are suitable, for example, for oral administration, and solutions, suspensions, easily reconstitutable dry formulations and sprays e.g. are suitable for parenteral, topical and inhalatory administration. Compounds of the general formula I according to the invention in a depot, in dissolved form or in a patch, optionally with the addition of agents which promote penetration of the skin, are suitable percutaneous administration formulations. Formulation forms which can be used orally or percutaneously can also release the compounds of the general formula I according to the invention in a retarded manner.
The amount of active compound to be administered to the patient varies according to the weight of the patient, the mode of administration, the indication and the severity of the illness. 2 to 500 mg/kg of body weight of the patient of at least one pyrrolidine-2,3,4-trione 3-oxime derivative of the general formula I are usually administered.
Pharmacological Studies
a) Studies of the Receptor Binding
Studies for determination of the affinity of the substituted pyrrolidine-2,3,4-trione 3-oxime derivatives of the general formula I according to the invention for the glycine binding site of the NMDA receptor channel were carried out on cerebral membrane homogenates (homogenate of the cortex and hippocampus area from the brain of male rats, Wistar strain, Charles River, WIGA GmbH, Sulzbach, Germany) by the method of Baron B. M. et al, J. Pharmacol. Exp. Ther., vol. 279, pp.62-68 (1996).
For this, the cortex and hippocampus were dissected free from freshly removed rat brains and homogenized in 5 mmol/l TRIS-acetate buffer, 0.32 mol/l sucrose pH 7.4 (10 ml/g fresh weight) with a Potter homogenizer (Braun/Melsungen, Germany, 10 plunger strokes at 500 revolutions per minute (rpm)), while cooling with ice, and the homogenate was then centrifuged for 10 minutes at 1,000 g and 4° C. The first supernatant was collected and the sediment was homogenized again with 5 mmol/l TRIS-acetate buffer, 0.32 mol/l sucrose pH 7.4 (5 ml/g original fresh weight of rat brain cortex and hippocampus) with the Potter homogenizer (10 plunger strokes at 500 rpm), while cooling with ice, and the homogenate was centrifuged for 10 minutes at 1,000 g and 4° C. The resulting supernatant was combined with the supernatant from the first centrifugation and the mixture was centrifuged at 17,000 g for 20 minutes at 4° C. The supernatant after this centrifugation was discarded, the membrane sediment was taken up in 5 mmol/l TRIS-acetate buffer pH 8.0 (20 ml/g original fresh weight) and the mixture was homogenized with 10 plunger strokes at 500 rpm.
The membrane homogenate was then incubated for 1 hour at 4° C. and centrifuged for 30 minutes at 50,000 g and 4° C. The supernatant was discarded and the centrifuge tube with the membrane sediment was closed with Parafilm and frozen at −20° C. for 24 hours. The membrane sediment was then thawed and taken up in ice-cold 5 mmol/l TRIS-acetate buffer, 0.1% saponin (weight/volume) pH 7.0 (10 ml/g original fresh weight) and homogenized with 10 plunger strokes at 500 rpm and the homogenate was then centrifuged for 20 minutes at 50,000 g and 4° C. The resulting supernatant was discarded and the sediment was taken up in a small volume of 5 mmol/l TRIS-acetate buffer pH 7.0 (approx. 2 ml/g original fresh weight) and the mixture was homogenized again with 10 plunger strokes at 500 rpm. After determination of the protein content, the membrane homogenate was brought to a protein concentration of 10 mg protein/ml with 5 mmol/l TRIS-acetate buffer pH 7.0 and frozen in aliquots until the analysis was carried out.
For the receptor binding test, aliquots were thawed, diluted 1:10 with 5 mmol/l TRIS-acetate buffer pH 7.0, homogenized with 10 plunger strokes at 500 rpm with the Potter homogenizer, while cooling with ice, and centrifuged for 60 minutes at 55,000 g at 4° C. The supernatant was decanted and the membrane sediment was brought to a protein concentration of 1 mg/ml with ice-cold 50 mmol/l TRIS-acetate buffer pH 7.0, and the mixture was homogenized again with 10 plunger strokes at 500 rpm and kept in suspension while stirring on a magnetic stirrer in an ice-bath. 100 μl portions of this membrane homogenate were employed per 1 ml batch in the receptor binding test (0.1 mg protein/ml in the final batch).
In the binding test, 50 mmol/l TRIS-acetate buffer pH 7.0 was employed as the buffer and 1 nmol/l ( 3 H)-MDL 105.519 (Baron B. M. et al, J. Pharmacol. Exp. Ther., vol. 279, pp. 62-68 (1996)) was employed as the radioactive ligand. The proportion of non-specific binding was determined in the presence of 1 mmol/l glycine.
In further batches, the compounds according to the invention were added in concentration series and the displacement of the radioactive ligand from its specific binding to the glycine binding site of the NMDA receptor channel was determined. The particular triplicate batches were incubated for 120 minutes at 4° C. and then harvested by means of filtration through glass fibre filter mats (type Whatman GF/B, Adi Hassel, Munich, Germany) for determination of the radioactive ligand bonded to the membrane homogenate. The radioactivity retained on the glass fibre filters was measured in a β-counter (Packard TRI-CARB Liquid Scintillation Analyzer 2000CA, Packard Instrument, Meriden, Conn. 06450, USA) after addition of scintillator (Ready Protein, Beckmann Coulter GmbH, Krefeld, Germany).
The affinity of the compounds according to the invention for the glycine binding site of the NMDA receptor channel was calculated as the IC 50 (concentration with 50% displacement of the radioactive ligand from its specific binding) by the law of mass action by means of non-linear regression and is stated as the Ki value after conversion (by the Cheng-Prussoff equation (Y. Cheng, W. H. Prusoff, 1973, Biochem. Pharmacol., vol. 22, pp. 3099-3108)).
b) NMDA/glycine-induced Ion Currents in Xenopus Oocytes Injected with RNA
The study for determination of function changes of the NMDA receptor channel by the compounds of the general formula I according to the invention was carried out on oocytes of the South African clawed toad Xenopus laevis. For this, neuronal NMDA receptor channels were formed in oocytes after injection of RNA from mouse brains, and ion currents induced by co-application of NMDA and glycine were measured.
Xenopus oocytes of stages V and VI (Dumont, J. N., J. Morphol. 136, pp. 153-180 (1972)) were microinjected with complete RNA from brain tissue of adult mice (100-130 ng/cell) and were kept for up to 10 days in culture medium (composition: 88.0 mmol/l NaCl, 1.0 mmol/l KCl, 1.5 mmol/l CaCl 2 , 0.8 mmol/l MgSO 4 , 2.4 mmol/l NaHCO 3 , 5 mmol/l HEPES, 100 IU/ml penicillin, 100 μg/ml streptomycin, pH 7.4) at 20° C. Transmembrane ion currents were recorded with the aid of the conventional two-electrode voltage clamping technique at a holding potential of −70 mV (Bloms-Funke P. et al, (1996) Neurosci. Lett. 205, pp. 115-118 (1996)). The OTC interface and Cellworks software (npi, Federal Republic of Germany) were used for recording data and controlling the test apparatus. The compounds according to the invention were added to a nominally Mg 2+ -free medium (composition: 89.0 mmol/l NaCl, 1.0 mmol/l KCl, 1.8 mmol/l CaCl 2 , 2.4 mmol/l NaHCO 3 , 5 mmol/l HEPES, pH 7.4) and applied to the system with the aid of a concentration clamp (npi, Federal Republic of Germany). To test substance effects mediated via the glycine B-binding site of the NMDA receptor channel, the glycine dose/effect curve with and without the particular compound according to the invention was plotted. For this, NMDA was co-applied cumulatively in a fixed concentration of 100 μmol/l with glycine in increasing concentrations (0-100 μmol/l). Thereafter, the experiment was repeated in the same manner with a fixed concentration of the compound according to the invention. The current amplitudes were standardized to those of the control response to co-application of NMDA (100 μmol/l) with glycine (10 μmol/l). The data were analysed with the Igor-Pro software (version 3.1, WaveMetrics, USA). All the results were stated as the mean from at least 3 experiments on different oocytes of at least two toads. The significance for non-paired measurement parameters is determined with the aid of the Mann-Whitney U test and that for paired measurement parameters by the Wilcoxon test (Sysstat, SPSS Inc., USA). The EC 50 values are calculated according to the following equation:
Y=Y min +( Y max −Y min )/(1+( X/ EC 50 ) −p )
(Y min =minimum test value, Y max =maximum test value, Y=relative current amplitude, X=concentration of the test substance, p=slope factor). With a right-hand shift of the glycine dose/effect curve, the pA 2 value of the compound according to the invention was determined graphically with the aid of a Schild regression. Concentration ratios were calculated with the aid of the EC 50 values, which were calculated independently for each dose/effect curve.
c) Formalin Test in Mice
The studies for determination of the antinociceptive action of the compounds according to the invention were carried out in the formalin test in male albino mice (NMRI, 25-35 g, Iffa Credo, Belgium).
In the formalin test, a distinction is made between the first (early) phase (0-15 min after formalin injection) and the second (late) phase (15-60 min after formalin injection) (D. Dubuisson et al, Pain, vol. 4, pp. 161-174 (1977)). The early phase represents a model for acute pain, as a direct reaction to the formalin injection, while the late phase is regarded as a model for persistent (chronic) pain (T. J. Coderre et al, Pain, vol. 52, pp. 259-285 (1993).
The compounds according to the invention were investigated in the second phase of the formalin test to obtain information on the actions of the compounds according to the invention on chronic/inflammatory pain.
By a single subcutaneous formalin injection (20 μl, 1% aqueous solution) into the dorsal side of the right hind paw of freely mobile test animals, a nociceptive reaction was induced, which manifests itself in significant licking and biting of the paw affected.
For the investigation period in the second (late) phase of the formalin test, the nociceptive behavior was recorded continuously by observing the animals. The pain properties were quantified by adding up the seconds in which the animals showed licking and biting of the paw affected in the investigation period. After injection of substances which have an antinociceptive action in the formalin test, the modes of behaviour described for the animals are reduced, and possibly even eliminated. In a manner corresponding to the experiments in which the animals had received an injection of the compounds according to the invention before the administration of formalin, the control animals were injected with the vehicle, i.e. solvent (e.g. 0.9% NaCl solution) before the administration of formalin. The behaviour of the rats after administration of the substance was compared with a control group (10 mice per substance dose).
On the basis of the quantification of the pain properties, the action of the substance in the formalin test was determined as a change from the control in per cent. The ED 50 calculations were made by means of regression analysis. The administration time before the formalin injection was chosen according to the mode of administration of the compounds according to the invention (intraperitoneal: 15 min, intravenous: 5 min).
d) Writhing Test in the Mouse
The study of the analgesic activity was also carried out in the phenylquinone-induced writhing in the mouse (modified by I. C. Hendershot et al, (1959) J. Pharmacol. Exp. Ther., vol. 125, pp. 237-240). Male NMRI mice weighing 25 to 30 g (Iffa, Credo, Belgium, were used for this. Groups of 10 animals per substance dose received 0.3 ml/mouse of a 0.02% aqueous solution of phenylquinone (phenylbenzoquinone, Sigma, Deisenhofen; preparation of the solution with the addition of 5% ethanol and storage in a water bath at 45° C.) administered intraperitoneally 10 minutes after intravenous administration of the particular compound. The animals were placed individually in observation cages. The number of pain-induced stretching movements (so-called writhing reactions=straightening of the body with stretching of the hind extremities) was counted by means of a push-button counter for 5 to 20 minutes after the administration of phenylquinone. Animals which received only physiological saline solution were also run as a control. All the substances were tested in the standard dosage of 10 mg/kg of body weight of the mouse. The percentage inhibition (% inhibition) of the writhing reaction by a substance was calculated according to the following equation: % inhibition = 100 - writhing reactions of the treated animals writhing reactions of the control animals * 100
For some of the compounds according to the invention the ED 50 values with the 95% confidence range of the writhing reaction were calculated by means of regression analysis (evaluation program from Martens EDV Service, Eckental) from the dose-dependent decrease in the writhing reactions compared with phenylquinone control groups investigated in parallel.
The following examples serve to illustrate the invention, but do not limit the general inventive idea.
EXAMPLES
The yields of the compounds prepared are not optimized.
The melting points determined are uncorrected.
Example 1
5-(Methoxyphenylmethylene)-pyrrolidine-2,3,4-trione 3-oxime
An aqueous solution of 1.1 mmol (0.075 g) sodium nitrite was added dropwise to an ice-cooled solution of 2 mmol 4-hydroxy-5-(methoxyphenyl-methylene)-1,5-dihydropyrrol-2-one (prepared in accordance with H. Poschenrieder et al (Arch. Pharm. Pharm. Med. Chem. 1998, 331, 389-394) and H. -D. Stachel et al (J. Heterocycl. Chem. 1980, vol. 17, pp. 1195-1199 and Liebigs Ann. Chem. 1985, pp. 1692-1696)) in 5 ml glacial acetic acid, while stirring. The resulting solution was then stirred at room temperature for 30 minutes and concentrated in vacuo. The residue is purified by recrystallization from ethanol. The yield of 5-(methoxyphenylmethylene)-pyrrolidine-2,3,4-trione 3-oxime was 60%, with a melting point of 174° C.
Analysis of this compound by means of 1 H-NMR spectroscopy gave the following signals:
(d6-DMSO, δ in ppm): 11.95 (s, 1 H); 10.74 (s, 0.66 H); 10.71 (s, 0.33 H); 7.46 (m, 5 H); 3.42 (s, 1 H); 3.41 (s, 2 H).
Example 2
5-(Bromophenylmethylene)-pyrrolidine-2,3,4-trione 3-oxime
An aqueous solution of 1.1 mmol (0.075 g) sodium nitrite was added dropwise to an ice-cooled solution of 2 mmol 5-(bromophenyl-methylene)-4-hydroxy-1,5-dihydropyrrol-2-one (prepared in accordance with H. Poschenrieder et al (Arch. Pharm. Pharm. Med. Chem. 1998, 331, 389-394) and H. -D. Stachel et al (J. Heterocycl. Chem. 1980, vol. 17, pp. 1195-1199 and Liebigs Ann. Chem. 1985, pp. 1692-1696)) in 5 ml glacial acetic acid, while stirring. The resulting solution was then stirred at room temperature for 30 minutes and concentrated in vacuo. The residue is purified by recrystallization from ethanol. The yield of 5-(bromophenylmethylene)-pyrrolidine-2,3,4-trione 3-oxime was 65%, with a melting point of 158° C.
Analysis of this compound by means of 1 H-NMR spectroscopy gave the following signals:
(d6-DMSO, δ in ppm): 14.46 (s, 1 H); 11.06 (s, 0.70 H); 11.00 (s, 0.30 H); 7.40-7.26 (m, 5 H).
Example 3
5-Benzylidene-pyrrolidine-2,3,4-trione 3-oxime
An aqueous solution of 1.1 mmol (0.075 g) sodium nitrite was added dropwise to an ice-cooled solution of 2 mmol 5-benzylidene 4-hydroxy-1,5-dihydropyrrol-2-one (prepared in accordance with H. Poschenrieder et al (Arch. Pharm. Pharm. Med. Chem. 1998, 331, 389-394) and H.-D. Stachel et al (J. Heterocycl. Chem. 1980, vol. 17, pp. 1195-1199 and Liebigs Ann. Chem. 1985, pp. 1692-1696)) in 5 ml glacial acetic acid, while stirring. The resulting solution was then stirred at room temperature for 30 minutes and concentrated in vacuo. The residue is purified by recrystallization from ethanol. The yield of 5-benzylidene-pyrrolidine-2,3,4-trione 3-oxime was 65%, with a melting point of 205° C.
Analysis of this compound by means of 1 H-NMR spectroscopy gave the following signals:
(d6-DMSO, δ in ppm): 14.66 (s, 1 H); 11.25 (s, 0.66 H); 11.18 (s, 0.33 H); 7.64-7.31 (m, 5 H); 6.42 (s, 0.33 H); 6.36 (s, 0.66 H).
Example 4
5-(2-Chlorobenzylidene)-pyrrolidine-2,3,4-trione 3-oxime
An aqueous solution of 1.1 mmol (0.075 g) sodium nitrite was added dropwise to an ice-cooled solution of 2 mmol 5-(2-chlorobenzylidene)-4-hydroxy-1,5-dihydropyrrol-2-one (prepared in accordance with H. Poschenrieder et al (Arch. Pharm. Pharm. Med. Chem. 1998, 331, 389-394) and H.-D. Stachel et al (J. Heterocycl. Chem. 1980, vol. 17, pp. 1195-1199 and Liebigs Ann. Chem. 1985, pp. 1692-1696)) in 5 ml glacial acetic acid, while stirring. The resulting solution was then stirred at room temperature for 30 minutes and concentrated in vacuo. The residue is purified by recrystallization from ethanol. The yield of 5-(2-chlorobenzylidene)-pyrrolidine-2,3,4-trione 3-oxime was 60%, with a melting point of 176° C.
Analysis of this compound by means of 1 H-NMR spectroscopy gave the following signals:
(d6-DMSO, δ in ppm): 11.40 (s, 0.66 H); 11.34 (s, 0.33 H); 7.46-7.21 (m, 4 H); 6.52 (s, 0.33 H); 6.47 (s, 0.66 H).
Example 5
5-(4-Chlorobenzylidene)-pyrrolidine-2,3,4-trione 3-oxime
An aqueous solution of 1.1 mmol (0.075 g) sodium nitrite was added dropwise to an ice-cooled solution of 2 mmol 5-(4-chlorobenzylidene)-4-hydroxy-1,5-dihydropyrrol-2-one (prepared in accordance with H. Poschenrieder et al (Arch. Pharm. Pharm. Med. Chem. 1998, 331, 389-394) and H.-D. Stachel et al (J. Heterocycl. Chem. 1980, vol. 17, pp. 1195-1199 and Liebigs Ann. Chem. 1985, pp. 1692-1696)) in 5 ml glacial acetic acid, while stirring. The resulting solution was then stirred at room temperature for 30 minutes and concentrated in vacuo. The residue is purified by recrystallization from ethanol. The yield of 5-(4-chlorobenzylidene)-pyrrolidine-2,3,4-trione 3-oxime was 50%, with a melting point of 190° C.
Analysis of this compound by means of 1 H-NMR spectroscopy gave the following signals:
(d6-DMSO, δ in ppm): 11.35 (s, 0.66 H); 11.28 (s, 0.33 H); 7.67-7.64 (m, 2 H); 7.45-7.35 (m, 2 H); 6.40 (s, 0.33 H); 6.35 (s, 0.66 H).
Example 6
5-(2,3-Dichlorobenzylidene)-pyrrolidine-2,3,4-trione 3-oxime
An aqueous solution of 1.1 mmol (0.075 g) sodium nitrite was added dropwise to an ice-cooled solution of 2 mmol 5-(2,3-dichlorobenzylidene)-4-hydroxy-1,5-dihydropyrrol-2-one (prepared in accordance with H. Poschenrieder et al (Arch. Pharm. Pharm. Med. Chem. 1998, 331, 389-394) and H.-D. Stachel et al (J. Heterocycl. Chem. 1980, vol. 17, pp. 1195-1199) and Liebigs Ann. Chem. 1985, pp. 1692-1696)) in 5 ml glacial acetic acid, while stirring. The resulting solution was then stirred at room temperature for 30 minutes and concentrated in vacuo. The residue is purified by recrystallization from ethanol. The yield of 5-(2,4-dichlorobenzylidene)-pyrrolidine-2,3,4-trione 3-oxime was 55%, with a melting point of 180° C.
Analysis of this compound by means of 1 H-NMR spectroscopy gave the following signals:
(d6-DMSO, δ in ppm): 11.43 (s, 0.66 H); 11.37 (s, 0.33 H); 7.63-7.37 (m, 3 H); 6.50 (s, 0.33 H); 6.45 (s, 0.66 H).
Example 7
5-(2,4-Dichlorobenzylidene)-pyrrolidine-2,3,4-trione 3-oxime
An aqueous solution of 1.1 mmol (0.075 g) sodium nitrite was added dropwise to an ice-cooled solution of 2 mmol 5-(2,4-dichlorobenzylidene)-4-hydroxy-1,5-dihydropyrrol-2-one (prepared in accordance with H. Poschenrieder et al (Arch. Pharm. Pharm. Med. Chem. 1998, 331, 389-394) and H.-D. Stachel et al (J. Heterocycl. Chem. 1980, vol. 17, pp. 1195-1199 and Liebigs Ann. Chem. 1985, pp. 1692-1696)) in 5 ml glacial acetic acid, while stirring. The resulting solution was then stirred at room temperature for 30 minutes and concentrated in vacuo. The residue is purified by recrystallization from ethanol. The yield of 5-(2,4-dichlorobenzylidene)-pyrrolidine-2,3,4-trione 3-oxime was 55%, with a melting point of 180° C.
Analysis of this compound by means of 1 H-NMR spectroscopy gave the following signals:
(d6-DMSO, δ in ppm): 11.38 (s, 0.66 H); 11.32 (s, 0.33 H); 7.68-7.65 (m, 2 H); 7.45-7.43 (m, 1 H); 6.42 (s, 0.33 H); 6.36 (s, 0.66 H).
Example 8
5-(2,6-Dichlorobenzylidene)-pyrrolidine-2,3,4-trione 3-oxime
An aqueous solution of 1.1 mmol (0.075 g) sodium nitrite was added dropwise to an ice-cooled solution of 2 mmol 5-(2,6-dichlorobenzylidene)-4-hydroxy-1,5-dihydropyrrol-2-one (prepared in accordance with H. Poschenrieder et al (Arch. Pharm. Pharm. Med. Chem. 1998, 331, 389-394) and H.-D. Stachel et al (J. Heterocycl. Chem. 1980, vol. 17, pp. 1195-1199 and Liebigs Ann. Chem. 1985, pp. 1692-1696)) in 5 ml glacial acetic acid, while stirring. The resulting solution was then stirred at room temperature for 30 minutes and concentrated in vacuo. The residue is purified by recrystallization from ethanol. The yield of 5-(2,6-dichlorobenzylidene)-pyrrolidine-2,3,4-trione 3-oxime was 65%, with a melting point of 232° C.
Analysis of this compound by means of 1 H-NMR spectroscopy gave the following signals:
(d6-DMSO, δ in ppm): 11.12 (s, 0.66 H); 11.08 (s, 0.33 H); 7.50-7.48 (m, 2 H); 7.39-7.35 (m 1 H); 6.27 (s, 0.33 H); 6.22 (s, 0.66 H).
Example 9
5-(3-Chlorobenzylidene)-pyrrolidine-2,3,4-trione 3-oxime
An aqueous solution of 1.1 mmol (0.075 g) sodium nitrite was added dropwise to an ice-cooled solution of 2 mmol 5-(3-chlorobenzylidene)-4-hydroxy-1,5-dihydropyrrol-2-one (prepared in accordance with H. Poschenrieder et al (Arch. Pharm. Pharm. Med. Chem. 1998, 331, 389-394) and H.-D. Stachel et al (J. Heterocycl. Chem. 1980, vol. 17, pp. 1195-1199 and Liebigs Ann. Chem. 1985, pp. 1692-1696)) in 5 ml glacial acetic acid, while stirring. The resulting solution was then stirred at room temperature for 30 minutes and concentrated in vacuo. The residue is purified by recrystallization from ethanol. The yield of 5-(3-chlorobenzylidene)-pyrrolidine-2,3,4-trione 3-oxime was 50%, with a melting point of 185° C.
Analysis of this compound by means of 1 H-NMR spectroscopy gave the following signals:
(d6-DMSO, δ in ppm): 14.69 (s, 0.66 H); 14.53 (s, 0.33 H); 11.47 (s, 0.66 H), 11.40 (s, 0.33 H); 7.72-7.20 (m, 4 H); 6.38 (s, 0.33 H); 6.33 (s, 0.66 H).
Pharmacological Studies
a) Studies of the Receptor Binding
The studies to determine the affinity of the compounds according to the invention according to example 1 and 2 for the glycine binding site of the NMDA receptor channel were carried out as described above.
The affinity of the glycine binding site of the NMDA receptor channel was calculated as the IC 50 (concentration with 50% displacement of the radioactive ligand from its specific binding) by the law of mass action by means of non-linear regression and is stated in the following table 1 as the Ki value after conversion (by the Cheng-Prussoff equation (Y. Cheng, W. H. Prusoff, 1973, Biochem. Pharmacol., vol. 22, pp. 3099-3108)).
TABLE 1
Glycine binding site of the NMDA receptor
Example
channel Ki (μmol/l)
1
0.116
2
0.430
b) NMDA/glycine-induced Ion Currents on RNA-injected Xenopus Oocytes.
The study to determine function changes in the NMDA receptor channel due to the compound according to the invention according to example 1 was carried out as described above.
The result of the study of the effect of the compound according to the invention according to example 1 on ion currents induced by NMDA/glycine on RNA-injected oocytes is shown in the following table 2.
TABLE 2
NMDA-induced
Ion currents
(relative current amplitudes)
NMDA +
NMDA +
Example no.
NMDA
glycine (0.3 μM)
glycine (10 μM)
Control
1.42%
70.23%
100%
Example 1
−0.58%
0.08%
59.93%
The studies show the antagonistic action of the compound according to example 1.
c) Formalin Test in Mice
The studies to determine the antinociceptive action of the compounds according to the invention were carried out as described above.
The corresponding results in the formalin test in mice are summarized in the following table 3.
TABLE 3
% change from the control at 10
Example
mg/kg
1
63.9
2
36.3
3
47.6
d) Writhing Test in Mice
The study of the analgesic activity was carried out in the phenylquinone-induced writhing in mice as described above. All the compounds according to the invention investigated showed a pronounced analgesic action. The results are summarized in the following table 4.
TABLE 4
% inhibition of the writhing reaction at 10
Example
mg/kg intravenously
3
25
4
55
5
50
6
52
7
46
8
51
9
81
The forgoing description and examples have been set forth merely to illustrate the invention and are not intended to be limiting. Since modifications of the described embodiments incorporating the spirit and substance of the invention may occur to persons skilled in the art, the invention should be construed broadly to include all variations falling within the scope of the appended claims and equivalents thereof.
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Novel substituted pyrrolidine-2,3,4-trione compounds of formula I
and methods for preparing the compounds. Also disclosed are pharmarceutical compositions comprising the compounds and methods of using the compounds for treating pain, anxiety and various other diseases or conditions.
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RELATED APPLICATIONS
[0001] This application claims priority to German application No. 100 11 564.0, filed Mar. 9, 2000.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention relates to a process for preparing polyorganosiloxane emulsions whose internal phase comprises the active polyorganosiloxane substance and whose external phase comprises, in solution or dispersion, an emulsifier or an emulsifier mixture and, if desired, an emulsion-stabilizing protective colloid, to the polysiloxane emulsion thus obtainable and, in particular, to the use of these macroemulsions, so prepared, as defoamers.
[0004] 2. Description of the Related Art
[0005] Known defoamer emulsions are, in accordance with the prior art (DE 28 29 906 A, DE 42 37 754 A), macroemulsions whose dispersed phase comprises particles having average sizes of up to 100 μm. The internal phase consists of the active defoamer substance or comprises it in a carrier medium such as, for example, a solvent.
[0006] The use of polyorganosiloxanes, in the form for example of silicone oils or polyethersiloxane copolymers, as defoamer oils is known (U.S. Pat. No. 3,763,021 and U.S. Pat. No. 5,804,099, herein incorporated be reference). The oils may comprise finely divided solids which reinforce the defoaming action. An example of a suitable finely divided solid of this kind is highly disperse, usually pyrolytically obtained silica, which may have been hydrophobicized by treatment with organosilicon compounds (R. E. Patterson, Coll. And Surfaces A, 74, 115 (1993) herein incorporated by reference).
[0007] The use of these polyorganosiloxanes is preferred in particular in the form of their o/w emulsions, since depending on the chosen stirring and homogenizing mechanism it is possible to carry out initial adjustment of the size of the defoamer oil droplets. If the input of shearing force into the system to be defoamed is low, this distribution can be transferred. The respective particle size distribution is critical to the characteristics of the defoamer in the system to be defoamed. In view of the meterability as well, the use of o/w emulsions is greatly preferred over the active substances alone.
[0008] However, the preparation of such o/w emulsions in many cases necessitates complex multistage processes; in particular, resulting product qualities of these macroemulsions are frequently inadequate.
[0009] For example, owing to their relatively large particles in the disperse phase, such polyorganosiloxane emulsions tend toward sedimentation and coalescence. As a result, in particular, the profiles of properties (activity, tendency toward surface defects) of such defoamer emulsions are fluctuating and variable over time, leading again and again to problems in use. Although this effect can be countered by increasing the viscosity using protective colloids, the achievable thermal stabilities and shaking stabilities are still inadequate in many cases. Moreover, there has been no lack of attempts to improve these properties by means of higher emulsifier contents. The skilled worker is well aware, however, that the activity of defoamers decreases drastically over time as the emulsifier content goes up.
[0010] A dispersing process based on the serial connection of product mixtures has hitherto been described for the preparation of inkjet printer inks (U.S. Pat. No. 5,168,022 or U.S. Pat. No. 5,026,427) or magnetic powder dispersions (U.S. Pat. No. 5,927,852).
[0011] A similar principle is known (U.S. Pat. No. 4,908,154, herein incorporated by reference) for the preparation of microemulsions (all droplets <1 μm). In this case, however, the product stream is divided into two parts, changes its direction, collides with itself in a countercurrent process, and then flows back together into one stream.
[0012] The preparation of polyorganosiloxane emulsions by means of this process is unknown.
SUMMARY OF THE INVENTION
[0013] It is an object of the present invention, therefore, to prepare polyorganosiloxane emulsions which are more stable with respect to coalescence and sedimentation on exposure to heat and shaking, have a lower emulsifier content, possess good defoaming properties, and retain this performance for a prolonged period.
[0014] An object on which the invention is based is surprisingly achieved by using the following process for preparing the polyorganosiloxane emulsions:
[0015] a) formulating a mixture from:
[0016] from about 5 to about 50% by weight of polyorganosiloxanes optionally comprising hydrophobic solid bodies,
[0017] from 0 to about 20% by weight of organic oil,
[0018] from about 0.5 to about 10% by weight of one or more nonionic or anionic emulsifiers,
[0019] from about 40 to about 95% by weight of water, and
[0020] if desired, thickeners, protective colloids and/or auxiliary preservatives;
[0021] b) passing this mixture through, and dispersing it in, at least one interaction chamber having a capillary thickness of from about 100 to about 500 μm in a pressure range from about 100 to about 1000 bar; and
[0022] c) releasing this mixture in an outlet reservoir,
[0023] the average droplet sizes being from about 0.5 to about 100 μm.
DETAILED DESCRIPTION OF THE INVENTION
[0024] Surprisingly, the emulsion stabilities of O/W polyorganosiloxane emulsions prepared in accordance with the invention are significantly improved in comparison to emulsions prepared by conventional methods (high-pressure homogenizer, rotor/stator systems, colloid mill, etc.) or, respectively, it is possible to prepare emulsions having a much smaller emulsifier requirement and, accordingly, an improved profile of properties. The formulation comprising polyorganosiloxane, emulsifier(s), water and, if desired, further additives is passed under a pressure of from about 100 to about 1000 bar, preferably from about 100 to about 600 bar, with particular preference from about 150 to about 450 bar, through one or more microchannels having capillary thicknesses of from about 100 to about 500 μm, ideally from about 200 to about 400 μm. A preferred feature of these capillary microchannels is that at least at one point they are angled, so that the product stream is diverted in its direction. Following release and collection of the polyorganosiloxane emulsion, a product is obtained which features average droplet sizes of from about 0.5 to about 100 μm.
[0025] The advantageous suitability of the process of the invention for preparing these macrodisperse polyorganosiloxane emulsions is, therefore, highly surprising.
[0026] Polyorganosiloxane emulsions of this kind may not only be used as defoamers but are also suitable as release agents or architectural preservatives, such as waterproofing agents.
[0027] The defoamer emulsions for preparation in accordance with the invention may be used in a conventional manner, inter alia, for defoaming surfactant solutions, surfactant concentrates, latices, all-acrylate dispersions (for papercoatings, adhesives and emulsion paints, for example), coating materials, and aqueous printing inks.
[0028] As emulsifiers, the polyorganosiloxane emulsions prepared by the process of the invention and intended for use in accordance with the invention comprise one or more nonionic or anionic emulsifiers. Examples of nonionic emulsifiers are the fatty acid esters of polyhydric alcohols, their polyalkylene glycol derivatives, the polyglycol derivatives of fatty acids and fatty alcohols, alkylphenol ethoxylates, and also block copolymers of ethylene oxide and propylene oxide, ethoxylated amines, amine oxides, acetylenediol surfactants, and silicone surfactants. It is preferred to use ethoxylation derivatives of fatty chemical raw materials. Particular preference is given to nonionic oleyl and stearyl derivatives.
[0029] Examples of anionic emulsifiers are dialkylsulfosuccinates (Emcol® 4500), alkyl ether sulfates and alkyl ether phosphates, alkyl sulfates (Witcolate® D5-10) and alpha-olefinsulfonates (Witconate® AOS). Mention may also be made of specific block copolymer emulsifiers, as described in DE 198 36 253 A, herein incorporated by reference.
[0030] Exemplary protective colloids and thickeners are cellulose derivatives such as methylcellulose, carboxymethylcellulose, hydroxyethylcellulose, hydroxypropyl-cellulose, and also synthetic polymers such as polyvinyl alcohol, polyacrylates and maleic anhydride copolymers (U.S. Pat. No. 4,499,233, U.S. Pat. No. 5,023,309) or, for example, in particular linear and branched polyurethanes (U.S. Pat. No. 4,079,028, U.S. Pat. No. 4,155,892), polyureas, polyetherpolyols (U.S. Pat. No. 4,288,639, U.S. Pat. No. 4,354,956, U.S. Pat. No. 4,904,466) and also biosynthetic polymers such as xanthan gum, all herein incorporated by reference.
[0031] Examples of inorganic solids are unhydrophobicized or hydrophobicized silica, alumina, alkaline earth metal carbonates or similar finely divided solids which are customary and known from the prior art. As finely divided organic substances it is possible to use alkaline earth metal salts of long-chain fatty acids of 12 to 22 carbon atoms that are known for this purpose, the amides of these fatty acids, and also polyureas.
[0032] Polyorganosiloxane emulsions for preparation in accordance with the invention are described by way of example in the working examples. In said examples, the material formulations correspond to the prior art as described, for example, in DE 24 43 853 A, DE 38 07 247 A, and DE 42 37 754 A, herein incorporated by reference.
WORKING EXAMPLES
Example 1
[0033] 5 parts of a mixture of equal parts of ethoxylated triglyceride (Atlas® G1300 from ICI) and ethoxylated fatty acid (Brij® 72 from ICI) were added to 74.55 parts of water at 60° C. 0.25 part of an anionic polyacrylamide (Praestol® from Stockhausen) was then scattered into this hot mixture. The mixture was stirred for 10 minutes and 20 parts of an SiO 2 (5 parts of Sipemat® D10 from Degussa)-containing organosiloxane (Tego® Glide B 1484 from Tego) which had a viscosity of 800 mPas and an average molecular mass of 8500 g/mol were added. After stirring for a further 10 minutes, the mixture was pumped at 300 bar through two interaction chambers connected in series, the capillary thickness of the first chamber being 400 μm and that of the second chamber being 200 μm. At the outlet, the mixture was cooled to <30° C. by means of a plate cooler. An emulsion was formed which showed no deposition in either neat or diluted form.
Example 2
[0034] 5 parts of a mixture of equal parts of ethoxylated triglyceride as in Example 1 and ethoxylated fatty acid as in Example 1 were added to 73.29 parts of water at 60° C. 0.16 part of the polyacrylamide as in Example 1 and 1.35 parts of a linear, water-dispersible polyurethane (Coatex® BR 910 from Coatex) were then scattered into this hot mixture. The mixture was stirred for 10 minutes and 16.00 parts of the SiO 2 -containing organosiloxane as in Example 1 and 4.00 parts of a polyalkylene glycol ether (Arcol® 2000N from Lyondell) having a MW of approximately 2000 g/mol were added. After stirring for a further 10 minutes, the mixture was pumped at 150 bar through an interaction chamber whose capillary thickness was 400 μm. At the outlet, the mixture was cooled to <30° C. by means of a plate cooler. An emulsion was formed which showed no deposition in either neat or diluted form.
Example 3
[0035] 5 parts of a mixture of equal parts of ethoxylated triglyceride as in Example 1 and ethoxylated fatty acid as in Example 1 were added to 74.55 parts of water at 70° C. 0.25 part of the polyacrylamide as in Example 1 was then scattered into this hot mixture. The mixture was stirred for 10 minutes and 20 parts of an SiO 2 (5 parts of Sipemat® D10 from Degussa)-containing organosiloxane (Tego® Antifoam EH 7284-6 from Goldschmidt) which had a viscosity of 1600 mPas and an average molecular mass of 12000 g/mol were added. After stirring for a further 10 minutes, the mixture was pumped at 250 bar through two interaction chambers connected in series, the capillary thickness of the first chamber being 400 μm and that of the second chamber being 200 μm. At the outlet, the mixture was cooled to <30° C. by means of a plate cooler. An emulsion was formed which showed no deposition in either neat or diluted form.
Example 4
[0036] 3 parts of a mixture of equal parts of ethoxylated triglyceride as in Example 1 and ethoxylated fatty acid as in Example 1 were added to 74.55 parts of water at 70° C. 0.25 part of the polyacrylamide as in Example 1 was then scattered into this hot mixture. The mixture was stirred for 10 minutes and 20 parts of an SiO 2 -containing organosiloxane as in Example 3 were added. After stirring for a further 10 minutes, the mixture was pumped at 150 bar through two interaction chambers connected in series, the capillary thickness of the first chamber being 400 μm and that of the second chamber being 200 μm. At the outlet, the mixture was cooled to <30° C. by means of a plate cooler. An emulsion was formed which showed no deposition in either neat or diluted form.
Comparative Example 1
[0037] 5.00 parts of a mixture of equal parts of ethoxylated triglyceride as in Example 1 and ethoxylated fatty acid as in Example 1 were added to 10.00 parts of water at 60° C. and the mixture was stirred for 10 minutes with a turbine at a peripheral speed of 6 m/s. 20 parts of the SiO 2 -containing organosiloxane as in Example 1 were added to this hot mixture over the course of 5 minutes. After stirring at 6 m/s for a further 10 minutes, 50.00 parts of the 0.5% strength polyacrylamide solution as in Example 1 were added with cooling. This was followed by the addition of 10.00 parts of water. The whole was stirred until a temperature of <30° C. was reached, but for at least 10 minutes. Thereafter, the mixture was pumped at 50 bar through a gap homogenizer. An emulsion was formed which showed no deposition in either neat or diluted form.
Comparative Example 2
[0038] 5.00 parts of a mixture of equal parts of ethoxylated triglyceride as in Example 1 and ethoxylated fatty acid as in Example 1 were added to 10.00 parts of water at 60° C. and the mixture was stirred for 10 minutes with a turbine at a peripheral speed of 6 m/s. 16.00 parts of the SiO 2 -containing organosiloxane as in Example 1 and 4.00 parts of the polyalkylene glycol ether as in Example 2 were added to this hot mixture. After stirring at 6 m/s for a further 10 minutes, 32.00 parts of the 0.5% strength polyacrylamide solution as in Example 1 and 30.00 parts of a 4.5% strength mixture of a linear, water-dispersible polyurethane as in Example 2 were added with cooling. The whole was stirred until a temperature of <30° C. was reached, but for at least 10 minutes. Thereafter, the mixture was pumped at 50 bar through a gap homogenizer. An emulsion was formed which showed no deposition in either neat or diluted form.
Comparative Example 3
[0039] 5.00 parts of a mixture of equal parts of ethoxylated triglyceride as in Example 1 and ethoxylated fatty acid as in Example 1 were added to 10.00 parts of water at 60° C. and the mixture was stirred for 10 minutes with a turbine at a peripheral speed of 6 m/s. 20 parts of the SiO 2 -containing organosiloxane as in Example 3 were added to this hot mixture over the course of 5 minutes. After stirring at 6 m/s for a further 10 minutes, 50.00 parts of the 0.5% strength polyacrylamide solution as in Example 1 were added with cooling. This was followed by the addition of 10.00 parts of water. The whole was stirred until a temperature of <30° C. was reached, but for at least 10 minutes. Thereafter, the mixture was pumped at 50 bar through a gap homogenizer. An emulsion was formed which showed no deposition in either neat or diluted form.
Comparative Example 4
[0040] 3.00 parts of a mixture of equal parts of ethoxylated triglyceride as in Example 1 and ethoxylated fatty acid as in Example 1 were added to 10.00 parts of water at 60° C. and the mixture was stirred for 10 minutes with a turbine at a peripheral speed of 6 m/s. 20 parts of the SiO 2 -containing organosiloxane as in Example 2 were added to this hot mixture over the course of 5 minutes. After stirring at 6 m/s for a further 10 minutes, 50.00 parts of the 0.5% strength polyacrylamide solution as in Example 1 were added with cooling. This was followed by the addition of 10.00 parts of water. The whole was stirred until a temperature of <30° C. was reached, but for at least 10 minutes. Thereafter, the mixture was pumped at 50 bar through a gap homogenizer. An emulsion was formed which in neat form showed slight deposition of active substance and in diluted form showed considerable deposition of active substance.
[0041] The particle distributions of Examples 1 to 4 and Comparative Examples 1 to 4 were measured using a Coulter LS 230.
Average particle size Particle size range [μm] [μm] Distribution form Example 1 2.7 0.2 to 10 Monomodal Example 2 1.4 0.3 to 10 Monomodal Example 3 0.8 0.2 to 3 Monomodal Example 4 0.8 0.2 to 3 Monomodal Comp. 1 2.6 0.1 to 40 Bimodal Comp. 2 1.6 0.1 to 35 Bimodal Comp. 3 1 0.1 to 20 Monomodal
[0042] Owing to the instability of the product, it was not possible to determine the particle sizes of the comparative emulsion 4.
[0043] The defoamer emulsions for preparation in accordance with the invention had the following improved performance properties in particular:
[0044] Higher Dilution Stability
[0045] Using a balance, 5 g of defoamer emulsion were weighed out into a 250 ml glass beaker.
[0046] The emulsion was then rapidly dispersed with the addition of 45 ml of deionized water by swirling the glass beaker until dispersion was complete.
[0047] Assessment was made immediately following dilution, in accordance with the following rating scale:
Rating: Surface assessment of the dispersion: 1 no deposition 2 very thin oil film (Newton rings) 3 thin oil film 4 small oil drops and thin oil film 5 oil drops and deposition 6 large oil drops and severe deposition Product Rating of the dilution Example 1 1 Example 2 1 Example 3 1 Example 4 1 Comp. 1 2 Comp. 2 2 Comp. 3 3 Comp. 4 6
[0048] Greater Stability to External Shearing and to Impact and Collision
[0049] A 100 ml powder flask was filled to 80% with the emulsion for analysis, screwed shut and shaken on a shaking machine with a deflection of 30 mm and a frequency of 300 min −1 . The emulsions were examined visually each hour for their stability. The test was terminated after a maximum of 8 h.
Time after which deterioration of Dilution after shaking Product the sample is observed Rating Example 1 >8 hours 1 Example 2 >8 hours 2 Example 3 >8 hours 2 Example 4 >8 hours 2 Comp. 1 1 hour 6 Comp. 2 4 hours 5 Comp. 3 3 hours 6 Comp. 4 — —
[0050] Greater Heat/Low-Temperature Stability
[0051] The emulsions prepared in Examples 1 to 4 and Comparative Examples 1 to 3 were tested in terms of their freezing stability by freezing the emulsions at −15° C. and then thawing them at room temperature. This freezing was conducted 3 times in succession. The emulsions were subsequently diluted with deionized water and then rated.
[0052] For the determination of the heat stability, the emulsions were stored at 50° C. for 2 weeks. After cooling, the samples were diluted with deionized water and then assessed.
Dilution after Dilution after hot 3 freeze/thaw cycles storage Rating Rating Example 1 2 1 Example 2 2 2 Example 3 2 2 Example 4 2 1 Comp. 1 4 4 Comp. 2 6 4 Comp. 3 5 5
[0053] Lower Emulsifier Requirement
[0054] The stability comparison of emulsion 4 and of comparative emulsion 4 alone showed clearly that in accordance with the process of the invention the preparation of this emulsion was indeed possible with a lower emulsifier requirement, with markedly improved stability properties.
[0055] Higher Stability and Activity in Surfactant Concentrates
[0056] To examine the stability in surfactant concentrates, 1% of defoamer emulsion was added to the surfactant concentrate Marlosol® 013/50 (Hüls AG). This mixture was then diluted to 1% with deionized water and examined in a gassing test. In the gassing test, 1 liter of dilution was gassed with 6 liters of air per minute in a graduated 2 liter measuring cylinder using a frit of porosity D 1. A measurement was made of the time taken for 1 liter of foam to form. In order to determine the loss of activity occurring as a result of storage of the surfactant/defoamer mixture, the test was repeated following storage for 4 weeks.
Gassing test of the unstored Gassing test after sample 4 weeks of storage Time until 1 liter of foam Time until 1 liter of foam [s] [s] No additive 12 12 Example 1 1970 1820 Example 2 2740 2480 Example 3 1750 1760 Example 4 1790 1690 Comp. 1 1610 65 Comp. 2 2160 670 Comp. 3 1440 185
[0057] Reduced Fault Susceptibility in Aqueous Overprint Varnishes
[0058] To examine the performance properties, a printing varnish was formulated in accordance with the following recipe, the amounts being % by weight.
Joncryl ® 74 50.5 acrylate dispersion/Johnson Polymer Joncryl ® 680 23.1 Solution* Jonwax ® 35 7.2 polyethylene wax emulsion/ Johnson Polymer Water, demineralized 12.4 Isopropanol 2.9 Zn solution 2.9 Defoamer emulsion 1.0 100.0 *Joncryl ® 680 45.0 acrylate resin/Johnson Polymer 25% ammonia 11.2 Isopropanol 10.0 Water, demineralised 33.8 100.0
[0059] The last recipe constituent added was the defoamer emulsion, incorporation taking place by means of a bead mill disk at 1500 rpm for 3 minutes.
[0060] Foam Test
[0061] 50 g of the aqueous printing varnish were weighed out into a 150 ml glass beaker and subjected to shearing with a dissolver disk (3 cm in diameter) at 2500 rpm for 1 minute. Subsequently, 45 g were weighed out into a measuring cylinder and the foam height was reported in ml.
[0062] Wetting Behavior
[0063] The aqueous printing varnish was knife-coated using a spiralwound coating bar (12 μm) wet onto transparent PVC film. The dried film thus applied was examined visually for wetting defects. The assessment was made in accordance with a scale from 1 to 4, 1 describing a defect-free film, 4 testifying to severe wetting defects.
[0064] Results
Example 1 48 ml/45 g Rating 1 Comparative Example 5 50 ml/45 g Rating 3
[0065] Better (long-term) Defoaming in All-Acrylate and Acrylate Copolymer Dispersions and Coating Systems Based on These Dispersions
[0066] To examine further performance properties, the following emulsion paint recipe was selected (amounts in % by weight):
[0067] Emulsion paint:
Water 36.2 Coatex ® P50 0.4 Coatex, dispersant Dispers 715 W 0.1 Tego, dispersant Mergal ® K7 0.2 Preservative Coatex ® BR100 2.3 Coatex, PU thickener Calcidar ® extra 22.1 Omya, filler Titanium dioxide 17.5 Finntalk ® M15 4.7 NaOH, 10% strength 0.1 Acronal ® 290D 16.2 BASF, styrene acrylate dispersion Defoamer 0.2
[0068] All recipe constituents were used in as-supplied form. The last recipe constituent added in each case was the corresponding defoamer emulsion. Incorporation was carried out at 1000 rpm for one minute.
[0069] The activity was examined on the basis of the roller test, which is described below.
[0070] Roller Test
[0071] The so-called roller test came relatively close to the conditions encountered in practice, thereby permitting good differentiation between the different defoamer formulations also in respect of the concentrations to be used.
[0072] In the roller test, 40 g of the test emulsion paint were spread using an open-pored foam roller onto a nonabsorbent test card having a total surface area of 500 cm 2 . Prior to the application of the paint, the foam roller was wetted with water. It was ensured that the additional amount of water introduced into the applied paint was always the same, so that the drying time of the paint always remained the same. The wet film add-on was approximately 300 g/m 2 surface area. After 24-hour drying of the film, the test panels were evaluated in respect of the macrofoam present (number of bubbles per 100 cm 2 ), in terms of the microfoam present (number of pinholes by comparison with test panels with differing defect patterns, scale from 1 (very good) to 5 (deficient, many pinholes), and for any wetting defects.
[0073] These tests were repeated with the emulsion paint to which the additive had been added and which had been stored at 50° C. for 6 weeks.
[0074] Results of the Roller Test in Emulsion Paint
Formu- Concen- Macrofoam Microfoam Wetting defects lation tration 0 w 6 w 0 w 6 w 0 w 6 w Blank 0 50 50 4 4 none none sample Ex.1 0.2 0 0 1 1 none none Ex.1 0.1 0 1 1 1 none none Ex.1 0.06 0 2 1 1 none none Comp. 1 0.2 0 3 1 2 none none Comp. 1 0.1 1 36 1 2 none slight Ex.2 0.1 0 0 1 1 none none Comp. 2 0.1 1 40 1 3 none severe
[0075] The superiority of the defoamers prepared by the process of the invention in respect of their efficiency and in particular in respect of their long-term activity was evident.
[0076] As is also evident from the above performance examples, the defoamer emulsions prepared by the process of the invention feature improved product stabilities such as improved shaking stability and heat stability, without which they would in many cases not be able to be transported or subsequently used. Owing to the fundamentally better stabilization of these macroemulsions, there is also an improved dilution stability in all cases. It is also possible to prepare certain emulsions with a reduced emulsifier requirement, which at least restricts the use of these surfactants, which for the most part are ecotoxicologically objectionable. In particular, however, properties showing consistently marked improvement are obtained in application-relevant test systems.
[0077] The above description of the invention is intended to be illustrative and not limiting. Various changes or modifications in the embodiment described herein may occur to those skilled in the art. These can be made without departing from the scope and spirit of the invention.
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The invention relates to a process for preparing polyorganosiloxane emulsions whose internal phase comprises the active polyorganosiloxane substance and whose external phase comprises, in solution or dispersion, an emulsifier or an emulsifier mixture and, if desired, an emulsion-stabilizing protective colloid, to the polysiloxane emulsions thus obtainable and, in particular, to the use of these macroemulsions, so prepared, as defoamers.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 11/624,755, entitled Presentation of Data on Multiple Display Devices Using a Wireless Home Entertainment Hub, filed Jan. 19, 2007, Attorney Docket No. TPL-012-1, which is a continuation-in-part of co-pending U.S. patent application Ser. No. 11/563,486, entitled Inventory of Home Entertainment System Devices Using a Wireless Home Entertainment Hub, filed Nov. 27, 2006, Attorney Docket No. TPL-010-1, which is a continuation-in-part of U.S. patent application Ser. No. 11/470,862, entitled Data Presentation Using a Wireless Home Entertainment Hub, filed Sep. 7, 2006, Attorney Docket No. TPL-009-1, the entire disclosures of which are incorporated herein by reference.
[0002] This application is related to co-pending U.S. patent application Ser. No. ______, entitled Presentation of Still Image Data on Display Devices Using a Wireless Home Entertainment Hub, filed ______, 2007, Attorney Docket No. TPL-012-3, U.S. patent application Ser. No. ______, entitled Data Presentation by User Movement in Multiple Zones Using a Wireless Home Entertainment Hub, filed ______, 2007, Attorney Docket No. TPL-012-4, U.S. patent application Ser. No. 11/470,872, entitled Control of Data Presentation Using a Wireless Home Entertainment Hub, filed Sep. 7, 2006, Attorney Docket No. TPL-009-2; U.S. patent application Ser. No. 11/470,879, entitled Data Presentation from Multiple Sources using a Wireless Home Entertainment Hub, filed Sep. 7, 2006, Attorney Docket No. TPL-009-3; U.S. application Ser. No. 11/470,895, entitled Control of Data Presentation from Multiple Sources Using a Wireless Home Entertainment Hub, filed Sep. 7, 2006, Attorney Docket No. TPL-009-4, U.S. patent application Ser. No. 11/535,211, entitled Device Registration Using a Wireless Home Entertainment Hub, filed Sep. 26, 2006, Attorney Docket No. TPL-009-5; U.S. patent application Ser. No. 11/535,216, entitled User Directed Device Registration Using a Wireless Home Entertainment Hub, filed Sep. 26, 2006, Attorney Docket No. TPL-009-6; U.S. patent application Ser. No. 11/535,232, entitled Source Device Change using a Wireless Home Entertainment Hub, filed Sep. 26, 2006, Attorney Docket No. TPL-009-7; U.S. application Ser. No. 11/563,366, entitled Control of Access to Data Using a Wireless Home Entertainment Hub, filed Nov. 27, 2006, Attorney Docket No. TPL-009-8; U.S. patent application Ser. No. ______, entitled Remote Control Operation Using a Wireless Home Entertainment Hub, filed ______, 2007, Attorney Docket No. TPL-009-9; U.S. patent application Ser. No. ______, entitled Audio Control Using a Wireless Home Entertainment Hub, filed ______, 2007, Attorney Docket No. TPL-009-10; U.S. patent application Ser. No. ______, entitled Power Management Using a Wireless Home Entertainment Hub, filed ______, 2007, Attorney Docket No. TPL-009-11; U.S. application Ser. No. 11/563,520, entitled Connecting a Legacy Device into a Home Entertainment System Using a Wireless Home Entertainment Hub, filed Nov. 27, 2006, Attorney Docket No. TPL-010-2; U.S. application Ser. No. 11/563,530, entitled Data Presentation in Multiple Zones Using a Wireless Home Entertainment Hub, filed Nov. 27, 2006, Attorney Docket No. TPL-010-3 and U.S. application Ser. No. 11/563,503, entitled Control of Data Presentation in Multiple Zones Using a Wireless Home Entertainment Hub, filed Nov. 27, 2006, Attorney Docket No. TPL-010-4, the entire disclosures of which are incorporated herein by reference.
BRIEF DESCRIPTION OF THE DRAWINGS
[0003] The following detailed description will be better understood when read in conjunction with the appended drawings, in which there is shown one or more of the multiple embodiments of the present invention. It should be understood, however, that the various embodiments of the present invention are not limited to the precise arrangements and instrumentalities shown in the drawings.
[0004] In the Drawings:
[0005] FIG. 1 is a system diagram of a home entertainment system according to one embodiment of the present invention;
[0006] FIG. 2 is a use-case diagram of a wireless home entertainment hub in accordance with the home entertainment system of FIG. 1 ;
[0007] FIG. 3 is a sequence diagram of user-initiated automatic registration in accordance with the home entertainment system of FIG. 1 ;
[0008] FIG. 4 is a sequence diagram of manual device registration in accordance with the home entertainment system of FIG. 1 ;
[0009] FIG. 5 is a sequence diagram of source activation in accordance with the home entertainment system of FIG. 1 ;
[0010] FIG. 6 is a sequence diagram of direct source to sink transmission of data within the home entertainment system of FIG. 1 ;
[0011] FIG. 7 is a sequence diagram of transmission of data directed by the wireless home entertainment hub within the home entertainment system of FIG. 1 ;
[0012] FIG. 8 is a sequence diagram of operation of a remote control in accordance with the wireless home entertainment system of FIG. 1 ;
[0013] FIG. 9 is a system diagram of an audio/visual receiver used to connect speakers to the wireless home entertainment hub of FIG. 1 ;
[0014] FIG. 10 is a system diagram of a wireless network interface box used to connect non-wireless enabled devices to the wireless home entertainment hub of FIG. 1 ;
[0015] FIG. 11 is a system diagram of a multiple display device configuration in accordance with the home entertainment system of FIG. 1 ;
[0016] FIG. 12 is a system diagram of an implementation of using multiple display devices for a wide-angle display in accordance with the home entertainment system of FIG. 1 ;
[0017] FIG. 13 illustrates a series of exemplary user interface display device screens for registering devices in accordance with the home entertainment system of FIG. 1 ;
[0018] FIG. 14 illustrates a series of exemplary user interface display device screens for registering speakers in accordance with the home entertainment system of FIG. 1 ;
[0019] FIG. 15 illustrates a series of exemplary user interface display device screens for showing missing devices in accordance with the home entertainment system of FIG. 1 ;
[0020] FIG. 16 a sequence diagram of an audio calibration procedure using the wireless home entertainment hub in accordance with the home entertainment system of FIG. 1 ;
[0021] FIG. 17 a sequence diagram of re-directing program content by the wireless home entertainment hub based on movement of a user within the home entertainment system of FIG. 1 ; and
[0022] FIG. 18 a sequence diagram of re-directing voice-over-IP data by the wireless home entertainment hub based on movement of a user within the home entertainment system of FIG. 1 .
DETAILED DESCRIPTION
[0023] Certain terminology is used herein for convenience only and is not to be taken as a limitation on the embodiments of the present invention. In the drawings, the same reference letters are employed for designating the same elements throughout the several figures.
[0024] The words “right”, “left”, “lower” and “upper” designate directions in the drawings to which reference is made. The words “inwardly” and “outwardly” refer to directions toward and away from, respectively, the geometric center of the home entertainment system and designated parts thereof. The terminology includes the words above specifically mentioned, derivatives thereof and words of similar import.
[0025] Unified Modeling Language (“UML”) can be used to model and/or describe methods and systems and provide the basis for better understanding their functionality and internal operation as well as describing interfaces with external components, systems and people using standardized notation. When used herein, UML diagrams including, but not limited to, use case diagrams, class diagrams and activity diagrams, are meant to serve as an aid in describing the embodiments of the present invention, but do not constrain implementation thereof to any particular hardware or software embodiments. Unless otherwise noted, the notation used with respect to the UML diagrams contained herein is consistent with the UML 2.0 specification or variants thereof and is understood by those skilled in the art.
[0026] An exemplary home entertainment system (HES) 100 including wirelessly connected devices in accordance with one embodiment of the present invention is shown in FIG. 1 . Interactions between the various wireless devices in the HES 100 and a user 120 are coordinated by a wireless home entertainment hub (WHEH) 102 . It is understood by those skilled in the art that a wireless device in the HES 100 may contain an external wire for the purpose of supplying power to the wireless device.
[0027] Referring generally to FIGS. 1 and 2 , devices in the HES 100 can broadly be classified into two categories: source devices 122 and sink devices 124 . Source devices 122 transmit data within the HES 100 . Source devices 122 include, but are not limited to, DVD players 104 , digital video recorders (DVR) (not shown), set-top boxes (STB) 106 (e.g., cable or satellite channel tuners), gaming consoles 108 (e.g. Xbox®, PlayStation®), CD players or other audio playback devices (e.g., MP3 player) (not shown). It is understood by those skilled in the art that external data can be introduced into the HES 100 for transmission by one or more of the source devices 122 by various means, such as optical fiber, co-axial cable, or a satellite dish system connected to the STB 106 . Sink devices 124 receive the transmitted data within the HES 100 , sometimes converting a signal into an audible or visible stimulus. Sink devices 124 include, but are not limited to, speakers 110 , audio/visual receivers (AVR) 145 (see FIG. 9 ), and display devices 112 such as an HDTV or other television, monitor, or display screen or mechanism.
[0028] Those skilled in the art will recognize that a PC 114 can act as a source device 122 and/or a sink device 124 within the HES 100 . The PC 114 can act ad an audio and/or a video source transmitting data from, for example, a CD, DVD, stored music and video media, or data accessed from the Internet. The PC 114 can also act as a sink device 124 displaying video and audio data from, for example, the DVD player 104 or STB 106 .
[0029] The HES 100 may also utilize a remote control 118 and a calibration device 116 , discussed in greater detail below.
[0030] The WHEH 102 facilitates the transfer of data between the source and sink devices in the HES 100 , as well as coordinates the interaction between the user 120 and the source and sink devices 122 , 124 . For example, referring to FIG. 2 , the WHEH 102 may perform a register devices use-case, change source use-case, direct audio and video signal use-case, program remote use-case, control volume use-case, and calibrate system use-case, which are described in more detail below. Within the HES 100 , the WHEH 102 controls the flow of data, information and other “traffic” by recognizing the devices within the HES 100 , tracking their current status (e.g., active, standby, etc.), directing the transfer of data between devices, etc. In addition, the WHEH 102 provides a central controller for the HES 100 that allows a user 120 to operate the HES 100 in an efficient manner through interaction with the WHEH 102 , which then subsequently provides instructions to the other devices in the HES 100 to perform the function requested by the user 120 . Such interactions with the WHEH 102 by the user may be performed through with a visual user interface presented on the screen of the display device 112 . Alternately, the remote control 118 may include a display screen, such as an LCD, to present the user with a visual interface to the WHEH 102 .
[0031] The WHEH 102 includes one or more wireless transceiver units to facilitate the wireless transfer of data between the source and sink devices 122 , 124 using wireless communication standards described below, a memory for storing data and other information generally used in the operation of the HES 100 , and a processor for executing the instruction sets for the functions of performed by the WHEH 102 , including the use-cases listed above. The WHEH 102 may exist as a standalone unit or it may be integrated into another device. For example, the WHEH may be included in the display device 112 or the remote control 118 . One skilled in the art will recognize that the WHEH 102 can act as a source device 122 and/or a sink device 124 in the HES 100 . For example, the WHEH 102 may receive data (i.e., acts as a sink unit) from a source unit currently transmitting data in the HES 100 , and process and transmit that data (i.e., acts as a source unit) to other sink devices in the HES 100 for presentation to a user 120 .
[0032] Ultra-wide band technology (UWB) utilizing orthogonal frequency division multiplexing (OFDM) or a direct sequence communication system may be used for the wireless communication between the WHEH 102 and the source and sink devices 122 , 124 in the HES 100 . Those skilled in the art will recognize that a number of other wireless commutation standards, including Bluetooth and various WiFi standards, can be used without departing from the spirit and scope of multiple embodiments of the present invention for transfer of data between devices within the HES 100 . In one embodiment, more than one wireless standard may be utilized within the HES 100 to facilitate data transfer between the devices. For example, the WHEH 102 and source and sink devices 122 , 124 may each contain a UWB transceiver for transfer of audio and/or video data and a WiFi transceiver for transferring operation instructions.
[0033] Referring generally to FIGS. 2-4 , audio and video devices in the HES 100 can be registered with the WHEH 102 . The registration creates a unique association between devices and the WHEH 102 such that registered devices belonging to the HES 100 are controlled by WHEH 102 , and cannot simultaneously be registered with a different home entertainment system or another wireless home entertainment hub operating in a nearby proximity, such as in a neighboring apartment or household.
User-Initiated Automatic Registration
[0034] Referring to FIG. 3 , the user 120 initiates the registration procedure. The WHEH 102 sends a request for any unregistered device to respond. The WHEH 102 request may include a unique identifier for the WHEH 102 , such as a WHEH ID number. A device response includes a unique device identifier, such as a device ID number. Referring to FIG. 13 , a list of responding devices 160 is presented to the user 120 , and the user 120 selects the device that is to be registered with WHEH 102 . The WHEH 102 sends a registration instruction to the selected device and the registration is stored on both the device and the WHEH 102 . Once a registration has been established 162, the device is removed from the list 164 , and the registration process is repeated for the remaining unregistered devices within the HES 100 that have responded to the WHEH 102 .
[0035] In an alternate embodiment, the registration procedure is accomplished automatically between the WHEH 102 and unregistered devices. For example, the WHEH 102 may periodically broadcast a request for any unregistered devices to report. In addition to replying with the device ID number, an unregistered device can respond with a list of its capabilities so that the WHEH 102 can determine the functionality of the device (i.e., if it is a DVD player, DVR, STB, etc.) before sending a registration instruction. Alternately, the unregistered device can respond with its make and model number from which the WHEH 102 can determine the functionality of the device using an internal database of devices and also obtain any necessary command codes for the device,
[0036] Alternatively, the user 120 may initiate the broadcast for unregistered sources instead of having the WHEH 102 perform a periodic broadcast for unregistered sources. For example, when a user 120 adds a new component or device to the HES 100 , a request to find unregistered sources may be initiated, such that once the request is initiated, the remaining registration procedure proceeds automatically as discussed above.
[0037] In an alternate embodiment, the WHEH 102 may automatically recognize and register all devices in the HES 100 . For example, a user 120 may purchase a set of coordinated devices for wireless HES 100 including, for example, a display, set of multi-channel speakers, a DVD player 104 , and a WHEH 102 (which may be a discreet device or contained in one of the system devices, such as the display or remote control). Each of these coordinated devices may contain a coordinated ID that is recognizable by the WHEH 102 . Additionally, the speakers may be labeled with their intended position within the HES 100 (e.g., front left, middle right) to aid the user 120 in their correct placement. Upon placement and power-up, without any additional actions by the user 120 , the WHEH 102 automatically registers the coordinated devices based on their coordinated ID's that have been set by the device manufacturer.
[0038] The wireless HES 100 may perform an error checking during the registration of the source and sink devices to make sure that the device being registered matches the type of device being requested for registration. The WHEH 102 can compare the list of capabilities received from the device during the registration with a list of expected capabilities stored in the WHEH 102 . If the capabilities in the device reply match the expected capabilities of the WHEH 102 , an indication of the registration is stored in the WHEH 102 and the device. If the capabilities and expected capabilities do not match, the registration is not stored and may be re-initiated.
Manual Registration
[0039] The registration may also be performed manually by the user 120 (see FIG. 4 ). The user 120 initiates a registration procedure by pressing a registration actuator on the WHEH 102 . Examples of actuators include buttons, touch pads, touch screens, or any other actuating assembly recognized by those skilled in the art. The user 120 presses a registration actuator on a selected source unit which sends a signal to the WHEH 102 that a registration should be stored with this unit. If the WHEH 102 is unable to determine the functionality of the source (e.g., DVR, DVD, etc), the user 120 may manually assign the functionality of the source to complete the registration. For example, if the user 120 selects the registration actuators on the WHEH 102 and the DVD player 104 , the WHEH 102 may cause “DVD registered” to be displayed if the selected source is recognized as a DVD player 104 by the WHEH 102 . If the selected source is not recognized, the WHEH 102 may prompt the user 120 to select the type of source device from a list. Thus, in this case, the user 120 may select “DVD” in order to complete the registration. This process is repeated until all the unregistered sources have been registered with the WHEH 102 , or similarly if a new source is added into an existing system. In other embodiments, the user 120 may initiate registration from a source device 122 , a sink device 124 , a remote control 118 , or over a network.
Multi-Instance Device Registration
[0040] For device types where multiple instances of the device exist within the system 100 (e.g., speakers 110 ), a number of approaches can be used to identify each device's specific role. For speakers 110 , the role of each speaker can be pre-identified by the manufacturer (e.g., “front-right”, “subwoofer”, etc.). The user-initiated automatic registration procedure described above could be used to register the speakers 110 with the WHEH 102 since the speaker 110 could identify itself, for example, as the front left speaker, during the registration process. Alternatively, each speaker 110 could have a physical input that the user 120 could set to indicate the speaker's role (e.g. “front-left”, “back-right-surround”). In another embodiment, the WHEH 102 could use one or more microphones within the HES 100 to elicit position and frequency response information, or the HES 100 could use other position detection technologies understood by those skilled in the art.
[0041] In another embodiment, each speaker 110 could have a registration actuator to be activated in response to a WHEH 102 prompt for a speaker playing a specific role. For instance, the WHEH 102 could prompt the user 120 for the front-left speaker and the user 120 could activate the registration actuator. Alternately, the user 120 may initiate the registration procedure by activating a registration actuator on the WHEH 102 . The user 120 then presses a registration actuator on a speaker 110 and identifies the functionality of that speaker 110 within the audio system 100 . For example, at the time of registration, the user 120 identifies the selected speaker as the left front, the repeats for right front, continuing until all the speakers 110 have been identified and registered. In one embodiment, the WHEH 102 may prompt the user 120 with a list or graphic display of speaker positions available as shown in FIG. 14 . The user 120 first selects the speaker 110 to be registered and then presses the registration actuator on the selected speaker. In an alternate embodiment, the WHEH 102 may first prompt the user 120 to enter the number of speakers to be registered with the WHEH 102 and then select the appropriate speaker configuration to match. For example, if only four speakers 110 are selected, the WHEH 102 would not present the user 120 with a Dolby® Digital 7.1 speaker configuration, but a four speaker list of left and right front, and left and right rear.
[0042] After device registration is complete, the WHEH 102 may compare the list of source devices 122 and sink devices 124 registered with the WHEH 102 to a list of possible types of source devices 122 and sink devices 124 that can be registered with the WHEH 102 . Using the display device 112 , the WHEH 102 may present to the user 120 a list of device types that are missing from the HES 100 . The user 120 can indicate whether one or more of the listed device types are present in the HES 100 , indicative of an error in the registration procedure. These devices can then be registered with the WHEH 102 using any appropriate method described above. For example, after registering all the detected devices in a HES 100 , the WHEH 102 determines that a gaming console 108 , a DVR, and a subwoofer are missing device types within the HES 100 . A list of these missing device types is displayed on the HDTV. The user 120 inputs that the subwoofer is present in the HES 100 . After the subwoofer is successfully registered, the user 120 is presented with a list of gaming console 108 and DVR as the missing device types. Referring to FIG. 15 , in one embodiment, the WHEH 102 may present the user with a list of devices missing in the HES 100 based on requirements to fully support playback of program content. For example, if a DVD program contains a 5 channel audio track, but only two speakers, front left and front right, are registered with the WHEH 102 , the WHEH 102 may display an indication to the user 120 that a rear left, rear right, center channel and subwoofer may be added to the HES 100 to enhance the audio experience of the user 120 .
[0043] Once the WHEH 102 has determined a list of missing device types, the WHEH 102 may then cause advertisements for the missing devices to be displayed to the user 120 on the display device 112 . The advertisements may be generic advertisements for the missing device type or may be sponsored advertisements for a specific brand of the missing device. Advertisements may be stored on the WHEH 102 or received from programming channels accessible using the STB 106 . Alternately, the advertisements may be retrieved from a computer network (e.g. the Internet) through a direct connection of the WHEH 102 to the computer network or via a PC 114 connected to the computer network and registered with the WHEH 102 . For example, the WHEH 102 determines that no DVR is registered with the WHEH 102 . The WHEH 102 transmits an advertisement for a DVR stored in the WHEH 102 to the display device 112 for presentation to the user 120 just after the user 120 has initiated the entertainment session and before displaying the requested programming. Alternately, the WHEH 102 may insert advertisements into the programming by replacing an advertisement from the programming stream with an advertisement for the missing device or device type. For example, if a gaming console 108 is determined to be missing, the WHEH 102 may detect an advertisement for a gaming console 108 on a programming channel received on the STB 106 . The WHEH 102 stores the advertisement for the gaming console 108 and replaces advertisements in the regular programming stream with the stored advertisement for a gaming console 108 .
[0044] The presentation of the advertisement may be repeated for a predetermined length of time (e.g. for 4 weeks) or until the missing device is registered with the WHEH 102 . The insertion of advertisements for missing devices or device types may also be limited to a range of dates and/or times. For example, advertisements for gaming consoles 108 may be presented to the user 120 from the middle of November until the end of December to correspond to a holiday shopping season. Alternately, the insertion of the advertisements may be based on an identification of the user by the WHEH 102 .
Source Selection
[0045] Referring generally to FIGS. 2 , 5 - 7 , in addition to coordinating the registration of device within the HES 100 as described above, the WHEH 102 is also used to coordinate and/or control the state of the source and sink devices and the transfer of data from the source devices to sink devices during typical operation of the HES 100 . Device states (also referred to as modes) may include “on”, “off”, “active”, “low power”, “standby”, etc. Data may include instructions, audio/video programming, or any other information generally passed between or among source/sink devices. Some examples of typical operations that are common in the general utilization of the HES 100 by the user 120 are a request or action by the user 120 to activate a source (e.g., start watching programming from a cable broadcast) or initiate a change from one source device to another (e.g., discontinue watching programming from a cable broadcast to watching a movie on the DVD player). The request to activate a source device or to change from one source device to another can be accomplished in a several ways. The user may initiate the action though the use of the remote control 118 , or interact directly with a source device. For example, when a user inserts a DVD into the DVD player 104 , it automatically causes the WHEH 102 to activate the DVD player 104 (or initiate a source change as described below if another source is already active in the HES 100 ). In either case, once the request has been made by the user 120 , the WHEH 102 completes the process as described below.
[0046] FIG. 5 . is sequence diagram showing the selection of a source device 122 by the WHEH 102 in one embodiment of the HES 100 . When a source device is activated, it begins transmitting data to the HES 100 . The instruction to activate also causes an internal reference count within the source device to increment by one, where the reference count represents the current number of zones (described in more detail below) that are receiving data from the source device For example, if the source device, currently in standby mode, is activated, its reference count increases to one. After a user 120 initiates a request to change to a new source, the WHEH 102 instructs the current active source device to decrement its internal reference count by one. When the active source device internal reference count is zero, the source device may stop transmitting and enter a low power or stand-by mode. If the internal reference count is not zero, the source device continues to transmit since there are other devices still listening to its transmission. The WHEH 102 then instructs the newly selected source unit to activate, including increasing its internal reference count by one, and the newly selected source device begins transmitting data to the HES 100 . The sink devices may receive the transmitted data directly from the current active source or from the WHEH 100 , both described below. In an alternate embodiment, a list of the sink devices 124 in one or more zones of the HES 100 that are listening for data from the source device 122 is stored in the source device 122 . Sink devices 124 are added or removed from the list as directed by the WHEH 102 . When there are no sink devices on the list, the source device may stop transmitting and enter a low power or stand-by mode.
Direct Source to Sink Data Transmission
[0047] Referring to FIG. 6 , after a source activation or change is initiated within the HES 100 as described above, the WHEH 102 broadcasts to all sink units, or those that are relevant, an instruction to discontinue receiving and transmitting data from the previously active source and begin receiving the transmitted data from the newly selected source, where the activities in FIG. 6 . labeled “transmitvideo( )” and “transmitAudio( )” represent a continuous stream of data from the source device 122 to the sink devices 124 . This instruction from the WHEH 102 may be broadcast as a single instruction to all units (i.e., a common instruction recognizable by any device in the HES 100 ) or may be a distinct instruction sent to each of the sink units. Audio and/or video data from the current active source device is transmitted directly to the relevant sink devices as instructed by the WHEH 102 . For example, the display device 112 and speaker 110 receive and present the video data and audio data, respectively, from the current active source device. In one embodiment, the newly selected source device that has been activated in the HES 100 may transmit one or more instructions directly to the sink units to begin receiving and presenting the data from the newly selected source and discontinue presenting the data from the previously active source.
Source to Sink Data Transmission Through the WHEH
[0048] In an alternate embodiment, the sink units in the HES 100 receive data from the wireless home entertainment hub (see FIG. 7 ). The WHEH 102 receives the audio and video data from the current active source device and transmits the audio and video data to the appropriate sink unit. If a source change is initiated within the HES 100 as described above, the sink units may be unaware of a change of source with the HES 100 since they always listen to (i.e., receive data from) the WHEH 102 , and not directly to the active source device.
[0049] In one embodiment, more than one source can be designed as an active source by the WHEH 102 . Data from multiple active sources can be simultaneously presented by the relevant sink devices as described by the two methods above. The WHEH 102 receives the data from the two or more active source devices and transmits the data to the relevant sink devices. The WHEH 102 may process (e.g., mix) the data from the two or more source devices before transmitting. Alternately, the WHEH 102 may instruct the sink devices to listen to and present data transmitted directly from the two or more active sink devices.
[0050] Referring to FIG. 8 , in one embodiment of the present invention, a remote control 118 is used with the HES 100 . The remote control 118 receives actuator assignments based on the currently active source in the HES 100 from the WHEH 102 . For example, if the DVD player 104 is currently the active source, the actuator assignment on the remote control 118 is for the DVD player 104 . When a user 120 activates an actuator on the remote control 118 , the actuator selection is sent directly to the DVD player 104 , which responds with the corresponding activity for that actuator. If the user 120 initiates a source change through the WHEH 102 as described above, (e.g. from the DVD player 104 to the set-top tuner), then the WHEH 102 sends a new actuator assignment to the remote control 118 for the set-top tuner. Actuators activated on the remote control 118 by a user 120 now cause an activity in the set-top box instead of the DVD player 104 . This method of operation of the remote control 118 is referred to a “dumb” remote. The functionality of the actuators on the remote control is controlled by the WHEH 102 based on the current active source in the HES 100 . The remote does not need to store any information about past or present states of the HES 100 or registration information between the devices in the HES 100 .
[0051] In an alternate embodiment, a “smart” remote may be used in conjunction with the HES 100 . The smart remote learns and stores the system configuration, i.e., what source and sink devices are registered with the WHEH 102 . It also learns and stores the current state of the system, i.e., what sources and sinks are active. In addition, the smart remote stores the actuator assignments in an internal memory and may store system status information along with device registration information. When a user 120 requests a source change using the remote, the WHEH 102 activates the new source as describe above, and the functionality of the remote control 118 is switched to controlling the newly active source without any input from the WHEH 102 to re-assign the actuators as described in the dumb remote case above. In one embodiment, the WHEH 102 may be contained in the smart remote instead of the display device 112 .
[0052] A handheld mobile device, such as cellular phone or personal digital assistant, can use appropriate wireless capabilities to communicate with a WHEH 102 , obtain information to build and present a user interface, and serve as a remote control 118 for the HES 100 . In addition, the capabilities of the HES 100 may be used to enhance the functionality of the handheld mobile device. For example, when a cellular phone is active the remote control 118 , the active display device 112 may display CallerID information or other information generally presented on the cellular phone display to the user 120 during an incoming telephone call.
[0053] The WHEH 102 may respond to voice commands. A user 120 can perform some or all of the functionality of the remote control 118 by using simple audible commands. For example, to change the STB to channel 21 , the user 120 might say “Channel 21 ” and the WHEH 102 sends the corresponding instruction to the STB to complete the channel change, or use the command “Volume Up” increase the system volume, where the WHEH 102 send instructions to the active sink unit to increase volume.
[0054] In one embodiment, the WHEH 102 may respond to physical gestures made by the user 120 with the remote control 118 . A user can provide instructions to the WHEH 102 corresponding to a predetermined set of physical motions of the remote. The remote control 118 may include a motion sensing system that can relay motion information in up to 3-dimensions to the WHEH 102 . Additionally, the WHEH 102 or remote control 118 may include directional sensors to determine the orientation of the remote control relative to the HES 100 or sense rotation. Such motion sensing systems and directional sensors are understood by those skilled in the art. For example, a user wishing to switch from watching the DVD player to the STB 106 may simply point the remote at the STB 106 , actuating an actuator on the remote control 118 to select a programming channel. Alternately, channel selection may be accomplished by a quick series of left or right motions of the remote control, each left or right motion decrementing or incrementing, respectively, the channel displayed by the STB 106 . Volume control may be accomplished, for example, by a vertical motion of the remote control 118 directed at the display device 112 or speakers 110 . In this manner, the volume of each speaker can be adjusted independently of the other speakers. In one embodiment, gestures may be used to move presentation of video content from one display device to another, engage picture-in-picture functionality, or perform other manipulations.
Power Management
[0055] At startup of an entertainment session, a user 120 may direct a power-on message to the WHEH 102 , via a remote control 118 or perhaps via an actuator on the WHEH 102 or device containing WHEH 102 functionality. The WHEH 102 can then retrieve input from the user 120 regarding the capabilities required for the session and send activation messages to appropriate devices.
[0056] In another embodiment, a source device 122 can send a broadcast message to the sink devices 124 in the home entertainment network indicating required presentation capabilities. Required devices can activate themselves and unneeded devices can enter a low-power state. For example, all devices in the system are in a lower power mode. The user inserts a DVD into the DVD player 104 which causes the DVD to become active. The WHEH 102 detects the activity of the DVD player 104 and instructs the display device 112 and speakers 110 to activate. Alternately, the display device 112 and speakers detect the activity of the DVD player 104 directly and activate.
[0057] In one embodiment, upon indication from the active source device of the required audio output channels, the WHEH 102 sends signals to the audio sink devices to indicate whether or not they should remain active. For instance, upon indication of a Dolby® Digital 2.1 program, the WHEH 102 may communicate to the side and rear speakers that they may enter a low power mode. Similarly, when an audio-only program is indicated, for example from the CD player, the WHEH 102 can communicate to the video display device 112 that it may enter a low power non-display state.
[0058] Devices in the HES 100 may contain low-powered radios (i.e., transceivers) that poll for activity or constantly monitor for WHEH 102 messages during a low-power device state. Wireless radios conforming to the “ZigBee” standards can be used in some embodiments. “Bluetooth” or “WiFi” radios can be used in other embodiments. Modes of “UWB” can also be used to detect communications during low-power operations.
Volume Control
[0059] Volume control, including system muting, can be accomplished in multiple ways.
[0060] In one embodiment, all active audio sink devices may individually detect that the remote control 118 has transmitted an instruction to change the volume. For instance, the eight speakers of a 7.1 surround sound system each detect a “volume up” instruction transmitted from the remote control 118 . Each speaker then increases the gain on its internal amplifier, thereby driving the speaker to higher volume. Alternatively, the WHEH 102 can detect an instruction from the remote control 118 requesting a volume change and transmit to all the audio sink devices one or more instructions to change their volume.
System Calibration
[0061] For calibration of the HES 100 , a wireless calibration device 116 may be placed at a typical viewing and/or listening position 121 (e.g., near or on a chair or couch that a user 120 would sit to view the television) of the HES 100 by the user 120 (see FIG. 1 ). Referring to FIG. 16 , for audio calibration, the WHEH 102 can direct a calibration signal to each audio device in sequence or in combination, or each audio device can be directed to generate its own calibration program. A microphone in the wireless calibration device 116 monitors the calibration signals from the audio devices, and can communicate its readings to the WHEH 102 or back to the audio devices in a point-to-point or broadcast mode. Adjustments can then be made to the frequency characteristics, volume, or other parameters to provide a calibrated home theater environment. Similarly, a wireless light sensitive device can be used to monitor a calibration signal from one or more display devices 112 to provide video calibration of the system. In one embodiment, the microphone and light sensitive device may be contained in a single calibration unit. Alternately, the microphone and light sensitive may be contained in separate calibration units. In one embodiment, an actuator on the microphone device can cause the device to communicate with the hub to initiate the calibration sequence.
A/V Receiver
[0062] Referring to FIG. 9 , one or more audio/visual receivers (AVR) 145 or amplifiers can be used to connect the HES 100 to speaker system. The speaker system may be wired 140 , wireless 142 or a combination thereof. For example, the front speakers 142 in a four speaker system may be wirelessly connected 146 to the AVR 145 , while the rear speakers 140 are connected by a wire 148 to the AVR 145 . The AVR 145 is registered with the WHEH 102 and receives audio data from an active source (not shown) or through the WHEH 102 , as described above. The AVR 145 transmits the received audio data to the appropriate speakers 140 , 142 , either through the wired connection 148 or by wireless communication 146 . It should be noted that if the AVR 145 is configured for use with wireless speakers 142 , these wireless speakers 142 are not registered with the WHEH 102 as described above and do not receive data from the WHEH 102 or source devices 122 in the HES 100 , but instead communicate with the AVR 145 using methods understood by those skilled in the art.
Legacy Adaptor
[0063] Referring to FIG. 10 , a home theatre network interface box (HTNIB) 125 may be used to connect “legacy” devices 130 into the HES 100 , including the WHEH 102 . Legacy devices generally include those devices that require hardwire connection for transmission and/or receipt of data and are not wireless enabled (e.g., an analog television connected to a set-top box using coaxial cable), although a wireless device may also be considered a legacy device if the wireless device can not be configured to communicate with the wireless home entertainment hub. The legacy device is connected to the HTNIB 125 using a hardwire connection 128 (e.g. coaxial cable). The HTNIB 125 is capable of being registered with the WHEH 102 , and recognized by the WHEH 102 as the legacy device to which it is connected. The WHEH 102 directs data to and/or from the HTNIB 125 as appropriate to the type of legacy device to which the HTNIB 125 is connected. The HTNIB 125 passes data to and/or from the connected legacy device as required by the current configuration of the HES 100 . If a legacy source device outputs data in either an analog format or a digital format different than that used by the WHEH 102 , the HTNIB 125 can convert the output data into a digital format compatible with transmission between the WHEH 102 and registered devices within the HES 100 . Similarly, if the HTNIB 125 is connected to a legacy sink device, the HTNIB may convert the digital data from the source device into either an analog format or a different digital format compatible with the legacy device. For example, if a video cassette recorder (VCR) is connected to the HTNIB 125 , the WHEH 102 will recognize the NTNIB 125 as a VCR, and when the user 120 selects the source unit VCR, will instruct the sink devices 124 in the HES 100 to listen to the transmission from the NTNIB 125 , which is transmitting the data received from the cable connected to the VCR. One or more HTNIBs 125 could be used in the HES 100 to connect one or more legacy devices. In one embodiment, a single HTNIB 125 could used to connect one or more legacy devices to the HES 100 , wherein the HTNIB 125 contains one or more connections for sink and source devices. Each connection can be uniquely registered with the WHEH 102 .
Multi-Zone Operation
[0064] A single WHEH 102 may provide programming to multiple sets of sink devices that are registered with the WHEH 102 . The HES 100 may be partitioned into one or more zones. Each sink device 124 in the HES 100 can be assigned to a zone. Zone assignment may be performed at the time of device registration with the WHEH 102 . Zone assignment or changing zone assignments can also be accomplished at any time after device registration. An example of zone partitions within a HES 100 is that zone 1 includes the display device and 7.1 speaker system in the living room; zone 2 includes a display device in the bedroom; zone 3 includes an AVR 145 connected to speakers in the kitchen; and zone 4 includes a PC 114 in the home office. Multi-zone operation allows users 120 in different partitions of the HES 100 to received data from different source devices 122 registered with the WHEH 102 . For instance, the sink devices in zone 1 are presenting the program from an HD-DVD, while the speakers in the kitchen connected to the AVR 145 in zone 3 are presenting audio from a wireless music storage device that is also registered with the WHEH 102 . Zone assignments can be designed by the user 120 . Alternately, devices can be assigned to a zone in the HES 100 by the WHEH 102 based on determining the location of the device and identifying clusters of device as separate zones. The device locations may be input by the user during or after the time of device registration, or the WHEH 102 may automatically determine the locations of registered devices.
[0065] In one embodiment, the WHEH 102 can receive an audio source signal containing more channels than can be presented in the current HES 100 (e.g., the audio signal is configured for a 7.1 system, but the installed HES 100 utilizes a 5.1 speaker configuration.) The WHEH 102 can process and downmix the audio signal for presentation on the available speaker configuration. As described above, the WHEH 102 may also provide to the user 120 an indication that the audio signal contains more audio channels than the current configuration of the HES 100 can support, and recommend to the user 120 that additional speakers 110 be added to the HES 100 to fully support playback of such audio.
[0066] Programming or program content may include multiple video streams, which may also be referred to as side channels. One or more of the multiple video streams may be presented to the user 120 on the display device 112 , depending on the configuration of the HES 100 (discussed in more detail below). As an example, a user may make a program selection from the offerings of a cable operator by tuning by tuning the STB 106 to “Channel 6 ”. The program content received by the STB 106 from the cable operator may include multiple video streams, including the video stream with the program selection that the user has requested. The video stream with the requested program selection is displayed on the display device 112 . The other video streams also contained in the program content received by the STB 106 may or may not be presented to the user 120 , depending on the configuration of the HES 100 , or preferences of the user 120 .
[0067] Display devices 112 of the HES 100 may also be used as picture displays to show still images, instead of video programming, such as a flat panel LCD display mounted on a wall or free-standing on a table top. Multiple display devices used as picture displays may be placed throughout a home and assigned to zones of the HES 100 as described above. In one embodiment, display devices in the same room of a household may be assigned to different zones of the HES 100 . The user 102 can coordinate the display of still images on the displays in each zone through the WHEH 102 . The user 120 can set up a folder of images on a PC 114 registered with the WHEH 102 , or use a pre-packaged gallery of images stored in the PC 114 or in the WHEH 102 . The WHEH 102 can coordinate the display of the images in the various zones of the HES 100 . The still images may be displayed for an extended period of time, such as favorite painting or landscape, or the displayed image may be changed periodically, such as showing a slideshow of family members. The WHEH 102 may cause the same still image to be displayed in all zones, or have a common theme, such as artist or subject, among all the images displayed in each of the zones. Images may be changed daily, seasonally, or at any predetermined interval. Such changes may be automatic determined by the WHEH 102 or may be manually triggered by the user 120 .
[0068] The HES 100 may also contain more than one display device 112 assigned to the same zone. Each display device 112 is registered with the WHEH 102 using one of the methods described above. The user may choose to designate one of the display devices 112 as the primary display device during or after registration of the display device 112 , or alternately the WHEH 102 may automatically designate one of the display devices 112 as a primary display based on the characteristics of the display device, such a screen size or pixel density, with the other display devices being designated as secondary displays. For example, referring to FIG. 11 , if a 51″ HDTV 180 and two 32″ HDTV's 185 are registered with the WHEH 102 and assigned to the same zone, the WHEH 102 may automatically designate the 51″ HDTV 180 as the primary display based on larger screen size, while the 32″ HDTV's 185 become the secondary displays. Secondary displays can be used to show supplemental program content that is complimentary to the main program content being displayed on the primary display. This supplemental program content may be encoded in the main program stream received from a content service provider, or may be transmitted as a separate program stream or side channel. Some examples of supplemental program content that may be shown on the secondary displays include viewer e-mails during a talk show, stock prices, financial, or other information about a company during a business report directed to that company, still images related to material presented during a documentary, and scores, playing schedules other team information during a sportscast related to that team. The secondary display may also present alternate views of an event during news reporting. For example, the on-location reporter is on the primary screen, while alternate video related to that location is shown on the secondary displays. The secondary display may also be used to display extra program content included on a DVD. For example, bloopers or directors commentary corresponding to the scene of a movie presented on the primary display can be shown on the secondary display. In one embodiment, the primary or secondary displays may be used to display content corresponding to a music program being presenting in the HES 100 . The video content may be video or still images contained on a compact disc or received along with the music stream from a PC 114 or other music channel, such as terrestrial or satellite radio.
[0069] Screen captures from video being presented on the primary display may also be shown on the secondary display. If there is more than one secondary display, previous screen captures can be retained while subsequent screen captures can be shown on a different secondary display until all the secondary displays are displaying a different still image. The next screen capture then replaces the screen capture on the first display. For example, during a sporting event, a replay is being viewed on the primary HD-TV. The user 120 activates an actuator on the remote control 118 to indicate the current frame of the HD-TV display should be stored and displayed on one of the secondary displays. Alternately, the WHEH 102 can automatically initiate a screen capture from the primary display. Using the previous example of a sporting event replay, the WHEH 102 may detect a slow-motion replay in the video stream using methods understood by those skilled in the art and select a frame from the video to display on the secondary display. The frame might be selected based on a still or nearly still video image on primary display, or the frame might be selected based on a repeated showing of the video clip in a short predetermined time interval. As another example of automatic screen capture, a frame may be captured from the primary display at a random or predetermined interval and sent to the secondary displays for presentation to the user 120 .
[0070] The secondary display may also be used to present advertisements concurrent with main program content shown on the primary display. The advertisements may be related to a product currently being featured in the main program content, such as for an automobile or a brand of food or drink.
[0071] The secondary display can present to the user 120 a website corresponding to an Internet address displayed on the primary display. The Internet address may be transmitted along with but separate from the program content and received by the WHEH 102 , which detects the Internet address in the program stream and retrieves the content of the website using a network connection available within the HES 100 . Alternately, the WHEH 102 may derive a web address shown on the primary display through OCR on frames formed from the program content of the main display, or the WHEH 102 may utilize other methods of character recognition understood by those skilled in the art. In one embodiment the user may browse the website presented on the secondary display using the remote control 118 .
[0072] Referring to FIG. 12 , the HES 100 may contain a number of identical or nearly identical display devices 112 arranged to provide the user 120 with a wide angle video experience. In one embodiment, the display devices 112 may be arranged to completely encircle the user 120 providing a surround video experience. A source device 122 provides program content containing multiple video streams which, when displayed on the multiple display devices 112 , provide a panoramic view of the program content to the user 120 . The WHEH 102 may direct the source device to transmit each of the video streams to the appropriate display device. Alternately, the WHEH 102 may receive the transmission from the source device, and transmit the appropriate video stream to the corresponding display device 112 . In an alternate embodiment, multi-stream video program content may be displayed on a single display device 112 by compositing the video streams by the WHEH 102 for display on a single device. For example, if program content contains data for three separate video streams that can be displayed to form a multi-display program, and the HES 100 contains only one display device, the WHEH 102 can composite the three video streams to be displayed on the one display device 112 in theHES 100 .
[0073] Systems using a WHEH 102 can be supplied in a low-security configuration to ease installation by non-technical users. In an embodiment with higher security, the user 120 can enter a code on one device and confirm the code on another device or on the user interface. In another embodiment, various system components can ship with awareness of unique identifiers of other devices in the system.
[0074] The WHEH 102 may be used to wirelessly connect musical devices. Musical source devices and musical sink devices can be connected to a mixing board containing an advanced embodiment of the WHEH 102 . Musical source devices include, but are not limited to, musical instruments, microphones, effects systems, and amplifiers. Musical sink devices include by are not limited to speakers, and audio monitors. The mixing board acts as both a sink unit and source unit, and is a convenient location for placement of the WHEH 102 . The musical devices are all registered with the WHEH 102 similar to the produce procedure described above for the HES 100 .
[0075] The WHEH 102 may detect and/or identify the specific user or users of the HES 100 through RFID, image capture and analysis, voice recognition, or other personal identification technologies understood by those skilled in the art. In one embodiment, the remote control 118 may be equipped with a fingerprint scanner used for identification of the user 120 . The identification of the user 120 can be used to control access to various devices of the HES 100 based on a set of rules customizable for each user of the HES 100 by an authorized user (i.e., parent). For example, access to one or more devices can be denied based on time of day. Similarly, access to certain programming channels can also be denied based on a television program rating system, time of day, or selected channels. For example, users identified as children may not be allowed access to an Xbox® gaming console before 5 PM on weekdays or may not be allowed to view channels showing television programming rated TV-MA (under the US TV Parental Guidelines).
[0076] Characteristics of the HES 100 may be automatically adjusted based on identification of the user 120 by the WHEH 102 . Characteristics of the HES 100 include physical characteristics, such as the height or orientation (e.g. rotation, tilt) of the display device or speakers, and system characteristics, such as volume or equalization of the audio, or channel on the STB 106 . A profile may be stored in the WHEH 102 with information about the characteristics of the HES 100 corresponding to the user 120 . The profile may be set by the user 120 or the WHEH 102 may store the last configuration of the HES 100 for each user 120 and return the HES 100 to that configuration when the user 120 begins an entertainment session. In one embodiment, the profile also contains information about positioning or adjustments of viewing location 121 , such as a couch or chair equipped with automatic adjustment mechanisms understood by those skilled in the art.
[0077] Referring to FIG. 17 , the movement of a user 120 in the HES 100 can be monitored by the WHEH 102 using personal identification technologies, such as those described above, so that the programming content presented to the user in one zone of the HES 100 can be automatically re-directed by the WHEH 102 to a different zone in the HES 100 as the user 120 moves into that zone. Personal identification devices located in the different zones of the HES 100 are used to detect the position of the user as the user moves from one zone to another within a zone of the HES 100 . The position information is transmitted to the WHEH 102 . The WHEH 102 then instructs the sink devices in the zone that the user has moved into to start presenting the program content. Thus, after a user 120 initiates an entertainment session in one zone of the HES 100 , the program content from a source device 122 being presented to a user 120 by sink device 124 in a first zone of the HES 100 is directed to an appropriate set of sink devices in a second zone of the HES 102 by the WHEH 102 . If the WHEH 102 detects that no users are present in the first zone, the WHEH 102 may instruct the sink devices in that zone to stop presenting the program content and enter a low power mode. In one embodiment, the WHEH 102 receives program content from a source device 124 , and transmits that programming content to sink devices 124 in the zone where the user is located. For example, in a multi-zone HES 100 equipped with an RFID system, if the evening news is being viewed in the living room zone of the HES 100 , and the user 102 identified using an RFID tag moves into the kitchen zone that includes a display device 112 , the evening news program is automatically directed to the kitchen zone by the WHEH 102 when the RFID system identifies the user 102 in the kitchen zone and transmits the location of the user 102 in that zone to the WHEH 102 . Audio program content can similarly be presented to a user 120 moving into different zones of the HES 100 .
[0078] In one embodiment, the WHEH 102 automatically presents a user 102 with program content based on their location in the HES 100 and viewing and/or listening trends of the user. The WHEH 102 keeps a history of the programming choices of a user for different zones and different times, and can present the user with programming content based on these trends. For example, if a user typically watches a specific weather broadcast every morning around a certain time, the WHEH 102 cause that programming channel to be displayed in the zone that the user is currently located, even if the user has not requested to start an entertainment session to view that program channel.
[0079] The HES 100 may be used as an interface for a voice-over-IP protocol (VoIP). VoIP systems are well understood by those skilled in the art. The VoIP data may be received from a computer network (e.g. the Internet) through a direct connection of the WHEH 102 to the computer network or via a PC 114 connected to the computer network and registered with the WHEH 102 . Referring to FIG. 18 , when an incoming call is detected by the WHEH 102 or the PC has sent an indication to the WHEH 102 of an incoming call, the WHEH 102 sends an alert to the user 102 . The alert may be a visual indicator on each display device 112 in the HES 100 , and/or and audible tone from the speakers 110 . The user accepts the VoIP call using the remote control device 118 or with a voice command. A microphone contained in one of the devices registered with the WHEH 102 is used as a receiver for voice, and the speakers are used to present voice data to the user 102 . If the caller has webcam or other video capture device, the video data of the VoIP call can be presented in the display device 112 . When alerted to a call, the user 120 may choose to pause or pre-empt the data being presenting in order to show video data from the caller. In one embodiment, the VoIP feature may utilize picture in picture technology for simultaneously displaying video VoIP data and video program content. The caller video can be displayed in a box inside the program content, or alternately, the video call may occupy the main portion of the display, and the program content in the box. For conference calling, split screen may be used to display the video data for each of the callers. In a multi-zone HES 100 configured with multiple receivers, the WHEH 102 may transfer the voice data to sink device 124 in the different zones as the user moves around the HES 100 . Tracking the position of the user may be accomplished through determining which microphone is closest to the user by monitoring relative intensity of the user's voice at the different microphones located in the HES 100 . If video data accompanies the voice data, the WHEH 102 can direct the video to a display device 112 in user's current zone. In one embodiment, the a wireless VoIP phone handset is registered with the WHEH 102 , where the handset is used to receive and dial calls in a manner similar to a standard telephone.
[0080] The embodiments of the present invention may be implemented with any combination of hardware and software. If implemented as a computer-implemented apparatus, the present invention is implemented using means for performing all of the steps and functions described above.
[0081] The embodiments of the present invention can be included in an article of manufacture (e.g., one or more computer program products) having, for instance, computer useable media. The media has embodied therein, for instance, computer readable program code means for providing and facilitating the mechanisms of the present invention. The article of manufacture can be included as part of a computer system or sold separately.
[0082] While specific embodiments have been described in detail in the foregoing detailed description and illustrated in the accompanying drawings, it will be appreciated by those skilled in the art that various modifications and alternatives to those details could be developed in light of the overall teachings of the disclosure and the broad inventive concepts thereof. It is understood, therefore, that the scope of the present invention is not limited to the particular examples and implementations disclosed herein, but is intended to cover modifications within the spirit and scope thereof as defined by the appended claims and any and all equivalents thereof.
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A method of calibrating a home entertainment system containing a wireless home entertainment hub using a calibration device comprises obtaining a registration from at least one sink device in the home entertainment system. A first instruction is transmitted to the calibration device to begin receiving a calibration signal emitted from the at least one sink device, where the calibration device is a wireless device. A second instruction is transmitted to the at least one sink device to emit the calibration signal. A representation of the calibration signal emitted from the at least one sink device is received from the calibration device. The representation of the calibration signal is analyzed. One or more indications of adjustments to parameters of the sink device based on results from the analyzing is transmitted to each of the sink devices.
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This application is a Divisional of U.S. patent application Ser. No. 09/994,840, filed Nov. 28, 2001, now U.S. Pat. No. 6,751,561, which claims priority to Korean Patent Application No. 71284/2000, filed Nov. 28, 2000. The entire disclosure of the prior application is considered as being part of the disclosure of the accompanying application and is hereby incorporated by reference herein.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an apparatus and method for lengthening a life span of a battery power supply in a portable appliance, and more particularly to improved power management.
2. Background of the Related Art
Many efforts have been made to develop multimedia and personal/notebook computers having various new functions. Such development has generally added new devices, increasing the total power consumption of the system. Many portable systems are optionally powered by batteries. Because power management of the new devices is inadequate in the related art, however, the life span of batteries powering such systems has been significantly reduced.
FIG. 1 illustrates a block diagram of a power supply of a notebook computer according to the related art. In FIG. 1 , a power supply of a notebook computer includes a DC (direct current) power supply output unit 11 outputting DC voltage V_DC supplied by either a battery source 15 or an AC source 16 and a AC/DC converter (not shown), a CPU(central processing unit) DC/DC converter 12 supplying a DC voltage required for driving a CPU 12 A by converting a DC voltage V_DC outputted from the DC power supply output unit 11 ; a main DC/DC converter 13 supplying DC voltages required for driving devices 13 A to 13 N respectively by converting the DC voltage V_DC, and an LCD inverter 14 supplying an LCD driving voltage by converting the DC voltage V_DC.
When being supplied with an AC source 16 , the DC power supply output unit 11 converts the AC source voltage into the DC voltage V_DC at a predetermined level and outputs the converted DC voltage V_DC. When the AC source 16 is disconnected, the DC power supply output unit 11 outputs the DC voltage V_DC from the battery 15 .
The CPU DC/DC converter 12 (i.e., transformer) converts the DC voltage V_DC outputted from the DC power supply output unit 11 into a DC voltage required for driving the CPU 12 A and outputs the converted DC voltage. The main DC/DC converter 13 converts the DC voltage outputted from the DC power supply output unit 11 into DC voltages required for driving the respective devices 13 A to 13 N installed in or connected to the notebook computer and outputs the converted DC voltages. The LCD inverter 14 generates a voltage required for the LCD by converting the DC voltage V_DC. As shown in FIG. 1 , the related art power supply apparatus does not include an additional power supply management apparatus.
FIG. 2 illustrates a data entry table on a window screen according to the related art, where the power supply apparatus fails to have an additional power supply management apparatus for power saving but has a function of warning a user regarding the remaining capacity of a battery supply. As shown in FIG. 2 , set up item 21 establishes whether a first alarm is outputted when the remaining capacity of the battery supply reaches a first predetermined level. A warning message of a shortage of the remaining capacity of the battery supply or an alarming sound is outputted on the basis of the set-up item 21 when the remaining capacity reaches the first predetermined level set up by the user. Another set-up item 22 as shown in FIG. 2 establishes whether a second alarm is outputted when the remaining capacity of the battery supply becomes below a second predetermined level. A warning message that a system power supply should be turned off immediately or an alarming sound is outputted on the basis of the set-up item 22 when the remaining battery capacity reaches the second predetermined level set up by the user. The battery alarm is not an effective power supply management technique. Instead, the battery alarm merely informs a user of the remaining capacity of the battery or stores the present status.
ACPI (Advanced Configuration and Power Interface) is an open industry standard for APM (Advanced Power Management) in the related art. With ACPI, power is reduced when a PC (Personal Computer) is not operated. A system supporting ACPI checks activity of peripheral devices through the OS (operating system) to optimize power consumption status for ACPI compatible devices. However, APM fails to meet the user's needs for active power supply management of peripheral devices attached to a PC that are not ACPI compatible. For instance, APM fails to consider compatibility of various communication tools that will be available for PCs in the near future.
Thus, systems in the related art are not sufficiently equipped with power supply management functions that can extend an operation time of a battery supply.
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 provide at least the advantages described hereinafter.
Another object of the present invention is to provide a power saving apparatus in a portable appliance and power saving method thereof by proposing methods to a user for saving a present battery power supply when a remaining capacity of the battery power supply in a portable appliance such as a notebook computer becomes below a predetermined level.
Another object of the present invention is to provide a power saving apparatus in a portable appliance and power saving method thereof that interrupts power supply to less critical or user-sorted devices consuming power in the portable appliance.
Another object of the present invention is to provide a power saving apparatus in a portable appliance and power saving method thereof that reduces a total power consumption of the portable appliance by disconnecting a power supply to certain devices according to a scheme selected or predetermined by a user.
In order to achieve at least the above objective as a whole or in part in accordance with the purposes of the invention, as embodied and broadly described herein, there is provided a power saving method in an appliance including inputting power management data into a user set up menu on a display in the appliance, outputting a control command to a micro-controller in accordance with the power management data, and executing the power control command of the micro-controller, wherein the execution includes disconnecting battery power from a selected one of a plurality of appliance devices.
Further, a power saving method in a portable appliance including checking respective systems in the portable appliance, displaying checked information for at least one of the respective systems in a user set-up menu on a screen when a remaining capacity of a battery is smaller than a first reference value set up previously by a user. The output control command is carried out by a micro-controller in accordance with power saving data input by a user on the user set-up menu, and then executing a power saving program in accordance with the control command of the micro-controller.
The power saving apparatus in an appliance including a DC power supply output unit that outputs a DC voltage of a predetermined level by converting an AC power supply or by converting a battery voltage, a main DC/DC converter that supplies a plurality of operating voltages to a corresponding plurality of devices by converting the DC voltage, and a plurality of power switches that selectively disconnect each of the plurality of devices selected by a user in order to carry out a power saving function, wherein the plurality of switches are controlled by a micro-controller.
The power saving method further includes a first step of displaying a user set-up menu for a power saving on a screen by checking respective systems in the portable appliance, a second step of outputting a control command to a micro-controller in accordance with power saving contents set up by a user on the user set-up menu, and a third step of executing a power saving program set up by the user in accordance with the control command of the micro-controller.
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 learned from practice of the invention.
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 illustrates a block diagram of a power supply of a notebook computer according to the related art;
FIG. 2 illustrates a power supply management window screen according to the related art;
FIG. 3 illustrates a block diagram of a power supply apparatus in a computer according to a preferred embodiment of the present invention;
FIG. 4 illustrates an example of a user set-up menu according to a preferred embodiment of the present invention; and
FIG. 5 illustrates a flowchart for a power saving method of a computer according to a preferred embodiment of the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Reference will now be made in detail to preferred embodiments according to the present invention, examples of which are illustrated in the accompanying drawings.
FIG. 3 illustrates a block diagram of a preferred embodiment of a power supply apparatus in a notebook computer to which a power saving method according to the present invention can be applied. The power supply apparatus may include a DC power supply output unit 31 outputting a battery voltage or a DC voltage of a predetermined level converted from an AC power supply 37 , a CPU DC/DC converter 32 supplying a DC voltage required for a CPU 32 A by converting the DC voltage V_DC outputted from the DC power supply output unit 31 , and a main DC/DC converter 33 supplying DC voltages required for driving devices 33 A to 33 N respectively by converting the DC voltage V_DC. An LCD inverter 34 can supply an LCD with a driving voltage by converting the DC voltage V_DC, and power switches 35 A to 35 N preferably turn on/off powers of the respective devices 33 A and 33 N to carry out a power saving function under control of a micro-controller or the like.
The power supply apparatus may further include a clock generator (not shown in FIG. 3 ) supplying the CPU 32 A with a clock. The clock generator may adjust the clock applied to the CPU 32 A by a selection of the user. Through this adjustment, a clock-throttling rate of the CPU 32 A, which will be described later, may be varied.
In a first mode of operation, an appliance such as a notebook computer shown in FIG. 3 may supply the respective devices 33 A to 33 N with a power supply by utilizing AC power supply 37 . In the first mode, the DC power supply output unit 31 may convert the normal AC power supply 37 voltage into a DC voltage of a predetermined level and may output the converted DC voltage. The DC/DC converter 32 may convert the DC voltage V_DC, which is outputted from the DC power supply output part 31 , into a DC voltage having a level required for the CPU 32 A and may output the converted DC voltage. The main DC/DC converter 33 may convert the DC voltage V_DC into DC voltages required for driving the respective devices 33 A to 33 N installed in or connected to the notebook computer and may output the converted DC voltages. The LCD inverter 34 may generate a voltage required for the LCD by converting the DC voltage V_DC.
FIG. 3 also illustrates a power saving features for a second mode of operation of the appliance that uses battery 36 . A battery power supply mode may exist when the external AC power supply applied to the DC power supply output unit 31 is disconnected. On/off switches 35 A to 35 N are coupled to power supply terminals of devices 33 A to 33 N, respectively so that the power for driving the respective devices may be selectively turned on or off. Each of the on/off switches 35 A to 35 N may be a transistor, thyristor, IGBT (insulated gate bipolar transistor), GTO (gate turn-off) thyristor, other electronic switch or the like. Moreover, the on/off switches 35 A to 35 N may be controlled by a MICOM (microcomputer) (not shown in FIG. 3 ) that may be built into the appliance such as the notebook computer and controlled via software. For example, a command of the user may be transferred to the MICOM through an application device driver in the Windows environment. However, the present invention is not intended to be so limited to a microcomputer.
FIG. 4 illustrates an example of a user set-up menu according to preferred embodiments of the present invention, in which various selectable options may be provided enabling a user to perform a power supply management task related to battery operation. When the battery power supply mode is activated, an application program for Windows in a portable appliance preferably may measure the remaining capacity of battery 36 and may determine the frequency that devices 33 A to 33 N are being used. In this case, the frequency of use means how many times the respective devices are used while the user uses the portable appliance.
There are alternative methods for measuring the frequency of use. In one embodiment, the system may record the number of times that each device 33 A to 33 N is used from the moment that the user turns on the power of the portable appliance to the moment that the user turns off the power. In another embodiment, the system may record the number of minutes that each device 33 A to 33 N is used from the moment that the user turns on the power of the portable appliance to the moment that the user turns off the power. Other methods for determining frequency for use may also be used. The system may display composite frequency of use information to a user. A user may use this information, for example, to identify un-used or less-used devices that do not require power at selected battery capacity levels or modes of operation.
When it is determined that the remaining capacity of battery 36 reaches a predetermined limit (for example 50%), the application program for Windows may display a user set-up menu for power saving in the form of pop-up window shown in FIG. 4. A user may also be able to access the user set-up menu shown in FIG. 4 upon demand or periodically.
A “power-off recommendation” (e.g., device) may be presented to a user on the basis of frequency of use calculations. This means that a user may save power by turning off the power of the recommended device without causing any inconvenience or limited inconvenience in using the system. In one embodiment, a user may also select a CPU state (i.e. a clock throttle rate) and an LCD brightness level, in accordance with the remaining capacity of battery 36 .
FIG. 5 illustrates a flowchart showing a preferred embodiment of a power saving method according to the present invention. In this example, a system may be driven using internal battery 36 when external power supply 37 is disconnected.
In a mode where external power is disconnected, an application program for Windows may proceed to display a user set-up menu for power saving in the form of a pop-up window, for example as shown in FIG. 4 , in step S 1 . In one embodiment, a user may select among “power-off recommendations” (e.g., of devices) presented to a user on the basis of frequency of use. A user may also select a CPU state (i.e. a clock throttle rate) and an LCD brightness level and an execution time or status (e.g., percentage of remaining battery capacity or none). The power-off recommendations can be selected by the user to disable connected devices (e.g., IEEE1394, IR, USB, Audio, CD-ROM, Modem or the like) to reduce a power consumption rate. The frequency of use is preferably an indication presented to the user indicating relative importance and can include how many times or how much time the respective devices are used since appliance turn-on, internal battery power selected, or a composite indication of such information. As shown in FIG. 4 , the respective devices have been preferably displayed in a ranked order. In step S 1 , the user set-up menu for power saving can preferably be determined for execution for one, more than one (e.g., 50%, 20% or x% battery residue) or no battery capacity levels. In FIG. 5 , step S 1 can be performed on (user) demand, periodically or optionally. However, if step S 1 is not performed, a system default level may be preset (e.g., 50%) for an Nth alarm data.
The application program for Windows may then determine in step S 2 , through a well-known battery capacity detector (not shown in FIG. 3 ), a present remaining capacity of battery 36 and the frequency of use for devices 33 A to 33 N. The application program for Windows may then determine in step S 3 whether battery residue alarm (control) data exists. If no battery residue alarm data exists, the process may terminate in step S 9 . Otherwise, control may continue to step S 4 .
The application program for Windows may then determine in step S 4 whether the battery residue or remaining capacity of the battery power supply is greater than an Nth limit or Nth alarm data, e.g. 50%, previously set by the user.
Where the remaining capacity of the battery power supply is larger than the user previously set-up Nth alarm data (e.g., first limit), the application program for Windows may return to step S 2 . Where the remaining capacity of the battery power supply is less than the user defined first limit, the application program for Windows may proceed to step S 5 to display a user set-up menu for power saving such as shown in FIG. 4 . Based on information from step S 2 , the system may recommend device(s) for power disconnect, enabling a user to achieve power savings with little or no inconvenience to the user.
In step S 5 , the application program for Windows may also display a corresponding menu so that the user can set the state of CPU 32 A, that is, a clock throttling rate (which represents a relative numeral value of processing speed) of CPU 32 A and a brightness level of the LCD. Where a user wishes to minimize power consumption, the user may select all recommended devices for power disconnect, and may further adjust the clock throttling rate of CPU 32 A and the brightness of the LCD to minimum levels.
If the user selects the recommended device(s), a list of selected devices may be transmitted (e.g., to a micro-controller (not shown)) as a code in step S 6 . The micro-controller may receive the code corresponding to the devices and may then output a disable signal (e.g., a switch-off signal) to the respective switches (e.g., 35 A to 35 N in FIG. 3 ), thereby turning off the corresponding device(s) in step S 7 .
Where a user has selected changes to the CPU state and/or LCD brightness, a control command may be transmitted to the micro-controller in step S 6 in order to control the clock throttling rate of CPU 32 A, the brightness of the LCD, and other power saving contents. Thus, the settings of step S 6 may be executed in step S 7 .
The application program for Windows may then determine in step S 8 an incremented value for N, which is preferably used to determine whether additional battery residue alarm (control) data exists in step S 3 , and the process may again return to step S 2 to monitor battery capacity and frequency of device use.
In one embodiment, a user may predetermine two alarm (control) data limits being a first limit at 50% and a second limit, e.g. 20%, for power management. In this case, the process may sequentially determine in step S 4 whether the remaining battery capacity has dropped below the first and then second limit. If it has, a user may select power management functions in step S 5 for execution in step S 7 before the process ends.
As described above, preferred embodiments according to the present invention provide methods for conserving battery power where the remaining capacity of the battery power supply in a portable appliance such as a notebook computer is reduced below one or more prescribed levels or values. Preferably, a user is guided to select less-used devices to reduce power consumption at prescribed levels. Accordingly, preferred embodiments according to the present invention enable a user to increase or maximize battery life, while reducing or minimizing functional inconvenience.
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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Disclosed a system and method of lengthening a life span of a battery power supply in an appliance such as a portable appliance, notebook computer or the like. A power saving method in an appliance includes displaying a user set-up menu for a power saving on a screen by respectively checking systems in the appliance, outputting a control command to a micro-controller in accordance with power saving contents determined on the user set-up menu by a user, and executing a power saving program set up by the user in accordance with the control command of the micro-controller.
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This application claims priority of PCT application PCT/EP2009/004123 having a priority date of Jul. 15, 2008, the disclosure of which is incorporated herein by reference.
TECHNICAL FIELD
The invention relates to a weaving machine for producing a fabric having a profiled cross section, in particular a rope.
BACKGROUND OF THE INVENTION
Ropes are generally produced on laying machines or braiding machines; the disadvantage here is that these machines have limited capacity and enable only ropes of limited length.
U.S. Pat. No. 2,130,636 describes a weaving machine, of the type mentioned initially, for producing a strip, that is a flat structure, the weaving station usually being assigned a cloth holder. The cloth holder serves exclusively for holding the strip fabric, which is already flat per se, and therefore has no influence at all on profile shaping. DE 20000593 describes a device for producing a bent strip, which is connected as an additional assembly downstream of a weaving arrangement. This additional device has two take-up rollers, between which the strip produced can be bent, but the cross section thereof cannot be changed. U.S. Pat. No. 4,467,838 describes a device which is connected downstream of a weaving machine and produces a three-dimensional hollow body from the strip produced.
SUMMARY OF THE INVENTION
It is an object of the invention to design a weaving machine such that it is suitable for producing a fabric having a profiled cross section, in particular a rope.
On account of the fact that, in order to form a profile fabric, the weaving station is assigned a cloth holder having a shaping opening, the opening cross section of which corresponds substantially to the cross section of the profile fabric, having a round or polygonal cross section, the warp threads, on account of the shaping opening, are bundled in the desired form of the profile fabric and fixed in the intended position with the aid of the inserted weft thread loops and the tying off thereof. Thus, profile fabrics, in particular ropes, can be produced easily on a weaving machine at high speed and in great lengths.
The expression “warp thread” should in the present case be understood very broadly and includes not only yams, but also any other elongate structure supplied in the manner of a warp thread, which may in turn be profiles or reinforcing inserts, which have been produced as profile structures by weaving, knitting, braiding or the like.
The shaping opening of the cloth holder can be substantially circular. However, shaping openings having a substantially oval or elliptical cross section are also conceivable. The cross section of the shaping opening can be in the form of a regular or irregular polygon, in particular a triangle or rectangle.
The cloth holder advantageously has an introduction slot, formed over the length of the shaping opening thereof, for introducing the warp threads. The introduction slot is designed here such that the introduced warp threads are prevented from sliding out. For this purpose, the introduction slot preferably has a wavy form. It is also advantageous for the cloth holder to have a split form in the direction of its shaping opening, so that, by removing a part of the cloth holder, the shaping opening is accessible in order to insert the warp threads.
It is advantageous that a heddle which is prestressed transversely to the warp thread course is present in the warp thread supply device upstream of the shedding device for each warp thread, in order to equalize alternating tensile stresses or differences of length between adjacent warp threads during weaving. At least one warp thread supply can be designed for a warp thread of relatively large diameter serving as a filler and can have a corresponding tension. Expediently, each heddle or the tensioning roller is connected to a contact piece, in order to trigger an error signal in the event of insufficient warp thread tension.
It is particularly advantageous when the weaving machine, has a cloth take-up device having a multiplicity of deflection points, preferably 5 to 15 deflection points, for the profile fabric. This ensures secure driving of the profile fabric at the cloth take-up and prevents deformation of the profile fabric as would occur in the case of conventional cloth take-ups. Stresses in the profile fabric produced can also be reduced by the deflection points. The cloth take-up will preferably have a mechanical or electromechanical drive, it being advantageous when the relationship between the take-up speed and the weaving machine speed can be controlled or regulated—preferably by an adjusting mechanism or an electronic control arrangement.
Such a cloth take-up can, consist of two parallel take-up rollers, at least one of which is driven and on which the profile fabric is guided with multiple looping. The take-up rollers have different diameters from one another, this serving to improve the reduction in tension in the profile fabric. It is particularly advantageous when the take-up rollers, has for the final looping a larger diameter than in the remaining region. The take-up properties can be improved by a refinement, in which at least the driven take-up roller has a slip-inhibiting surface. It is particularly expedient when the weaving machine, has deflection points with a accommodating profile which is at least matched to the cross-sectional form of the profile fabric, in order to improve the profile consistency of the profile fabric.
It is advantageous when a deflecting roller for partially stretching the profile fabric is arranged between the cloth holder and the cloth take-up device, in order to reduce internal stresses in the profile fabric produced. The deflecting roller is preferably arranged such that the profile fabric is deflected downward, it being necessary to arrange the deflecting roller approximately in the middle between the cloth holder and the cloth take-up.
Such a weaving machine is very particularly advantageous when the cloth holder is arranged such that it can pivot through a particular angle about an axis transverse to the weaving direction, that is to say approximately parallel to the weft direction. In particular when weaving ropes, in which a weave repeat is usually provided, where the distribution of the warp threads in the upper shed with respect to the warp threads in the lower shed and vice versa is three quarters to one quarter or even more uneven (e.g. one eighth to seven eighths), geometric problems occur, particularly in needle weaving machines, with enabling the weft needle to pass through freely. Even in the case of sometimes very thick warp threads, e.g. a thick weaving core, which represents an average warp thread, the raising and lowering of the warp threads—in particular including the weaving core—into a region outside the weft region is made easier. The effect achieved in this way is improved even further when, the cloth holder, although having in the front shaping region an opening cross section which corresponds substantially to the cross section of the profile fabric to be produced, is widened in the rear region, that is to say, in the case of a rope to be woven in a circular manner, is widened upwardly and downwardly in an oval manner with approximately straight, parallel sides. This shaping then assists the pivoting movement of the cloth holder. For an explanation, reference is made to the fact that, in the case of a square shaping cross section of the cloth holder, the rear cross section is then preferably rectangular. This embodiment of the invention with a pivotable shaping cloth holder has, in particular, the advantage that, compared with a weaving machine without the pivotability measures, raising and lowering when forming the shed can be reduced with the same rope thickness or weaving core thickness to be achieved, without disrupting the ability of the weft needle—or any other well insertion arrangement—to move freely. Since raising and lowering when forming the shed has a considerable influence on the speed of weaving, a higher speed of weaving can be achieved with the measure mentioned by the reduced necessary raising and lowering when forming the shed. On the other hand, with a given weaving machine—with respect to the formation of the shed—having the measures of this advantageous embodiment, greater profile thicknesses (than e.g. rope thicknesses) can be achieved and thicker weaving cores can be processed. In principle, the pivoting movement can be driven from the outside. In the preferred embodiment, it is, however, free and is performed by the raising and lowering of the warp threads. Furthermore, it is possible to use a pivotable cloth holder even in a conventional weaving machine, in which the cloth holder is designed as a spreader for woven materials woven in the form of a strip.
The abovementioned elements and also the elements to be used according to the invention and claimed and described in the following exemplary embodiments are subject to no particular exceptions in terms of their size, shaping, use of material and their technical design, and so the selection criteria known in the respective field of use can be used in an unrestricted manner.
The person skilled in the art should recognize that on their own the following measures are already advantageous in a rope weaving machine compared with the prior art and even independently of claim 1 are able to form a separate invention:
A weaving machine for producing a fabric having a profiled cross section, in particular a rope, having a weaving station, at which warp threads can be woven together by means of at least one weft thread, having a device for supplying the warp threads, having a device for supplying the at least one weft thread, further having a shedding device for forming a shed from the warp threads, furthermore having a weft insertion needle for inserting a weft thread loop into the shed, having a knitting needle for tying off the weft thread loop, having a reed for beating up the weft thread loop, and also having a cloth holder assigned to the weaving station, and having a cloth take-up for taking up the woven cloth, in which the cloth holder has a shaping opening and an introduction slot, formed over the length of the shaping opening, for introducing the warp threads, the introduction slot being designed such that the introduced warp threads are prevented from sliding out. In this case the introduction slot preferably has a wavy form.
A weaving machine for producing a fabric having a profiled cross section, in particular a rope, having a weaving station, at which warp threads can be woven together by means of at least one well thread, having a device for supplying the warp threads, having a device for supplying the at least one well thread, further having a shedding device for forming a shed from the warp threads, furthermore having a weft insertion needle for inserting a weft thread loop into the shed, having a knitting needle for tying off the weft thread loop, having a reed for beating up the well thread loop, and also having a cloth holder assigned to the weaving station, and having a cloth take-up for taking up the woven cloth, in which a heddle for equalizing alternating tensile stresses between adjacent warp threads and prestressed transversely to the warp thread course is present in the warp thread supply device upstream of the shedding device for each warp thread, and wherein preferably at least one warp thread supply is designed for a warp thread of relatively large diameter serving as a filler and has a tensioning roller, and wherein furthermore preferably each heddle or the tensioning roller is connected to a contact piece, in order to trigger an error signal in the event of insufficient warp thread tension.
A weaving machine for producing a fabric having a profiled cross section, in particular a rope, having a weaving station, at which warp threads can be woven together by means of at least one weft thread, having a device for supplying the warp threads, having a device for supplying the at least one well thread, further having a shedding device for forming a shed from the warp threads, furthermore having a well insertion needle for inserting a well thread loop into the shed, having a knitting needle for tying off the well thread loop, having a reed for beating up the weft thread loop, and also having a cloth holder assigned to the weaving station, and having a cloth take-up for taking up the woven cloth, in which the cloth take-up has a multiplicity of deflection points, preferably 5 to 15 deflection points, for the profile fabric, the cloth take-up has a mechanical or electromechanical drive, and the relationship between the take-up speed and the weaving machine speed can be controlled or regulated, preferably by an adjusting mechanism or an electronic control arrangement, wherein the cloth take-up preferably has two parallel take-up rollers, at least one of which is driven and on which the profile fabric is guided with multiple looping, and the take-up rollers preferably have different diameters from one another. In this case, the take-up rollers preferably have for the final looping a section with a larger diameter than in the remaining region. At least the driven take-up roller preferably has a slip-inhibiting surface. Furthermore, at least a number of the deflection points have a take-up profile which is at least matched to the cross-sectional form of the profile fabric.
A weaving machine for producing a fabric having a profiled cross section, in particular a rope, having a weaving station, at which warp threads can be woven together by means of at least one weft thread, having a device for supplying the warp threads, having a device for supplying the at least one weft thread, further having a shedding device for forming a shed from the warp threads, furthermore having a weft insertion needle for inserting a weft thread loop into the shed, having a knitting needle for tying off the weft thread loop, having a reed for beating up the weft thread loop, and also having a cloth holder assigned to the weaving station, and having a cloth take-up for taking up the woven cloth, in which a deflecting roller for partially stretching the profile fabric is arranged between the cloth holder and the cloth take-up. The deflecting roller preferably deflects the profile fabric downward and is arranged approximately in the middle between the cloth holder and the cloth take-up.
A weaving machine having a weaving station, at which warp threads can be woven together by means of at least one well thread, having a device for supplying the warp threads, having a device for supplying the at least one well thread, further having a shedding device for forming a shed from the warp threads, furthermore having a well insertion needle for inserting a weft thread loop into the shed, having a knitting needle for tying off the well thread loop, having a reed for beating up the well thread loop, and also having a cloth holder or spreader assigned to the weaving station, and having a cloth take-up for taking up the woven cloth, in which the cloth holder is arranged such that it can pivot about an axis transverse to the cloth running direction and preferably its shaping opening has an upwardly and downwardly widened form in the rear region.
BRIEF DESCRIPTION OF THE DRAWINGS
Exemplary embodiments of the invention will be described in more detail below with reference to schematic drawings, in which:
FIG. 1 a shows a side view of a weaving machine,
FIG. 1 b shows a plan view of the weaving machine in FIG. 1 a,
FIG. 2 shows a cloth holder having a shaping opening with a circular cross section,
FIG. 3 shows a cloth holder having a shaping opening with an elliptical cross section,
FIG. 4 shows a cloth holder having a shaping opening with a rectangular cross section,
FIG. 5 shows a longitudinal section through a cloth holder,
FIG. 6 shows a semicircular accommodating profile of a deflection point,
FIG. 7 shows a semielliptical accommodating profile of a deflection point,
FIG. 8 shows a wedge-shaped accommodating profile of a deflection point,
FIG. 9 shows the accommodating profile in FIG. 8 with a rope inserted,
FIG. 10 shows a schematic side view of a further weaving machine,
FIG. 11 shows a device for supplying a filler,
FIG. 12 shows a weaving machine of a further embodiment of the present invention, having a pivotable cloth holder, the cloth holder being located in the normal or middle position,
FIG. 13 shows a weaving machine of a further embodiment of the present invention, having a pivotable cloth holder, the cloth holder being located in a strongly raised position,
FIG. 14 shows a weaving machine of a further embodiment of the present invention, having a pivotable cloth holder, the cloth holder being located in a slightly raised position, and
FIG. 15 shows a comparison to illustrate the increase in the raising and lowering range of the weaving machine according to FIG. 12 with respect to a weaving machine without the measures of this further embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIGS. 1 a and 1 b schematically illustrate a side view and a plan view of a weaving machine, which has a device 2 for supplying warp threads 4 . By means of a shedding device 6 , the warp threads 4 are opened to form a shed 8 , so that a weft thread loop 12 of a weft thread 14 can be inserted into the shed 8 by means of a weft insertion needle 10 . The weft thread loop 12 is tied off on the side facing away from the insertion side by means of a knitting needle 16 . The weft thread loop 12 can be tied off using the weft thread loop which has already been inserted, but tying off preferably takes place with the aid of an auxiliary thread 18 . Tying off advantageously takes place such that the inserted weft thread loops 12 are prevented from rippling. At the weaving station 20 , the inserted and tied off weft thread loop is beaten up by means of a reed 21 and supplied to the cloth holder 22 , which has a shaping opening 24 , the opening cross section of which corresponds substantially to the cross section of the profile fabric 26 to be produced. The warp threads 4 are kept at the weaving station 20 , already in the desired form of the final profile fabric, with the aid of the shaping opening 24 and this form is kept by the inserted and tied off weft thread loops 12 .
FIGS. 2 to 4 show cloth holders 22 a , 22 b and 22 c having different shaping openings 24 a , 24 b and 24 c with circular, elliptical and polygonal, such as quadrilateral, cross sections. The cloth holders have a split form along their horizontal mid-plane, so that a part can be removed in order to make it easier to insert the warp threads. However, it is also possible to provide, for example along the mid-plane on one side of the cloth holder, an introduction slot (not shown in more detail) for introducing the warp threads. In order to make it difficult for the warp threads to slide out, the introduction slot can have a wavy form.
FIG. 5 shows a longitudinal section through the cloth holder 22 . In order to reduce the frictional resistance of the profile fabric in the shaping opening 24 , the latter can have a slightly widening cross section in the running direction of the profile fabric. The profile fabric 26 emerging from the cloth holder 22 is taken up by means of a cloth take-up 28 at which the profile fabric is guided in multiple looping in order that the profile fabric is taken up securely and that deformation of the profile fabric is prevented.
The cloth take-up 28 has two rollers 30 , 32 , which are spaced apart from one another, and of which the roller 30 facing the cloth holder 22 has a smaller diameter and the roller 32 facing away from the cloth holder 22 has a larger diameter. For the last turn, the roller 32 has a section 34 having an even larger diameter, in order to enable satisfactory discharging of the profile fabric 26 . A running roller 36 having a relatively small diameter forms the run-in to the cloth take-up 28 . In order to supply the profile fabric 26 to the final section 34 on the roller 32 , a securing device 38 is additionally provided, in order that the profile fabric 26 is driven securely at the section 34 and that an alarm signal is triggered in the event of a malfunction. The rollers 30 and 32 can be provided with a slip-free coating and/or have accommodating profiles 40 , which are matched to the cross section of the profile fabric 26 produced, as can be gathered from FIGS. 6 to 8 . Particularly advantageous is the refinement according to FIG. 9 , in which the accommodating profile 40 is designed such that the chord of the profile fabric lies at the level of the lateral surface 42 of the roller, so that the tensile force acts as far as possible in the central axis, that is the neutral fiber of the profile fabric.
FIG. 10 shows further refinements of a weaving machine in FIGS. 1 a and 1 b . The device 2 for supplying warp threads 4 comprises for each warp thread a thread cone 42 , from which the warp thread 4 is supplied, via a thread brake 44 , to rollers 46 , 48 . From there, the warp thread 4 runs via two guide rods 50 , 52 to the shedding device 6 . The roller 48 is prestressed against the warp thread 4 by means of a spring 54 . Between the guide rods 50 , 52 there is provided for each warp thread a lifting heddle 56 , in which the warp thread 4 is guided through an eyelet 58 . The lifting heddle 56 is prestressed downwardly by means of a spring 60 , in order to equalize fluctuations, which occur during weaving, between adjacent warp threads. At the upper end of the lifting heddle there is positioned a contact rail 62 of a warp stop motion 64 , which is activated if a warp thread breaks or the warp thread sags impermissibly. It should be noted that the illustration of the warp thread course via the guide rails 50 , 52 in relation to the contact rail 62 of the warp stop motion is not true to scale, but rather is schematic.
Between the cloth holder 22 and the cloth take-up 28 , a guide roller 66 and a stretching roller 68 are arranged such that the profile fabric 26 is deflected slightly downward between the cloth holder 22 and the guide roller 66 . This deflection has the purpose of stretching the profile at the cloth holder 22 and at the guide roller 66 in the upper region and in the region of the stretching roller 68 in the lower region. This has a positive influence on the warp thread tension of the profile fabric produced. A container 70 for accommodating the finished profile fabric 26 is assigned to the cloth take-up 28 .
FIG. 11 shows a device 72 for supplying a filler 74 at the weaving machine. A filler of this kind can have properties and dimensions which are very different from the rest of the warp threads. Thus, the filler can consist of plastic material, steel wire or steel cable or have a cross section which is substantially larger than that of the warp threads. Thus, the filler can, for example, be a tubular structure. Since it is more difficult to handle the filler 74 than the rest of the warp threads, special measures are require for supplying it. The supply device 72 for the filler 74 comprises firstly a filler bobbin 76 , which is connected to a braking device 78 . The filler 74 taken up from the filler bobbin 76 is guided over various guides 80 , 82 , 84 to the shedding device 6 . Between the guides 80 and 84 there is provided a tensioning device 86 , which has a rocker arm 88 , secured to which is a clamping roller 90 which is prestressed against the filler 74 by means of a spring 92 . Assigned to the rocker arm 88 is a contact point 94 , which the rocker arm 88 strikes if the filler 74 is broken or the prestress of the filler is not strong enough.
A wide variety of profile fabrics can be produced by means of the weaving machine, in particular ropes having a wide variety of structures. The weaving machine enables higher production speeds than braiding machines and enables ropes having great lengths to be produced.
FIGS. 12 to 15 show a weaving machine in a further improved embodiment of the present invention, having a pivotable cloth holder 22 d . In FIG. 12 , the cloth holder is located in the normal or middle position, and the warp threads are neither raised nor lowered. In FIG. 13 , the cloth holder is in a position, in this weaving machine, which corresponds to a “strongly raised” position. Here, “strongly raised” means that most warp threads 4 , typically more than 75%, are raised, while fewer than 25% of the warp threads 4 are lowered, or wherein, if a thicker and harder weaving core 96 is used, this weaving core 96 is raised. In this case, the distribution of the further, thinner warp threads 4 is less important. In FIG. 14 , the cloth holder 22 d is in a position, in this weaving machine, which corresponds to a “slightly raised” position. Here, “slightly raised” means that most warp threads 4 , typically more than 75%, are lowered, while fewer than 25% of the warp threads 4 are raised or wherein, if a thicker and harder weaving core is used, this weaving core 96 is lowered. In this case, the distribution of the further, thinner warp threads 4 is again less important. FIG. 15 shows a comparison to illustrate the increase in the raising and lowering range of the weaving machine according to FIG. 12 with respect to a weaving machine without the measures of this improved embodiment. The effect achieved thereby is further improved in the present exemplary embodiment, in that, although the cloth holder 22 d in the front shaping region has the circular opening cross section 24 d , which corresponds to the cross section of the rope in the example of a round rope, in the rear region it is widened. The cross section of the rear opening is in this case widened upwardly and downwardly in an oval manner, the widening being formed by straight, parallel sides. The widening is linear within the cloth holder 22 d , i.e. the straight, parallel side lengths forming the widening increase in the exemplary embodiment shown here from zero (at the front) to the full side length (at the rear). This shaping assists the pivoting movement of the cloth holder 22 d . In the exemplary embodiment shown here, the pivotable cloth holder 22 d can pivot freely above the shaping opening 24 d about an axis 100 transversely to the weaving direction, the pivotability being limited by the shaping and by the cloth (rope) being guided through. Of course, the pivotable, shaping cloth holder 22 d is positioned such that in all pivoting states the reed 21 stops in front of the cloth holder 22 d —in each of its pivoting positions—without touching it. For an explanation, reference is made to the fact that, in the case of a square shaping cross section of the pivotable cloth holder—i.e. when a square rope is intended to be woven—the rear cross section is then preferably rectangular.
LIST OF REFERENCES
2 Supply device for warp thread
4 Warp thread
6 Shedding device
8 Shed
10 Weft insertion needle
12 Weft thread loop
14 Weft thread
16 Knitting needle
18 Auxiliary thread
20 Weaving station
21 Reed
22 , a,b,c,d Cloth holder
24 , a,b,c,d Shaping opening
26 Profile fabric
28 Cloth take-up
30 Roller
32 Roller
34 Section
36 Running roller
38 Securing device
40 Accommodating profile
42 Thread cone
44 Thread brake
46 Roller
48 Roller
50 Guide rod
52 Guide rod
54 Spring
56 Lifting heddle
58 Eyelet
60 Spring
62 Contact rail
64 Warp stop motion
66 Guide roller
68 Stretching roller
70 Container
72 Supply device
74 Filler
76 Filler bobbin
78 Braking device
80 Guide
82 Guide
84 Guide
86 Tensioning device
88 Rocker arm
90 Tensioning roller
92 Spring
94 Contact point
96 Weaving core
98 Neutral axis
100 Pivot axis of the cloth holder
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The loom contains a weaving station, at which warp yarns can be interwoven by at least one weft yarn, a device for supplying the warp yarns, and a device for supplying the at least one weft yarn. A shedding device for forming a shed from the warp yarns, and a weft insertion needle for inserting a weft yarn loop into the shed, are also present. The weft yarn loop is tied off with a knitting needle and beaten with a reed. A take-down device serves to draw off the woven fabric that is produced. In order to produce a profiled woven article, the weaving station is assigned a fabric holder with a shaping aperture whose opening cross section corresponds substantially to the cross section of the profiled woven article that is to be produced with a round or polygonal cross section.
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This is a continuation of application Ser. No. 08/283,618, filed Aug. 1, 1994.
BACKGROUND OF THE INVENTION
This invention relates to training users of computer software. More particularly, this invention relates to a computer based system employing a multimedia approach to training users of various types of computer applications by providing audio\visual instruction along with on-line practice sessions using a multi-dimensional lesson monitoring approach.
For many years application programs, on-line services, and other computer application software have been available for use with digital computers. Application programs perform word processing functions, numeric functions, data-base functions, accounting functions, inventory control functions, and a wide variety of other functions. Application programs serve not only to increase the efficiency of the user but to increase the user's accuracy as well. On-line services allow a user to access large databases of information. However, when first implementing the computer application software or on-line service, a significant amount of time is required to educate the user in the use of the computer application software or information services. Not until the user is sufficiently trained in the use of the computer application software or service may substantial benefits be derived from the program or service.
The earliest approaches to training users were by the providers of computer application software. The first training tools involved written instruction books that were included with the programs. These books described the functions available in the software, how to implement the functions, and the limitations of the functions. The earliest training books were written in a highly technical manner that prevented the average user from gaining a thorough understanding of the program. Resultantly, a large industry grew around providing written training materials for training users to use the programs. Over time, with increased competition, the written materials became easier to read and understand, providing more thoughtful approaches to educating the user.
While the software industry developed, some persons and organizations recognized the shortcomings of the written book type instruction and stepped in to provide classroom and interpersonal instruction. Classroom type instruction targeted specific software that was popular enough to justify the large capital expenses associated with this type of training. Levels of instruction varied from lectures given in large auditoriums all the way down to one-on-one training sessions. While this type of instruction proved to be quite successful due to its human aspect, it was very expensive and generally required that the new user leave his or her place of employment to attend. Further, because the user generally was not provided with hands on training, and even if he or she was, the training was not performed on his or her own machine. Because of differences in machines and environments used in the training classes, the user could not always transfer the knowledge he or she had obtained to his or her own computer.
Over time, vendors of the software and others in the industry recognized the value of training the user on his or her own machine while inside the software itself. Thus, on-line tutorials were developed. On-line tutorials typically combined a written description of a particular function of the software and instruction in specific commands that would allow a user to perform the function. These on-line tutorials typically allowed a user to perform a few instructions at a time as directed by the tutorial with the instructions being monitored to ensure correctness of operation. While these on-line tutorials provided the benefit of learning while doing, they were typically difficult to follow and did not provide adequate explanation. Part of the problem related to inadequate written explanation that carried over from the user's manual was that such information was conveyed to the user only in a written format displayed on the screen. Further, because they were specific to the particular application program, they did not provide a familiar reference frame for the user and the user first had to learn to use the on-line tutorial in the particular program.
Thus, attempts were made to combine the benefits of classroom training with the benefits of hands-on training on the user's own machine. A few vendors recorded classroom training programs on video cassettes so that a user could play the lessons at his or her own speed on a nearby television while simultaneously working on the computer. Thus, a user could combine the benefits of working on his or her own machine while also obtaining the benefits of being in a classroom. Unfortunately, there was no interplay between the video being viewed and the user's commands issued to the computer application software. While this system allowed the user to play the video in his of her office, it did not provide the interactive benefits available from other techniques. Thus, the system did not reinforce the commands described in the video and required the simultaneous operation of two separate machines.
A recent visual teaching aid, sold under the tradename LOTUS SCREENCAM, displays images on a computer screen that are identical to those displayed within an application program. However, even though the teaching aid displays images that a user would encounter during use of the program, the teaching aid merely functions like a video player. The teaching aid merely displays to the user a proper sequence of keystrokes and/or mouse movements that would be required to execute specific functions and does not provide interaction between the user and the actual application program.
SUMMARY OF THE INVENTION
It is therefore a general object of the invention to overcome the above described limitations, and others, of the prior tutorial devices and methods. More particularly, it is an object of the invention to provide a computer based tutorial interface system that provides a user with audio/visual training on specific functions of a computer program or computer service, provides actual samples of the implementation of the functions, assists the user in learning to perform the function within the computer application software, and requires the user to take an active approach in the training by performing actual instructions within the application software on the user's own machine.
To accomplish these objects, a computerized, multimedia tutorial interface system for training a user to use a computer application comprises, generally, a user control interface, an audiovisual tutorial interface, and a computer application software interface. The system preferably takes the form of a software engine that performs all necessary control and interface functions between the user, a video tutorial that is displayed on the user's computer screen, and the computer application software itself. In this fashion the interface system allows a user to control the video tutorial, view an execution of program functions, and practice performing the functions of the program itself. The system resides on the user's machine so that the user may perform all of the functions at his or her leisure. In this manner, lessons learned will be imprinted fully.
Preferably, the system includes control display means, instruction input and interpretation means, audiovisual enablement means, and computer application software interface and control means. The control display means displays a control window on a computer screen through which the user may select any of a plurality of instructions using keyboard, mouse, or verbal input. As one option, the user views a video segment that describes a specific function of the computer application software. Preferably, the user may select these video segments on a chapter-by-chapter and lesson-by-lesson basis. Other functions include moving forward, backward, or searching for a particular lesson, viewing the execution of a sequence of instructions within the computer application software, and gaining control over the computer application software, among others. In this fashion, the user can control the operation of the system as desired. Responsive to the user's input, the instruction input and interpretation means receives the instruction and executes the respective command within the system.
When a video play command is selected by the user, the audiovisual enablement means receives the execution instruction, retrieves the selected audiovisual information, and displays the audiovisual information on at least a portion of a computer screen. Preferably, the audiovisual information comprises various pre-recorded tutorial video clips that describe a specific function or feature of the computer application software. Preferably, these video clips are displayed on a window on the computer screen separate from the control bar. However, at the user's option, the window could be expanded or contracted to provide a larger or smaller viewing area.
Preferably, after the video clip is displayed, the computer application software interface means interfaces with the computer application software and selectively executes the function described in the video segment so that the user may watch the particular functions that were described in the video clip execute within the computer application software. While the function that is executed will generally be the one that was previously described in an video segment, the user may also request that a specific function within the computer application software be demonstrated without first displaying the related video segment. After the user has been educated on the function by the video segment, the software demonstrates how the function is executed within the program. In this manner, the lesson has been reinforced and taught in a manner such that it may be duplicated by the user. Preferably, at this point, a synopsis and explanation of the executed commands are provided to the user.
After the system has demonstrated the computer application software function to the user and provided the user with a synopsis, the computer application software control means selectively relinquishes control of the computer application software to the user. The user may then perform the functions that were previously described in the video clip and performed by the system. Preferably, in this portion of the operation, the system will monitor the instructions executed by the user and issue an error message to the user on the computer screen if the user executes an instruction that is erroneous. Typically, a plurality of sets of "correct" instructions will be used as a guide and compared to the user's instructions. In this fashion, the system provides immediate feedback to the user.
The system of the present invention may also include evaluation means that evaluates the instructions issued by the user and issue a summary of the user's performance in issuing the instructions. In this fashion, the user's knowledge and proficiency may be gauged and reported. Further, the progress made by the user in his completion of the training may also be monitored.
The present invention also comprises a computerized method for providing a multimedia tutorial interface for training a user to use computer application software. The steps of this method parallel those described above for use of the system. The method includes steps of providing a user with an audiovisual tutorial, executing certain program functions, and allowing a user to execute the described functions. These steps are carried out in a manner analogous to the use of the system described above. The method also includes additional instructions more fully described herein.
The system and method of the present invention provide many important advantages over the prior tutorial methods and systems. Among other advantages, the system of the present invention provides, in combination, the benefits of a plurality of techniques so that the benefits may compound and reinforce each other. The present invention provides a user controllable audiovisual tutorial program that displays visual information on the user's own computer screen. Therefore, the user may selectively view any lesson in the tutorial without leaving his or her office and machine.
After the video clip has been played, the system confirms and enforces the lesson by demonstrating the function or service feature that was described in the video clip. The system demonstrates, step-by-step, the instructions required to perform the described function or service feature. Therefore, the user is instructed exactly how to perform the function described in the video. Because these instructions are demonstrated as performed within the computer application software itself, the environment is exact, and no translation of techniques is required.
The system also allows the user to practice the commands that were described immediately after they were performed by the system. This reinforcement ensures that the user has mastered the function described. Because the system and method of the present invention combines the benefits of varied other approaches it more effectively tutors the user. Further, because the program provides the same user interface, independent of the computer application software it is teaching, it provides the user with a familiar point of reference. And, because the user operates the system completely from his or her own machine, training time is minimized. Further, individual retention of knowledge is maximized through the self-paced interaction with the particular software or service provided by the system.
Because the system of the present invention provides a generic interface to any computer application software, the system may be used to teach users of on-line services in the use of the services as well as many other computer applications. Further, even though the system is generic, it could even be embedded in a particular software program to provide a specific interface. Thus, the system has great flexibility and adaptability in its application.
These and other objects, advantages, and features of the invention will be apparent from the following description of the preferred embodiments, considered along with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a functional block diagram of a computer utilized in conjunction with the present invention.
FIG. 2 is a functional block diagram showing the functional relationship between the components of a system embodying the principles of the present invention.
FIG. 3 is a functional flow chart detailing the operation of the system of FIG. 2.
FIGS. 4A and 4B are sample display screen view detailing a visual interface of the embodiment of the present invention disclosed in FIG. 2.
NOMENCLATURE AND DEFINITIONS
The descriptions which follow are presented in part in terms of algorithms and symbolic representations of operations within a computer. These descriptions and representations are the means used by those skilled in the software arts to most effectively convey the substance of their work to others skilled in the art.
An algorithm is here, and generally, conceived to be a self-consistent sequence of steps leading to a desired result. These steps are those requiring physical manipulations of physical quantities. Usually, though not necessarily, these quantities take the form of electrical or magnetic signals capable of being stored, transferred, combined, compared, and otherwise manipulated. It proves convenient at times, principally for reasons of common usage, to refer to these signals as, values, symbols, characters, display data, terms, numbers, or the like. It should be borne in mind, however, that all of these and similar terms are to be associated with the appropriate physical quantities and are merely used here as convenient labels applied to these quantities.
Further, the manipulations performed are often referred to in terms, such as comparing, commonly associated with mental operations performed by a human operator. No such capability of a human operator is necessary, or desirable in most cases, in any of the operations described herein which form part of the present invention, since the operations are machine operations. Useful machines for performing the operations of the present invention include general purpose digital computers or other similar devices. The present invention relates to method steps and apparatus for operating a computer in processing electrical or other physical signals to generate other desired physical signals.
The present invention also relates to a system for performing these operations. This system may be specifically constructed for the required purposes or it may comprise a general purpose computer as selectively activated or reconfigured by a computer program stored in the computer. The algorithms presented herein are not inherently related to any particular computer or other apparatus. In particular, various general purpose machines may be used with programs written in accordance with the teachings herein, or it may prove more convenient to construct more specialized apparatus to perform the required method steps. The required structure for a variety of these machines will appear from the description below.
In the following description, several terms are used frequently, have specialized meanings in the present context, and are thus defined. The terms "environment", "windowing environment" and "running in windows" are used interchangeably to denote a computer user interface in which information is manipulated and displayed within bounded regions on a raster scanned video display.
The terms "application", "computer application software", and "program" are used interchangeably herein to refer to any computer program run in conjunction with the present inventive system. Such computer programs could relate to computer applications, with on-line services, communication systems, or any other computer oriented function.
The term "current" is sometimes used herein as an antecedent to "window", "application", etc., and is used to denote system components which are currently being utilized or performing operations with respect to a particular computer application software running in the environment.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the following description, certain details are set forth to provide a complete understanding of the present invention. It will be apparent to one skilled in the art, however, that these specific details are not required in order to practice the present invention. Also, well known electrical structures and circuits are depicted in block diagram form so as not to obscure the present invention unnecessarily.
A system 10 embodying the principles of the present invention is shown by way of illustration in FIGS. 1-4. The system 10 of the present invention is implemented on a typical computer system 11 as shown in FIG. 1. This computer system 11 typically comprises a CPU 12, a computer bus 14, a disc drive 16, main memory 18, a compact disc drive 20, and user interface components. These user interface components preferably comprise a mouse 22 and mouse controller 24, a video display 26 and video display controller 28, and a keyboard 30 and keyboard controller 32. Preferably, the computer system 11 also includes an audio interface 34 that transmits audio information to and receives audio information from a user of the system.
As one skilled in the art will appreciate, the system and method of the present invention are implemented on the computer system 11 but are not readily identifiable as specific components of the system. Those skilled in the art will readily understand how the described invention may be implemented on any of a variety of computer systems. Therefore, the implementation of the system on a particular hardware platform will not be more fully described herein.
Referring now to FIGS. 2 through 4, a computerized, multimedia tutorial interface system 10 for training a user to use computer application software comprises control display means 40, instruction input means 42, instruction interpretation means 44, audiovisual enablement means 46, computer application software interface means 48, and computer application software control means 50.
Referring specifically to FIGS. 2 and 3, the control display means 40 comprises a control bar 51 and a chapter/lesson selection screen 53, each of which are selectively displayed on the computer screen 26. Together, the control bar 51 and the chapter/lesson selection screen 53 provide a plurality of instructions to a user that may be selected by the user. As is shown, the control bar 51 preferably has commands similar to those found on a video tape player, including exit, rewind, goto, fast forward, stop, back, pause, and play. The chapter/lesson selection screen 53 allows a user to access video segments relating to specific lessons to be learned. Typically the user accesses specific video segments on a chapter-by-chapter and lesson-by-lesson basis as desired. In the preferred embodiment, the chapter/lesson selection screen 53 is displayed only when certain commands are executed via the control bar 51. However, depending upon the application, the chapter/lesson selection screen 53 could also be continuously displayed.
The instruction input means 42 operates to receive an instruction from a user 49. Preferably, the instruction input means 42 combines hardware and software components. In the preferred embodiment of the present invention, the instruction input means 42 comprises the combination of the mouse 22, the keyboard 30, the control bar 51, the chapter/lesson selection screen 53, and related software that allows the user 49 to select a desired function. Selecting a command from a menu displayed on a computer screen 26 using a mouse 22 and via a keyboard 30 are both well known in the art and are not fully described herein. As one skilled in the art will readily appreciate, however, the instruction input means 42 could also include the combination of the audio interface 34 in conjunction with voice recognition software.
The instruction interpretation means 44 interprets the user instruction, creates at least one execution instruction, and selectively issues the execution instruction. The instruction interpretation means 44 preferably comprises a series of software instructions executed on the computer system 11 in a fashion well known in the art. For example, when the user selects an instruction via the instruction input means 42, software code monitors the mouse controller 24 and keyboard controller 32 interfaces, receives input from the interfaces, processes the input to determine what function has been executed, and issues the proper execution instruction to the respective system component.
Still referring to FIGS. 2 and 3, the audiovisual enablement means 46 operates to receive execution instructions from the instruction input means 44, to selectively retrieve audiovisual information responsive to the execution instruction, and to display the audiovisual information on the computer screen 26. Preferably, the audiovisual information comprises a video clip that is retrieved from a compact disc via the CD drive 20. The video clip is then decoded, formatted, and displayed on the computer screen 26 in a video window 55. The video window 55 may cover only a portion of the computer screen 26 or may be expanded to be as large as the screen. Preferably, as is shown in FIG. 3, the video window 55, the control bar 51, and the chapter/lesson selection screen 53 all reside on top of the computer application software window 57 when they are active. However, when they are inactive, they are all hidden. Further, in the preferred embodiment the chapter/lesson selection screen 53 is displayed only when certain user instructions are executed.
In a typical use of the tutorial interface system, the user 49 selects a specific video clip that corresponds to a particular chapter and lesson to be learned. The video clip is then retrieved and displayed on the computer screen 26 in the video window 55. After the information has been displayed, and if the process has not been aborted or otherwise interrupted by the user, control may be returned to the user or be given to another system 10 component. In the preferred embodiment, immediately after the video clip has been displayed, or during a user 49 initiated break in the video clip, control is taken again by the computer application software interface means 48. However, the system 10 may also be operated such that the computer application software interface means 48 takes control during a video clip, halts the video clip to demonstrate a function or service feature, and then later restarts the video clip.
The computer application software interface means 48 also receives execution instructions from the instruction interpretation means 44. The computer application software interface means 48 interfaces directly with computer application software and selectively executes a function of the computer application software that is described in a video clip. Thus, the functions performed by the computer application software interface means 48 within the computer application software provides a second visual training tool to the user 49 on the computer display 26. Preferably, the function or set of functions executed within the computer application software relate directly to the audiovisual segment that was just displayed to the user 49. Preferably, the computer application software interface means 48 comprises a dynamic link library (DLL) interface communication agent that is loaded into main memory at system 10 startup. The DLL interface communication agent accesses instruction sets specific to the computer application software of interest that are stored in separate files on the disc drive 16. Thus, to perform a specific set of instructions within the computer application software, the DLL interface communication agent brings the computer application software up on the computer display 26, accesses the instructions, and then executes the instructions within the computer application program.
The computer application software control means 50 selectively relinquishes control of the computer application software to the user 49 so that the user may practice operating the computer application software. The computer application software control means 50 also selectively regains control of the computer application software from the user 59. In this fashion, the user may practice those techniques that were previously described to him via the video clip and also were performed by the computer application software interface means 48. As one skilled in the art will readily appreciate, the computer application software control means 50 is preferably implemented as a combination of software instructions.
Preferably, the system 10 of the present invention also comprises user instruction monitoring means 52, error message issuance means 54, and evaluation means 56, all of which provide feedback to the user when the user has control of the computer application software. Specifically, the instruction monitoring means 52 monitors the user instructions issued to the computer application software, keeping track of the instructions. When activated, the error message issuance means 54 issues an error message to the user on the computer screen 26 if the user issues instructions that are erroneous. To determine whether the issued instructions are erroneous, the error message issuance means 54 compares the user's issued instructions to a list of correct instructions. Further, when activated, the evaluation means 56 evaluates the instructions issued to the computer application software by the user and issues a summary of the user's performance in issuing the instructions. Thereby, the evaluation means 56 provides an indication of the user's performance in learning to use the computer application software. As one skilled in the art will readily appreciate, the user instruction monitoring means 52, error message issuance means 54, and evaluation means 56 are all preferably implemented as a combination of software instructions and executed accordingly.
Referring specifically to FIG. 4, the operation of the tutorial interface system 10 is described. In the description of the system 10 operation, each relevant system event is identified with a numeral in parentheses. Immediately after the system 10 is started (100), the interface with the computer application software is initiated and the control bar 51 and video window 55 are created (102). Next, the interface between the main program and the DLL is established (104) and the DLL interface communication agent is loaded into main memory 18. At this point, the product logo is displayed and an introduction video segment may be played (108) on the computer screen 26. The system 10 then prompts the user to enter an instruction from the control bar 51. Immediately upon entering the program a chapter index is set to a predetermined value and a lesson index is also set to a predetermined value. When the program is run for the first time, these two indexes are set at one. However, when the user 49 continues with a previously started lesson, the indexes may be automatically set to those of the prior session.
Each instruction available on the control bar 51 may be executed by the user 49. The EXIT instruction (110) provides notification of an exit to the DLL via the DLL communication agent (112), stops the DLL communication agent (114), and closes all DLL command files (116). The EXIT instruction (110) further shuts down the core program (118), closes the control bar 51 window, the chapter/lesson selection screen window 53, and the video window 55 (120), and ends the training session (122).
Executing the REWIND (RWD) instruction (124) with a double click causes the current lesson index and the current chapter index, as displayed in the chapter/lesson selection screen window 53, to index to the first chapter and first lesson (126). Executing the REWIND (RWD) instruction with a single click causes the current chapter index to decrement by a single chapter (126).
Executing the GOTO instruction (128) opens the chapter/lesson selection screen 53 and allows the user to select a particular chapter and lesson to be indexed (130). Then the user 49 has the option of playing the video clip or the demonstration of the particular lesson. Depending upon the option selected, the video clip plays or the demonstration plays (130).
Executing the FAST FORWARD (FF) instruction (132) with a double click causes the current lesson index and the current chapter index, as displayed in the chapter/lesson selection screen window 53, to index to the last chapter and last lesson (134). Executing the FAST FORWARD (FF) instruction (132) with a single click causes the current chapter index to increment by a single chapter (134).
Executing the STOP instruction (136) causes the process that is running when the instruction is executed to stop immediately (138). Executing the BACK instruction (140) freezes the current chapter and lesson indexes and plays the previously viewed video clip again (142). The PAUSE instruction (144) causes the currently playing video clip, if one is playing, to stop for later continuation (146).
The PLAY instruction (148) first causes the chapter counter to increment (150). The chapter counter indexes the relevant video clip and DLL instructions. The next video clip is then played in the video window 55 (152). Then, the control bar 51 and the video window 55 are hidden and the DLL instructions may be executed (154). A notification of play is transmitted to the DLL interface communication agent (156), the order is received by the DLL interface communication agent (158), and instructions are read from the DLL library and executed within the computer application software (160). Once the instructions are completed, a backwards notification is sent (162) so that the control bar 51 and the video window 55 are again displayed (164). Next, a short, written synopsis of the demonstration that was executed is displayed to the user 49 on the computer screen 26 (168). Then, the computer application software interface means 48 allows the user to practice within the computer application software to enforce what he or she has learned (168). Then, the user's performance is evaluated (170).
The COUNTER INFO instruction (172) toggles the time information displayed between elapsed time from the start of the video clip to the time remaining in the video clip (174). Optionally, the counter could also display the time since the user 49 logged on or the clock time. The counter hide instruction (176) toggles the counter display between being hidden or displayed (178).
The system 10 of the present invention can be easily implemented with application programs, on-line services, or any computer application software. The system 10 is generic and provides a familiar training interface that can be used in many varied situations. As one skilled in the art will readily appreciate, the system 10 of the present invention is readily transportable to provide tutorial instruction in any computer based system.
The present invention also includes a computerized, multimedia tutorial interface method for training a user to use computer application software. The method is analogous to the previously described system and is not described to the same extent. With reference to the FIGURES, the method of the present invention comprises as a first step displaying a control window 51 and 53 on a computer screen 26. As previously described, the control window provides a plurality of instructions to a user 49 that may be selected by the user.
A next step is receiving a user instruction from a user 49. Once the instruction is received the steps of interpreting the user instruction to creating an execution instruction are received. Once created, the steps of issuing the execution instruction and receiving the execution instruction are performed.
Responsive to the execution instruction, one of three separate steps is performed. A first step is selectively retrieving audiovisual information responsive to the execution instruction. A second step is displaying the audiovisual information on at least a portion of a computer screen 26. And a third step is selectively executing a function of the computer application software that is described in the audiovisual information.
A further step is selectively relinquishing control of computer application software to a user. This allows the user to practice the skills he has learned. A final step includes selectively regaining control of the computer application software from the user.
The method of the present invention also preferably includes the steps of monitoring user instructions issued to computer application software by a user. Another additional step is issuing an error message to a user on a computer screen if a user issues an instruction to computer application software that is erroneous as compared to a list of correct instructions. Further additional steps are evaluating the instructions issued to computer application software by a user and issuing a summary of the user's performance in issuing the instructions.
As one skilled in the art will readily appreciate, the method of the present invention could be used in a wide variety of systems. Whenever training of a user is required, the method of the present invention could be employed. While specific applications of this method involve application programs, the method could also be used with other computer based services such as on-line services.
The above described preferred embodiments are intended to illustrate the principles of the invention, but not to limit the scope of the invention. Various other embodiments and modifications to these preferred embodiments may be made by those skilled in the art without departing from the scope of the following claims.
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A computerized, multimedia tutorial interface system (10) and method for training a user to use computer application software. The system incorporates the training techniques of video segments, on-line tutorials, written instruction, and learning-by-doing lessons. The system and method incorporate the video segments into the system so that they may be displayed on a computer screen (26). User input is given by way of a mouse (22), keyboard (30), or by voice through an audio interface (34). Once the video clip is displayed on a video window (55), the system preferably runs a set of instructions within the computer application software to demonstrate the exact sequence of instructions that were discussed in the video clip. Once this is completed, written instruction is provided and the user is then given an opportunity to execute the same functions as previously described and executed by the system. In this fashion, lesson content is multiply reinforced. The system may also include user monitoring to ensure that the user correctly enters the instructions as well as to monitor the progress the user is making in his or her training. Preferred applications of the system and method of the present invention include application software, on-line services, and other complicated computer software systems.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is the US National Stage of International Application No. PCT/EP2004/053283, filed Dec. 6, 2004 and claims the benefit thereof. The International Application claims the benefits of German Patent application No. 10 2004 009 615.5 filed Feb. 27, 2004. All of the applications are incorporated by reference herein in their entirety.
FIELD OF THE INVENTION
The invention relates to a method for determining current oxygen loading of a 3-way catalytic converter of a lambda-controlled internal combustion engine having a linear pre-converter lambda probe connected upstream of the catalytic converter, a post-converter lambda probe connected downstream of the catalytic converter, and a device for measuring the air-mass flow rate. The invention is furthermore directed toward a number of methods for regulating, controlling, and/or monitoring the exhaust treatment of a lambda-controlled internal combustion engine that use the values determined by means of the inventive method for the catalytic converter's current oxygen loading.
BACKGROUND OF THE INVENTION
A 3-way catalytic converter can only convert pollutants in an optimal manner if the fuel/air ratio is within a narrow range around lambda≈1. Said range is referred to also as the catalytic-converter window. Only with fuel/air ratios of said kind will the exhaust composition be such that the oxygen released when the nitrogen oxides are reduced will suffice to almost completely oxidize the exhaust gas's HC and CO components into CO 2 and H 2 O. Mixing is therefore controlled in an internal combustion engine having a 3-way catalytic converter by what is termed a lambda controller to a target value of lambda≈1. To compensate brief fluctuations in the fuel/air ratio the catalytic converter also contains a coating (washcoat) made of a material, for example Ce 2 O 3 (di-cerium tri-oxide), that can briefly store oxygen and will bind or release it as and when required.
A linear pre-converter lambda probe is arranged upstream of the catalytic converter so that mixing can be controlled. Said probe measures the residual oxygen component contained in the exhaust gas. A post-converter lambda probe downstream of the catalytic converter serves to monitor the catalytic converter function. The catalytic converter's oxygen storage capacity is therein checked using what is termed OSC-based catalytic-converter diagnosing (OSC=oxygen storage capacity). Rich/lean oscillating of the mixture is produced for this purpose through pre-controlling by the lambda controller. An intact catalytic converter will compensate oscillating using its oxygen storage capacity so that the post-converter lambda probe's probe voltage will oscillate with only a small amplitude. If, though, the catalytic converter has lost its oxygen storage capacity through ageing, the residual oxygen content will be similar upstream and downstream of the catalytic converter and the post-converter lambda probe's signal will oscillate widely.
The post-converter lambda probe is often used, moreover, to compensate long-term drifting in the pre-converter lambda probe's signal. This is referred to also as trimming.
The post-converter lambda probe's signal is therefore usually constant in the case of a catalytic converter having sufficient oxygen storage capacity and a properly functioning lambda controller. If the signal rises or falls, the catalytic converter has been either sated with oxygen or completely emptied of oxygen so that it will no longer be able to compensate a fluctuation in the fuel/air ratio. This is referred to also as “breaking through” of the post-converter lambda probe's signal to a rich or, as the case may be, lean mixture.
Breaking through of the post-converter lambda-probe signal hence indicates that the catalytic converter's oxygen storage capacity is exhausted or that no more oxygen is stored. However, no information is available between said two limiting values about the catalytic converter's actual, current oxygen loading. Said information would, though, be very helpful for maintaining the oxygen loading at around half the storage capacity and hence for providing the same buffering on the rich and lean side, as a result of which breaking through of the post-converter lambda-probe signal will be preventively avoided and the most favorable conditions for catalytic-converter diagnosing furthermore created.
SUMMARY OF THE INVENTION
The object of the invention is therefore to provide a method for determining current oxygen loading of a lambda-controlled internal combustion engine's 3-way catalytic converter.
Said object is achieved by means of the invention defined in the claims.
Advantageous developments of the invention are the subject of the subclaims.
The method for determining current oxygen loading employs the signals of a linear pre-converter lambda probe, of a post-converter lambda probe, and of a device for measuring the air-mass flow rate, with a value for current oxygen loading being calculated from the pre-converter lambda probe's signal and from the measured air-mass flow rate by integration over time and said value being set to 0 if the post-converter lambda probe's signal breaks through to rich mixtures, because breaking through indicates that no more oxygen is stored in the catalytic converter. Integrated faults, for example measuring faults in the air-mass flow rate or in the pre-converter lambda probe's signal, will be reset through said calibrating.
The value for current oxygen loading is preferably calculated using the formula
m
O
2
=
[
O
2
]
air
∫
0
t
(
1
-
1
λ
)
m
.
L
ⅆ
t
,
where mO2 is the current oxygen loading, λ is the pre-converter lambda probe's signal, {dot over (m)}L is the air-mass flow rate, and [02] air is the mass component of oxygen in air. The latter is about 23%. The values for λ and mL are time-dependent.
If current oxygen loading is determined continuously in this manner it will also be possible to calculate a value for the catalytic converter's oxygen storage capacity. In the case of breaking through to a lean mixture the new value for the oxygen storage capacity is for this purpose calculated from the difference between the integrated oxygen loading and a hitherto adapted value for the oxygen storage capacity. That is because breaking through indicates that the catalytic converter's maximum oxygen storage capacity has been reached. Since the oxygen storage capacity also depends on certain operating parameters, the adapted value can optionally additionally be multiplied by a working-point-dependent factor that has been taken from a corresponding characteristics map and corrected thereby.
In the case of breaking through to a lean mixture the current oxygen loading can furthermore be set to the adapted value for the catalytic converter's oxygen storage capacity.
The current oxygen quotient is preferably additionally calculated from the quotient of the catalytic converter's current oxygen loading and oxygen storage capacity. Said value will be especially helpful if it is desired, for example, to keep the oxygen loading at a certain value to preventively avoid emissions.
In preferred embodiments of the invention the values calculated according to the method described above for current oxygen loading, oxygen storage capacity, and/or the current oxygen quotient are used in conjunction with different methods for regulating, controlling, and/or monitoring the exhaust treatment of a lambda-controlled internal combustion engine.
A first application is in OSC-based catalytic-converter diagnosing. Rich/lean oscillating resulting in maximum oxygen loading of the catalytic converter is therein set by means of forced activation or, as the case may be, pre-controlling of the fuel/air ratio. Maximum oxygen loading is selected to be still just manageable by a borderline catalytic converter exhibiting maximum permissible ageing without causing the post-converter probe signal to break through. This diagnostic method is implemented within the scope of OBD (on-board diagnosis) at intervals controlled by the ECU (electronic control unit). For said OSC-based diagnosing it is, however, of major importance prior to the start of forced activation to have set a defined oxygen loading necessary for diagnosing. The transition from lower nominal to maximum oxygen loading for catalytic-converter diagnosing therefore takes place in several steps in the prior art because the catalytic converter's loading condition is to a very large extent unknown and high additional oxygen loading can result in an oxygen quotient of below 0% or above 100% and hence in emissions behind the catalytic converter requiring to be diagnosed. The conventional function of trimming via the post-converter signal is to indirectly set mean oxygen loading during the transitional phase in such a way that OBD borderline catalytic-converter loading will only cause breaking through in the case of a borderline catalytic converter. This setting operation lasts a few forced-activation periods, however, and so requires additional time in the driving cycle the result of which can be that the number of diagnostic cycles necessary for catalytic-converter diagnosing cannot be performed in one piece or that the transitional phase for diagnosing will be interrupted without having determined a valid diagnostic value, resulting in avoidable emissions.
In a preferred embodiment of the invention the oxygen quotient is therefore set by the lambda controller prior to the start of diagnosing to a predetermined target value necessary for diagnosing. Said target value is selected in such a way that forced activation for catalytic-converter diagnosing will actuate the catalytic converter possibly only slightly, as a result of which the influence of catalytic-converter diagnosing on emissions will be minimal. Preconditioning of the catalytic converter for setting oxygen loading is implemented thereby and the process of changing over to OBD borderline catalytic-converter forced activation substantially accelerated.
Owing to the more precisely known level of oxygen loading, breaking through of the post-converter lambda-probe signal during catalytic-converter diagnosing can furthermore be implemented in a more reproducible manner and spreading of the individual diagnostic cycles consequently minimized. The overall accuracy of catalytic-converter diagnosing is improved thereby.
As the inventive method enables the catalytic converter's oxygen storage capacity to be determined, OSC-based catalytic-converter diagnosing can alternatively also be dispensed with entirely since conclusions about the catalytic converter's ageing condition can be drawn directly from the information about the oxygen storage capacity. However, that will only apply if the linear pre-converter lambda probe's signal and the available information about the air-mass flow rate are accurate enough for determining a sufficiently reliable value for the oxygen storage capacity. Replacing the OSC method has the advantage that active and emission-influencing forced activation is no longer necessary. At least preliminary information about the catalytic converter's condition of ageing can be generated by the determined maximum oxygen storage capacity.
In contrast to conventional catalytic-converter diagnosing methods the proposed approach allows the oxygen storage capacity to be determined on a permanent basis, although it must be said that different values for the oxygen storage capacity can occur owing to differing allowance being made for surface-storage and deep-storage effects.
A further preferred embodiment of the invention is controlled rinsing of the catalytic converter after an overrun fuel-cutoff phase. The catalytic converter is sated with oxygen after overrun fuel-cutoff phases, making it necessary to enrich the mixture in order to “rinse” the catalytic converter, which is to say to reset it as quickly as possible to an oxygen quotient of approximately 50%. The values determined for the oxygen storage capacity and oxygen loading allow a loading model to be set up in which enriching for “rinsing” the catalytic converter up to a defined oxygen quotient is pre-specified that has been matched to the converter characteristics (ageing, for example) and in which the oxygen quotient is controlled to the target value by the lambda controller after an overrun fuel-cutoff phase. NO x and HC/CO emissions are thus very largely avoided.
In a further preferred embodiment of the invention the lambda controller is set in such a way that the oxygen quotient is controlled to a specific target value of, for example, 50%. 50% is in most operating conditions the optimal setting for the oxygen quotient as that provides the catalytic converter's maximum oxygen buffer reserves for non-stationary operations or faults in general in the fuel/air ratio in the case of departures toward either a rich or a lean mixture. It enables a lambda controller that performs local oxygen balancing by means of the I 2 component to be greatly simplified and even ensures complete balancing. A separation is also provided between regulating and balancing.
The values determined for the oxygen quotient are preferably used also for controlling or, as the case may be, prioritizing the regulating and controlling interventions of the lambda controller, the trimming controller, and forced-activation means during OSC diagnosing. All regulating and controlling interventions of the lambda controller, forced-activation means, and trimming controller will make the mixture richer or leaner. The different information sources for this (post-converter signal for trimming and pre-converter signal for lambda controlling) result in temporally displaced interventions. Pre-controlling of forced activation is overlaid. If current oxygen loading or, as the case may be, the current oxygen quotient is known, the interventions can then be assessed as a function of the loading level. A provided controlling or regulating intervention for making the mixture leaner will preferably not take place if the oxygen quotient is above a predetermined first threshold value and a provided controlling or regulating intervention for making the mixture richer will preferably not take place if the oxygen quotient is below a predetermined second threshold value. A lean phase of forced activation can alternatively also be prevented if the oxygen quotient is above the first threshold value. The trimming controller's deferred intervention can furthermore be assessed. If, for instance, the intervention which the trimming controller would make based on the post-converter lambda-probe signal has already been compensated through other measures (for example by the lambda controller's reaction to a fault), then said intervention can be omitted.
Minor faults can also be compensated by varying the period lengths of forced activation. For example, enriching which the lambda controller would like to carry out takes place instead by not changing over to the lean half-wave in forced activation or by extending the rich half-wave. This type of regulator intervention can be referred to as fine tuning.
BRIEF DESCRIPTION OF THE DRAWINGS
Exemplary embodiments of the inventive method are described in more detail below with the aid of the attached drawings.
FIG. 1 is a diagrammatic representation of an internal combustion engine for implementing the inventive method,
FIG. 2 is an exemplary time curve of current oxygen loading and of the signal of the post-converter lambda probe,
FIG. 3 is a flowchart of a procedural flow in diagrammatic form,
FIG. 4 is an exemplary time curve of the oxygen quotient prior to and during OSC diagnosing,
FIG. 5 is an exemplary time curve of the oxygen quotient while the catalytic converter is being rinsed,
FIG. 6 is an exemplary time curve of the oxygen quotient while a main catalytic converter is being rinsed and the pre-converter is being actuated,
FIG. 7 is an exemplary time curve of the oxygen quotient for the lambda controller, and
FIG. 8 is an exemplary time curve of the oxygen quotient after a fault with and without intervention coordinating.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows an internal combustion engine 1 having a fuel-feed system [ 2 ] and a control device 3 . The fuel-feed system 2 is controlled by the control device 3 via leads, which are not referenced further, and takes care of the fuel allocation needs of the internal combustion engine 1 . A 3-way catalytic converter 6 is located in the exhaust tract 4 of said combustion engine 1 . Provided upstream of the catalytic converter 6 is a pre-converter lambda probe 5 for performing lambda controlling and provided downstream of said converter is a post-converter lambda probe 7 for measuring the lambda value. Said pre-converter lambda probe 5 is a linear lambda probe, while what is termed a binary lambda probe is used here as the post-converter lambda probe 7 in which the output voltage in the range lambda=1 virtually jumps from, for instance, below 100 mV in the case of lean mixtures (lambda>1) to over 0.7 V in the case of rich mixtures (lambda<1); this is referred to also as two-output. Both lambda probes supply their measured values via leads, which are not referenced further, to the control device 3 . In the intake tract 8 is an air-mass sensor 9 which is located in, for example, the intake pipe and supplies its measured values to the control device 3 via leads that are not referenced further. The air-mass flow rate can alternatively also be calculated with the aid of corresponding other sensors indirectly from the throttle-valve position, or, as the case may be, intake-pipe pressure and the rotational speed. The values obtained by further sensors, in particular the rotational speed, the catalytic-converter temperature, etc., are also ducted to the control device 3 . The control device 3 controls the operation of the internal combustion engine 1 with the aid of said values.
When the internal combustion engine 1 is operating the catalytic treatment of exhaust gas is regulated in the exhaust tract 4 as follows: The fuel feed in the fuel-feed system 2 is regulated in such a way that the signal of the pre-converter lambda probe 5 performs a slight oscillation around λ≈1. In a standard lambda probe a voltage level of 450 mV, for example, corresponds to the value λ≈1. The signal of the pre-converter lambda probe 5 oscillates around said value so that exhaust gas having the value λ≈1 is on average supplied to the catalytic converter 6 . The post-converter lambda probe 7 measures the lambda value in the treated exhaust gas downstream of the catalytic converter 6 . Said probe's signal will be approximately constant if the catalytic converter is intact and the lambda controller has been set well. Only in certain operating conditions such as, for example, following fuel cutoff on overrun or during forced activation during OSC diagnosing, will the post-converter lambda probe's signal change abruptly up or down and indicate thereby that the catalytic converter's maximum oxygen storage capacity has been reached or that the oxygen reserve is exhausted. This is referred to also as breaking through of the post-converter probe signal.
FIG. 2 is an exemplary time curve of the oxygen loading mO2 of the catalytic converter 6 which is integrated from the signal of the pre-converter lambda probe 5 and from the air-mass meter 9 using the formula
m
O
2
=
[
O
2
]
air
∫
0
t
(
1
-
1
λ
)
m
.
L
ⅆ
t
.
mO2 is therein the current oxygen loading, λ is the pre-converter lambda probe's signal, {dot over (m)}L is the air-mass flow rate, and [02] air is the mass component of oxygen in air, which is about 23%. The signal of the post-converter lambda probe λ_post is shown by way of example under the time curve of mO2.
The time curve shown for mO2 initially falls, which is to say that a rich mixture is being ducted to the catalytic converter. The catalytic converter's stored oxygen is exhausted at 12 so that the post-converter lambda-probe signal swings upward, which is to say toward rich mixtures. It is detected from this breakthrough that mO2 has the value 0 mg at this instant. The value for mO2 can as a result be calibrated to 0 mg. The value for mO2 thereafter rises again until held for a while by the lambda controller in the proximity of a mean value 13 . Oxygen loading subsequently rises further owing, for example, to brief overrun fuel-cutoff phases during which the fuel supply is throttled. The catalytic converter's oxygen storage capacity has been reached at 14 and the signal of the post-converter lambda probe 7 swings downward because the oxygen content downstream of the catalytic converter 7 is increasing. This breakthrough is registered by the control device 3 and is used to calculate adapting of the oxygen storage capacity mO2_max. The difference between the previous adapted value and current oxygen loading is calculated therefor and the new adapted value of the oxygen storage capacity calculated therefrom. Current oxygen loading (90 mg in the example shown) is then set as equaling the oxygen storage capacity mO2_max.
FIG. 3 is a flowchart of an exemplary method for calculating and initializing the value for current oxygen loading mO2. Said method begins at step 16 with a first initializing following breaking through of the post-converter lambda probe signal up or down. If the signal swings upward, the lambda value downstream of the catalytic converter will be too low and the catalytic converter's oxygen buffer thus completely empty. mO2 is therefore set to the value 0 (step 18 ). Current values for mO2 are continuously determined in step 20 through integration over time. This continues until further breaking through of the post-converter lambda probe's signal is determined in step 22 . That can point, for example, in the direction opposite that in step 16 , meaning downward. Said breakthrough indicates that the catalytic converter's oxygen storage capacity is exhausted. A new value for the oxygen storage capacity mO2_max can hence be calculated by comparing the value for mO2 calculated through integration in step 20 with the last assumed value for the oxygen storage capacity.
That, though, is to be recommended only if the value integrated between the two breakthroughs in 16 and 22 for the air-mass flow rate is not excessively high because the measured values for the air-mass flow rate and also for the lambda value contain measuring errors. Said measuring errors are integrated in step 20 and accumulate over time. An inquiry is therefore made at 24 to establish whether the air-mass flow rate integrated since the last breakthrough is excessively high, and only if the air-mass integral is below a certain threshold value will the value for mO2_max be adapted, which is to say recalculated, and stored in the control device (step 26 ). Integration over time is then resumed for continuously determining current values for mO2 (step 28 ). Said newly determined current values are additionally divided by the adapted oxygen storage capacity to continuously obtain values for the current oxygen quotient qO2. Said steps are possibly repeated each time the post-converter lambda-probe signal breaks through in order to avoid an accumulation of measuring errors and to continuously obtain new values for the catalytic converter's maximum oxygen storage capacity.
FIGS. 4-8 show the time curve of the oxygen quotient qO2 for different applications and exemplary embodiments of the inventive method.
FIG. 4 is the time curve for qO2 shortly before and during OSC-based catalytic-converter diagnosing. The oxygen quotient happens to have a relatively high value X at the instant 30 . The maximum oxygen capacity corresponding to a value of qO2=100% would be reached in a short time were forced activation to start at this particular instant, and that would result in increased NO x output. That cannot be avoided with a conventional lambda controller because the value X for the current oxygen quotient is not known. However, qO2 is calculated continuously in this exemplary embodiment of the invention, making it possible to set a defined oxygen quotient necessary for diagnosing before forced activation commences. Said value is 50% in the example shown and is reached at the instant 32 . That is when forced activation begins, during which mixing is subjected to a rich/lean oscillation. Loading of the catalytic converter, and hence the calculated oxygen quotient, consequently fluctuates with an amplitude P. The maximum values 0% and 100% are not reached during said oscillating in the example shown so that the post-converter lambda probe signal does not break through and a catalytic converter still capable of functioning is diagnosed.
FIGS. 5 and 6 show exemplary targeted curves of the oxygen quotient while the catalytic converter is being rinsed. The overrun fuel-cutoff phase has ended in each case at the instant t PUC end (PUC=pull fuel cutoff). The catalytic converter is sated with oxygen at said instant. The mixture is enriched from time to time in order to reset the catalytic converter as quickly as possible to an oxygen quotient of approximately 50%. Where possible, though, the catalytic converter should not to be rinsed too forcefully as CO and HC emissions will otherwise occur. A loading model in which a target value and, where applicable, a targeted curve for the oxygen quotient are set is therefore established with the aid of the known variables “oxygen storage capacity” and “oxygen quotient”.
For a main catalytic converter the result is, for example, the curve shown in FIG. 5 for the oxygen quotient.
If, alongside the main catalytic converter, there is also a pre-converter, then that should also be “rinsed”. A further loading model will thus furthermore allow the defined setting in the pre-converter of an oxygen concentration in which a reduction can also be represented when the main catalytic converter has been rinsed (during which the pre-converter will be “activated”). FIG. 6 is a possible curve of the oxygen quotient in the pre-converter while a main catalytic converter is being rinsed, during which the pre-converter is “activated” at 34 .
Since a suitable rinsing level can now be determined with the aid of actual oxygen loading, rinsing can in a further embodiment also be initiated after a brief overrun fuel-cutoff phase during which the post-converter lambda-probe signal has not reacted at all. Said rinsing level can also be adjusted to the catalytic converter's ageing condition.
In another development of the invention a lambda controller is used having a value of approximately 50% (45% in the example shown) as the target value for the oxygen quotient qO2. The catalytic converter's maximum oxygen buffer reserves for non-stationary operations or faults in general in the air/fuel-mixture—for departures toward either a rich or a lean mixture—will always be provided when the oxygen quotient is 50%. The buffer for lean mixtures will be somewhat larger if the oxygen quotient is 45%, which is advantageous for avoiding NO x emissions. FIG. 7 shows by way of example the curve of an oxygen quotient controlled by the lambda controller to 45%.
Finally, FIG. 8 shows an example of a further embodiment of the invention wherein the information about the current oxygen quotient is used to compensate a fault in the air/fuel-composition as quickly as possible. Curve 36 shows the present-day solution in which the regulating and controlling interventions of the lambda controller, trimming controller, and forced activation are not prioritized. Because of the different information sources for said controllers (post-converter signal for trimming and pre-converter signal for lambda controlling), said controllers' interventions are in part temporally displaced, causing the fault to be corrected less quickly. Curve 37 , by contrast, shows the value of the oxygen quotient with the interventions being coordinated, with, for example, an intervention, that the trimming controller would perform based on the post-converter signal, being omitted if said intervention has already been compensated through other measures. Furthermore, a lean phase of forced activation, for example, can be prevented if oxygen loading exceeds a threshold.
The inventive method enables a 3-way catalytic converter's current and maximum oxygen loading to be determined on a permanent basis and the emissions to be reduced through selective interventions based on said information. The described controlling, regulating, and monitoring methods furthermore allow reduced emissions, shorter times, and improved accuracy of catalytic-converter diagnosing, in particular for systems without a second catalytic converter. Continuous information on ageing is moreover provided by way of the catalytic converter's condition so that functions such as, for instance, rinsing of said converter following overrun fuel-cutoff can be adapted, which also contributes to emission reduction. Finally, a further reduction in emissions can be achieved as a result of coordinating controlling and regulating interventions as a function of the loading level.
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The invention relates to a method for determining the actual oxygen load of a 3-path catalyst of a lambda-controlled internal combustion engine, whereby a value for the actual oxygen load is calculated from the signal of a pre-catalyst lambda probe and the measured air mass flow rate by integration over time, whereby the post-catalyst lambda probe is initialized when the signal is interrupted.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to the field of drive wheel suspension for vehicles.
2. Prior Art
T3 Motion, Inc., assignee of the present invention, now manufactures and sells the three-wheeled battery operated vehicle shown in FIG. 1 . The vehicle is operated standing up, with all of the controls necessary being accessible on the handlebars. The vehicle has found wide application for security purposes, as it typically can operate all day in a typical application on a single charge, both indoors such as in shopping centers and outdoors for policing such areas as parking lots, parking structures, beach areas and the like. The vehicle has found wide use for such purposes not only because of its efficiency (cost of operation), but also because the operator is elevated somewhat, so can see over people for a better view of the area.
In the prior art vehicles as shown in FIG. 1 , the wheels are rigidly mounted, that is, the rear wheels are rigidly mounted to the frame of the vehicle and the front wheel, which is the drive wheel, is rigidly mounted to the steering post, as in a typical tricycle. However because of the functionality and practical appeal of the vehicles, the same are being used in environments not having a particularly smooth operating surface, such as by way of example, poorly maintained parking lots and the like where rigid mounting of the vehicle substantially affects performance.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a view of a prior art vehicle in which the present invention may be used.
FIG. 2 is a first side perspective view of the suspension and drive of the present invention.
FIG. 3 is a second side perspective view of the suspension and drive system.
FIG. 4 is a front view of the drive and suspension of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention comprises a spring mounted drive wheel for an electric powered vehicle such as that shown in FIG. 1 . FIG. 2 is a first side perspective view of the suspension and drive, FIG. 3 is an opposite side perspective view of the suspension and drive system, and FIG. 4 is a front view thereof. A main crossbar 20 has a socket-like opening 22 therein to which a steering post will be fastened. Welded to the main crossbar 20 are a pair of downward and rearward projecting struts 24 which provide support for swing arms 26 , which support the axle 28 , which in turn supports wheel 30 on bearings (not shown) of conventional design. Between the upper ends of struts 24 and the forward part of swing arms 26 , just above axle 28 , are clips 34 which support coil springs 36 , each having a shock absorber 38 therein. The springs are generally chosen to support the weight applied to that wheel, with the swing arms 26 in a substantially level or horizontal position, as may be seen in FIG. 3 . For the drive system, an electric motor 40 mounts on a plate 42 which is rigidly welded to the main crossbar 20 and further supported by a corner filler member 44 welded in place. The motor 40 has a toothed pulley 41 on the end of its shaft which drives a belt 46 that is connected to and drives a toothed pulley 48 supported on bearings on shaft 50 . Coupled to toothed pulley 48 is a hollow counter shaft 52 having a smaller toothed pulley 54 (visible only in FIG. 3 ) having a toothed belt 56 driving wheel 30 and tire 31 through toothed pulley 48 . Shaft 50 may be rigidly fastened to the adjacent ends of swing arms 26 so as to form a rigid “U” shape with the legs of the “U” extending to each side of the wheel 30 and tire 31 , or not rigidly fastened, as desired.
Motor 40 is fastened to plate 42 by three bolts 57 , each in a slot 59 in plate 42 . This allows a screw 60 supported on plate 42 to be used to slide the motor toward main crossbar 20 before bolts 57 are tightened to provide the proper tension in belt 46 . Similarly, wheel 30 is supported on axle 28 which passes through a U-shaped clip 62 at each end of the axle. The swing arms 26 have a hollow rectangular cross section which is closed, at least at the end adjacent axle 28 , so that adjustment bolts 64 , together with jam nuts (best seen in FIG. 4 ), may be tightened to slide axle 28 forward, away from each swing arm bearing in region 66 at each side of the suspension. This allows tightening of belt 56 as required, with the jam nuts then tightened to lock the adjustment bolts 64 in their set position.
Also visible in FIG. 3 is a member 68 which is disposed to strip the toothed belt 56 from the toothed pulley 58 in the event of a break in belt 56 . A similar member 70 , supported from plate 42 by extension 72 as may be seen in FIG. 2 , is disposed to strip the toothed belt 46 from the toothed pulley 48 in the event of a break in belt 46 . Also visible in these two Figures are straps 74 . These are merely support for a fender such as the front fender in the prior art unit of FIG. 1 , which keeps foreign matter, clothing, etc. away from the belt drive.
The preferred embodiment has been described herein with respect to the use of toothed belts and toothed pulleys, though conventional belts may be used if desired. It will be noted from the indication of the direction of wheel rotation in FIGS. 2 and 3 that the swing arms 26 project forward from their pivot axes as opposed to rearward for conventional swing arm suspension. By projecting forward, the tire may represent the forward most point of the system, yielding the appearance of the vehicle in accordance with FIG. 1 . This also allows placement of the axis of rotation of the wheel somewhat forward of the axis of rotation of the steering column, as is normally done with tricycles, bicycles and motorcycles, and as is done in the prior art vehicle of FIG. 1 . Reversing the arrangement shown in FIGS. 2 to 4 so that the forward motion of the vehicle would be in the opposite would put the countershaft 52 and pulleys associated therewith forward of the tire, which would be both aesthetically and functionally undesirable. Having the swing arms projecting forward from the pivot point is facilitated in part by making the nominal position of the swing arms approximately horizontal and using the shock absorber/spring assembly as limiting of the swing arm motion. Accordingly the present invention enhances the functionality while preserving the appearance of a front wheel drive device such as the prior art vehicle of FIG. 1 . Thus the present invention has a number of aspects, which aspects may be practiced alone or in various combinations or sub-combinations, as desired. While a preferred embodiment of the present invention has been disclosed and described herein for purposes of illustration and not for purposes of limitation, it will be understood by those skilled in the art that various changes in form and detail may be made therein without departing from the spirit and scope of the invention as defined by the full breadth of the following claims.
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A drive wheel and suspension for a vehicle for mounting on a steering post to provide both a steering capability and propulsion to the vehicle. The drive wheel and suspension provides a spring suspension for that wheel of the vehicle, as well as what is effectively vehicle body mounting of the propulsion system so as to minimize un-sprung weight and to provide a compact assembly to support a suitable aesthetic and protective fender over the drive wheel and suspension.
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CROSS REFERENCES TO RELATED APPLICATION
This application is a continuation-in-part application for our copending application, Ser. No. 680,882 filed on Apr. 27, 1976, now abandoned.
BACKGROUND OF THE INVENTION
This invention relates to a dielectric insulator separated substrate for semiconductor integrated circuits, which includes a large number of monocrystalline semiconductor island regions in which circuit elements are to be formed and a polycrystalline semiconductor support region for supporting fixedly the island regions.
In a semiconductor integrated circuit, circuit elements such as resistors, diodes, transistors, thyristors and the like may be formed integrally in island regions while being required to be electrically separated from each other. For this, a large number of island regions are electrically insulated from each other and from a support region which supports them. One of the insulating methods uses dielectric materials and a substrate prepared according to this method is called a dielectric insulator separated substrate (hereinafter referred simply to as DI substrate).
The DI substrate, however, undergoes curveness deformations during its preparation process and upon the production of semiconductor integrated circuits. The deformation brings about various defects including cracks in the substrate, degraded accuracy of metal deposition for the electrodes, degradation of the withstand voltage and fluctuations in characteristics of the circuit elements.
The U.S. patent applications Ser. Nos. 604,947 now U.S. Pat. No. 4,017,341 and 637,959 now U.S. Pat. No. 4,079,506 assigned to the same assignee of the present application describe in detail causes for the curveness deformations of the DI substrate and propose a countermeasure therefor. More particularly, there are two types of curveness deformations of the DI substrate. In one type, the DI substrate is deformed convexly toward the side of the monocrystalline semiconductor island regions. In the other type, the DI substrate is deformed convexly toward the side of the polycrystalline semiconductor support region. The curveness deformation of the former type is caused by the difference in thermal expansion coefficient between the monocrystalline island regions and the polycrystalline support region. In the latter type, the deformation results from the wedge action due to oxygen diffused into the polycrystalline support region.
Accordingly, the prior patent applications set forth above proposed to provide a film for preventing the diffusion of oxygen into the surface of the polycrystalline layer of the support region and/or a film for compensating for the difference in thermal expansion coefficient between the island regions and the support region.
According to inventions disclosed in the prior patent applications set forth above, it was confirmed that the DI substrate per se is removed of the curveness deformations but some disadvantages still remain in the production of semiconductor integrated circuits.
Herein, these disadvantages will be explained with reference to the drawing illustrating the production process according to the above prior patent applications.
As illustrated in FIG. 1a, after thermal oxidation of one principal surface of an N-type monocrystalline silicon wafer 1, a mesh (grid) pattern of separation channels 2 is formed on the surface by photoetching. Thereafter, a dielectric insulative silicon oxide film 3 is again formed by heating over the principal surface of the water. Next, as shown in FIG. 1b, a thick polycrystalline silicon layer 4a is formed in a vapor growth reaction furnace, and then a silicon oxide film 5a, a thin polycrystalline silicon layer 4b, a silicon oxide film 5b for preventing the oxygen diffusion and a polycrystalline silicon layer 4c are grown one over another in this order to form a lamination.
The alternate lamination of the polycrystalline silicon layers 4a to 4c and the silicon oxide films 5a and 5b can easily be prepared by introducing at desired number of times water vapor or carbon dioxide into the reaction furnace during the thermal decomposition growth of trichloride silane or quadrachloride silane to thereby react thermally decomposed silicon with oxygen.
By regulating the number of the alternate lamination of the polycrystalline silicon layers 4a to 4c and the silicon oxide films 5a and 5b, the thickness of individual layers and films and the vapor growth temperature, the curveness deformation of the monocrystalline silicon wafer 1 due to the difference in thermal expansion coefficient between the layers and films can be reduced to zero.
By using the flat bottom principal surface of the monocrystalline silicon wafer 1 as datum plane, the polycrystalline silicon layer 4c is polished flatly to a level A designated as a chained line, as shown in FIG. 1b. Next, by utilizing the flattened surface of the polycrystalline silicon layer 4c, the single crystalline silicon wafer 1 is polished flatly to a level B designated as a chained line to thereby obtain a number of monocrystalline silicon island regions 1a, 1b, . . . , 1n insulatedly separated from each other by means of the previously formed silicon oxide film 3.
When forming circuit elements in the plurality of single crystalline silicon island regions 1a, 1b, . . . , 1n by diffusion technique, the extreme outer polycrystalline silicon layer 4c yields the wedge action owing to the heat treatment of the substrate in oxidization atmosphere with the result that the DI substrate as shown in FIG. 1c would undergo the curveness deformation. For this reason, the extreme outer polycrystalline silicon layer 4c was removed by etching and the surface of the silicon oxide film 5b was exposed as shown in FIG. 1d.
As illustrated in these figures, traces corresponding to the separation channels remain on the outer film 5b and the surface of the silicon oxide film 5b becomes considerably irregular.
In addition to the traces corresponding to the separation channels 2, the irregularity results from projections due to local abnormal growth of the polycrystalline silicon.
When diffusing impurities into the individual monocrystalline silicon island regions 1a, 1b, . . . , 1n, the silicon oxide film 5b side of the substrate is attracted by a vacuum chuck and fixed thereto and then a mask is applied to the opposite side of the substrate. Thereafter, a photoresist is applied upon the surfaces of the monocrystalline silicon island regions 1a, 1b, . . . , 1n through the mask. In this process, however, the irregularities present on the surface of the silicon oxide film 5b prevents steady support for the substrate by the vacuum chuck thereby to degrade the masking accuracy.
If the mask was pressed on the surfaces of the monocrsytalline silicon island regions 1a, 1b, . . . , 1n in order to ensure an intimate contact of the mask with the DI substrate, the DI substrate was sometimes broken down owing to the projections which act as fulcrums.
SUMMARY OF THE INVENTION
An object of the invention is to provide a DI substrate having insulated island regions in which integrated circuit elements are to be formed.
Another object of the present invention is to provide a DI substrate which is prevented from its breakage during preparation of integrated circuits.
A further object of this invention is to provide a DI substrate wherein the DI substrate is free from curveness deformations and precisely and finely dimensioned circuit elements can be formed in the DI substrate at high yield rate.
A further object of this invention is to provide a DI substrate applicable to the preparation of various types of DI substrate.
According to this invention, there is provided a dielectric insulator separated substrate which comprises a plurality of monocrystalline semiconductor island regions in which circuit elements are to be formed and a support region which comprises polycrystalline semiconductor layers and at least one oxygen diffusion preventive film. These layers and the film are laminated alternately to form the support region having its extreme outer layer of the polycrystalline semiconductor layer. The extreme outer polycrystalline semiconductor layer has a highly flat surface and predetermined thickness as to prevent the substrate from being curved greatly by the wedge action due to the oxygen diffusion.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1a to 1d are longitudinal section views showing preparation steps based on single-poly method of a DI substrate disclosed in the prior United States patent applications.
FIGS. 2a and 2b are longitudinal section views showing preparation steps based on single-poly method of a DI substrate according to this invention.
FIGS. 3 and 4 are graphic representations showing the relation between the ultimate thickness of the extreme outer polycrystalline silicon layer after polished and the magnitude of curveness deformation of the DI substrate when the entire thickness of the DI substrate and the number of the alternately laminated polycrystalline silicon layers and silicon oxide films are changed.
FIG. 5 is a longitudinal section view of one example of DI substrate prepared according to this invention.
FIGS. 6a to 6d and FIGS. 7a to 7d are longitudinal section views showing preparation steps of DI substrates according to this invention based on double-poly method and etch epitaxial refill method, respectively.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Hereunder, the preparing method of this invention will be described by way of examples.
FIG. 2a shows the same DI substrate as that shown in FIG. 1b. This substrate is prepared by the method employed in steps of FIGS. 1a and 1b.
Polycrystalline silicon layers 14a, 14b and 14c and silicon oxide films 15a and 15b representative of oxygen diffusion preventive films are alternately laminated on the monocrystalline silicon wafer 11 provided with separation channels 12 through a silicon oxide film 13.
More particularly, these films 15a, 15b in the lamination prevent the monocrystalline silicon wafer 11 from undergoing the curveness deformations by compensating for the difference in thermal expansion coefficient between the monocrystalline silicon wafer 11 and the polycrystalline silicon layers 14a to 14c.
It is an essential feature of the present invention that the extreme outer layer 14c is a polycrystalline silicon layer.
The number of the silicon oxide films to be laminated is determined dependent upon the structure of a DI substrate 10 and by no means limited to two as illustrated by the silicon films 15a and 15b. Further, their insertion position is not limited to that shown in the figure.
Next, by using as datum plane the flat bottom principal surface of the monocrystalline silicon wafer 11, the extreme outer polycrystalline silicon layer 14c is polished to a level C designated at a chained line as shown in FIG. 2a. Through this polishing process, the traces corresponding to the separation channels 12 are removed. Thereafter, by using as datum plane the flattened top principal surface of the extreme outer polycrystalline silicon layer 14c, the monocrystalline silicon wafer 11 is polished to a level D designated at a chained line, thereby obtaining a plurality of monocrystalline silicon island regions 11a to 11n insulatedly separated by the silicon oxide film 13. This phase is shown in FIG. 2b.
Conventionally, the extreme outer polycrystalline silicon layer was removed by etching in the next phase. In accordance with this invention, however, the extreme outer layer is not removed completely and oxidization and diffusion are carried out in the next step.
In a preparatory process for the diffusion step, a silicon oxide film that acts as diffusion mask is formed by thermal oxidization process. During the preparatory process, oxygen would diffuse into the extreme outer polycrystalline silicon layer 14c. In this invention, the extreme outer polycrystalline silicon layer 14c is polished to be of a small thickness and the oxygen diffusion is prevented by the silicon oxide film 15b. Namely, the layer responsible for inducing the curveness deformation due to the wedge action of oxygen diffusion is thin and the DI substrate 10 is almost freed from the curveness deformations.
Then, a diffusion mask corresponding to a diffusion pattern is applied on the monocrystalline silicon island regions 11a to 11n. The photoetching is applied to the silicon oxide film. Since the DI substrate is freed from the curveness deformations, and moreover since the top principal surface of the extreme outer polycrystalline silicon layer 14c is flattened by polishing, the substrate may be supported steadily by the vacuum chuck. Even if a compressive force is applied to the substrate during this process, the DI substrate 10 cannot be cracked, because it has a polished flat surface on the extreme outer polycrystalline layer 14c.
Thereafter, the DI substrate is placed in a diffusion furnace and impurities are diffused into the monocrystalline silicon island regions 11a to 11n. In this process, too, oxygen atmosphere inside the diffusion furnace will cause the oxygen diffusion into the extreme outer polycrystalline silicon layer 14c but the DI substrate 10 is almost freed from the curveness deformation for the same reason as that for the oxidization step.
In this manner, even if similar diffusion treatments are repeated, the effect of this invention may be alive and the curveness deformation of the DI substrate may be prevented without fail.
Where an upper limit of the magnitude range of the curveness deformation of the DI substrate due to the oxidization and diffusion processes, which is no trouble for effecting the subsequent photoetching, electrode formation and the like handling, is set to 30 microns, the ultimate thickness x of the extreme outer polycrystalline silicon layer 14c after polished shown in FIG. 2b must satisfy x≦y/40 when the entire thickness y of the DI substrate 10 also shown in FIG. 2b is 200 microns to 500 microns.
The lower limit of the entire thickness y of the DI substrate 10, which depends on the handling conditions and the degree of heat treatment, can be reduced to about 200 microns if the condition for heat treatment is not severe, i.e., if the temperature for oxidization is lower and the time thereof is shorter relatively. Although it is preferable to make thicker the entire thickness y in view of the mechanical strength and reduction of curveness deformation, an upper limit of the entire thickness is about 500 microns in view of the reduction of cost price. The relation between the ultimate thickness x and the curveness deformation magnitude Δh after the diffusion step is completed was measured in accordance with the entire thickness y of the DI substrate 10 of 500 microns, 450 microns, 300 microns and 200 microns to obtain corresponding curves a to d shown in FIG. 3.
It will be understood from FIG. 3 that, for a fixed value of the ultimate thickness x, the thicker the entire thickness y of the DI substrate 10 is, the smaller the magnitude of the curveness deformation becomes.
From FIG. 3, the following relationships will be found. FIG. 3 shows a heat treatment conditions for thermal oxidization. When an upper limit of curveness deformation Δh is set to 30 microns, the ultimate thicknesses x of the polycrystalline layer are less than 14 microns, less than 11 microns, less than 8 microns and less than 6 microns for the entire thicknesses y of 500 microns, 450 microns, 300 microns and 200 microns, respectively. In other words, these relationship may be represented by the relation x≦y/40.
A measurement was conducted to study how the ultimate thickness of the extreme outer polycrystalline silicon layer 14c affects the curveness deformation magnitude of the substrate when the number of the polycrystalline silicon layers 14 and silicon oxide films 15 is changed. The results are shown in FIG. 4.
Substrates were prepared under the condition that growth temperature for both the polycrystalline silicon layers 14 and the silicon oxide films 15 is 1200° C., each one of the silicon oxide films 15 has a thickness of 1.4 microns and the entire thickness y of the DI substrate 10 is 500 microns for each case.
It will be seen from FIG. 4 that the curveness deformation magnitude of the substrate is determined by the ultimate thickness x of the extreme outer polycrystalline silicon layer 14c and hardly affected by the number of the alternately laminated layers and films.
Further, an experiment was conducted to study how the curveness deformation magnitude of the substrate is affected by changing within the range from 0.3 microns to 1.4 microns the thickness of the silicon oxide films 15a and 15b. It was confirmed that the thickness of the silicon oxide films 15a and 15b is no relation to the curveness deformation magnitude. That is to say, this shows that even thin silicon oxide films sufficiently prevent the oxygen diffusion into the adjacent polycrystalline silicon layer 14b.
It will be appreciated from the foregoing description that when the ultimate thickness x of the extreme outer polycrystalline silicon layer 14c satisfies x≦y/40, the magnitude of the curveness deformations is independent of both the number of the alternately laminated polycrystalline silicon layers 14 and silicon oxide films 15 and the thickness of the silicon oxide films 15. As the DI substrate 10 is almost freed from the curveness deformations even after manufacturing processes including the diffusion process, whereby desired circuit elements can be formed in the monocrystalline silicon island regions 11a to 11n with high accuracy.
FIGS. 3 and 4 show that the smaller the ultimate thickness x of the extreme outer polycrystalline silicon layer 14c after polishing, the smaller the curveness deformation of the DI substrate will be.
Even when irregular growth of the polycrystalline silicon layers 14a to 14c as shown at a circle α of FIG. 5 causes a local difference in the ultimate thickness of the extreme outer polycrystalline silicon layer 14c or when a local difference in the thickness of the layer 14c takes place after polishing, there is no problem as far as the polished surface of the extreme layer is highly flat.
Accordingly, in consideration of the parallelism of top and bottom surfaces of the DI substrate, the roughness of the extreme outer polycrystalline silicon layer surface, the working accuracy and the strength of the substrate, it is not preferable to polish the extreme outer polycrystalline silicon layer to make zero its ultimate thickness but preferable to polish it to make large its ultimate thickness as possible within the allowable range that the DI substrate is freed from the curveness deformation during the diffusion process.
While, in the foregoing description, the oxygen diffusion preventive film has been explained by way of a silicon oxide film, silicon nitride (Si 3 N 4 ) films aluminum oxide (Al 2 O 3 ) films or composite films of these components may be used.
The preparation processes of FIGS. 1 and 2 are called a single-poly method wherein polycrystalline silicon layers are formed on one surface of the monocrystalline silicon wafer. This invention, however, may be applicable to a double-poly method wherein polycrystalline silicon layers are formed on both surfaces of the monocrystalline silicon wafer and other various preparation methods of the DI substrate.
Referring now to FIG. 6, one example of the invention will be described wherein a DI substrate is prepared in accordance with a double-poly method.
As shown in FIG. 6a, silicon oxide films 22a and 22b are formed on both principal surfaces of a monocrystalline silicon wafer 21 by thermally oxidizing the monocrystalline silicon wafer 21, and a polycrystalline silicon layer 23 is formed on the silicon oxide film 22a on one side by the vapor growth. Then, as shown in FIG. 6b, the silicon oxide film 22b on the opposite side is partially removed and the monocrystalline silicon wafer 21 is selectively etched to form a grid pattern of separation channels 24, thereby the silicon oxide film 22a on one side being exposed partially.
Since the monocrystalline silicon wafer 21 separated into a plurality of monocrystalline silicon island regions 21a by the grid pattern separation channel 24, individual monocrystalline silicon island regions 21a are temporarily supported by the polycrystalline silicon layer 23. In this point, the double-poly method differs from the previous single-poly method.
Next, after, forming a silicon oxide film 25 on the side peripheral surface of individual monocrystalline silicon islands 21a by thermal oxidization, the polycrystalline silicon layer 23 to which the monocrystalline silicon island regions 21a are secured is placed in a vapor growth furnace. Therein, a support region 28 including an alternate lamination of polycrystalline silicon layers 26a, 26b and 26c and silicon oxide films 27a and 27b is prepared.
As shown in FIG. 6a, the polycrystalline silicon layer 23 is formed on the flat monocrystalline silicon wafer 21 so that the surface of the polycrystalline silicon layer 23 is considered to be flat. By using as datum plane this flat surface of the polycrystalline silicon layer 23, the extreme outer polycrystalline silicon layer 26c is polished to a level E as shown in FIG. 6c.
Thereafter, by using as datum plane the flat surface of the extreme outer polycrystalline silicon layer 26c thus obtained by polishing, the polycrystalline silicon layer 23 is polished to form a DI substrate 29 as shown in FIG. 6d.
The layer 26c may be removed by chemical etching. The polycrystalline silicon layer 23 is removed uniformly to ensure uniformity of the thickness of the monocrystalline silicon island regions 21a and that of the DI substrate 29.
Further, the exposed flat surface of the extreme outer polycrystalline silicon layer 26c of the support region 28 ensures easy handling of the substrate by means of the vacuum chuck so that various circuit elements may be formed accurately in the monocrystalline silicon island regions 21a without yielding the curveness deformation of the DI substrate 29.
Turning to FIG. 7, one example will be described wherein the invention is applied to an etch epitaxial refill method hereunder.
This preparation method is an improvement of the single poly method explained with reference to FIGS. 1 and 2, and uses as mother material a monocrystalline silicon wafer into which N-type impurities are diffused at a high concentration.
The steps employed in the example shown in FIG. 2b are similar to those of this example and a description thereof will be omitted in the following explanation. Additionally, FIG. 2b corresponds to FIG. 7a. A plurality of monocrystalline silicon island regions 31a into which impurities are diffused at a high concentration are supported by a support region 38 through a silicon oxide film 32.
The support region 38 is an alternate lamination of polycrystalline silicon layers 36a, 36b and 36c and silicon oxide films 37a and 37b, and the extreme outer polycrystalline silicon layer 36c is polished, leaving behind a certain thickness, to make a flat surface.
A silicon oxide film 39 acting as mask is formed on the top principal surface to which the monocrystalline silicon island regions 31a are exposed, and the film 39 on the island regions 31a is selectively removed by etching. As shown in FIG. 7b, individual monocrystalline silicon island regions 31a are also removed, leaving behind a predetermined thickness portion.
Thereafter, a silicon layer 40 added with impurities at low concentration is applied by vapor growth. Some parts of the silicon vapor grown layer 40 in register with the silicon oxide film 39 become polycrystalline regions 40a whereas the remaining parts in register with the etched monocrystalline silicon island regions 31a become monocrystalline regions 40b.
Next, by using as datum plane the bottom flat surface of the extreme outer polycrystalline silicon layer 36c, the silicon vapor grown layer 40 is removed by polishing at a level F designated at a chained line to obtain a DI substrate 41 as shown in FIG. 7d.
Therefore, the island regions 42 comprise the monocrystalline silicon high concentration regions 31a and the monocrystalline silicon low concentration regions 40b.
In this method, too, the DI substrate 41 is freed from the curveness deformation during the oxidization and diffusion processes so that various circuit elements can be formed in the monocrystalline silicon low concentration regions 40b with high accuracy.
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A dielectric insulator separated substrate comprises a plurality of monocrystalline semiconductor island regions in which circuit elements are to be formed and a support region for supporting the island regions while a dielectric film formed on the supporting region electrically separates the island regions from each other. The supporting region comprises crystalline semiconductor layers and at least one oxygen diffusion preventive film laminated alternately.
The extreme outer polycrystalline semiconductor layer of the supporting region is polished to such a thickness as to prevent the substrate from being curved greatly by the wedge action due to the oxygen diffusion. Since the extreme outer polycrystalline semiconductor layer thus polished has a flat surface, the handling of the substrate is easy. The substrate devoid of any curveness deformation assures a highly accurate formation of the circuit elements in the island regions.
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[0001] This application claims the benefit of Korean Patent Application No.P2004-99158 filed on Nov. 30, 2004 which is hereby incorporated by reference as if fully set forth herein.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a drying apparatus, and more particularly, to a composite washing system which is capable of continuously circulating laundry-drying air through dryers while obtaining a more efficient drying effect, so that the composite washing system has a suitable built-in structure.
[0004] 2. Discussion of the Related Art
[0005] Generally, laundry dryers are adapted to dry laundry such as clothes. Such a laundry dryer receives completely-washed laundry, and then performs an operation to dry the laundry while continuously supplying hot air.
[0006] FIG. 1 illustrates a general drum dryer as an example of a conventional laundry dryer.
[0007] As shown in FIG. 1 , the conventional drum dryer mainly includes a body 10 , a drying drum 20 , a door 40 , a motor 50 , a drying heater 60 , and a blowing fan 70 .
[0008] The body 10 defines an appearance of the drum dryer. The drying drum 20 is rotatably disposed in the body 10 . A laundry inlet 11 is formed through the front of the body 10 . The door 40 is mounted to the front of the body 10 to open and close the laundry inlet 11 .
[0009] The motor 50 is fixedly mounted on the bottom of the body 10 inside the body 10 . The motor 50 generates a drive force to rotate the drying drum 20 and the blowing fan 70 .
[0010] The drying heater 60 is arranged in a hot air supply path 91 in order to heat air flowing through the hot air supply path 91 . The hot air supply path 91 guides a flow of hot air supplied into the drying drum 20 .
[0011] The blowing fan 70 operates to outwardly discharge the hot air, namely, drying air, flowing through the interior of the drying drum 10 . The blowing fan 70 communicates with a hot air discharge path 92 .
[0012] In accordance with the above-mentioned configuration, when the blowing fan 70 operates, air around the laundry dryer, namely, ambient air, is introduced into the body 10 , is heated while passing through the drying heater 60 , and is then introduced into the drying drum 20 while being guided by the hot air supply path 91 .
[0013] Accordingly, wet laundry received in the drying drum 20 is gradually dried by the hot air.
[0014] The air used to dry the laundry while passing through the drying drum 10 is outwardly discharged while being guided by the hot air discharge path 92 .
[0015] When the laundry is completely dried in accordance with repeated execution of the above-mentioned procedure, the operations of the blowing fan 70 and drying heater 60 are stopped to complete the drying cycle.
[0016] In the conventional drum dryer, however, there is a problem in that laundry is inefficiently dried because the drying cycle is carried out while the laundry is in an entangled state.
[0017] Furthermore, there is a problem in that the laundry cannot be maintained in the dryer.
[0018] To this end, a demand for a new laundry dryer has recently been made which has an increased drying capacity and enables storage of dried laundry for a prolonged period of time. To satisfy this demand, a combination type dryer has been developed, as disclosed in U.S. Published Patent Application Nos. 2004/0194339 A1 and 2004/0154194 A1. Such a combination type dryer includes a separate drying cabinet, in addition to a drum dryer, namely, a tumble dryer.
[0019] In such a combination type dryer, a drying cabinet, which has a drying compartment for various clothes, is mounted on the top of a general drum dryer having a rotatable drum such that hot air is supplied to the drying cabinet.
[0020] The drying cabinet receives hot air supplied from the drum dryer to dry clothes received in the drying cabinet. The drying cabinet may also be used to store the dried clothes for a prolonged period of time.
[0021] However, the above-mentioned combination type dryer has a problem in that it cannot be of a built-in type because it has an air discharge type structure in which the air used to dry laundry is outwardly discharged from the dryer.
[0022] In other words, where the combination type dryer is built in a wall, it is necessary to provide a sufficient built-in space to provide a sufficient gap from the surface of the wall such that air is adequately discharged away from the dryer. For this reason, the appearance of the dryer is unattractive.
[0023] Furthermore, the air discharged from the combination type dryer is hot and humid, thereby causing the indoor environment to be an environment undesirable for the user, namely, a high-temperature and humid environment.
[0024] In addition, in order to receive laundry having a long length, such as trousers, in the laundry compartment of the drying cabinet in the conventional combination type dryer, the laundry compartment of the drying cabinet is connected with a part of the space defined in the drum dryer. For this reason, there is a problem in that the drum, which is disposed in the drum dryer, must be of a limited size.
SUMMARY OF THE INVENTION
[0025] Accordingly, the present invention is directed to a composite washing system that substantially obviates one or more problems due to limitations and disadvantages of the related art.
[0026] An object of the present invention is to provide a composite washing system which is capable of continuously circulating air to dry laundry contained in a drying drum and laundry contained in a drying cabinet, and uniformly drying the laundry contained in the drying cabinet.
[0027] Another object of the present invention is to provide a composite washing system which can receive laundry having a long length in a drying cabinet without wrinkling the laundry.
[0028] 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 objectives and other advantages of the invention may be realized and attained by the structure particularly pointed out in the written description and claims hereof as well as the appended drawings.
[0029] To achieve these objects and other advantages and in accordance with the purpose of the invention, as embodied and broadly described herein, a composite washing system comprises: a drum dryer which dries laundry to be dried, and includes a drying drum adapted to receive the laundry, a hot air supply path adapted to guide a flow of hot air, a hot air supplier arranged in the hot air supply path to generate the hot air, and an air condenser adapted to condense the hot air; a cabinet dryer which is coupled to one side of the drum dryer, and is defined with a laundry receiving compartment, the cabinet dryer including a hot air inlet duct adapted to receive the hot air flowing through the hot air supply path; and a laundry folder which is disposed in the cabinet dryer to receive laundry having a long length without wrinkling the laundry.
[0030] The hot air supply path may include a first air supply duct which guides the hot air into the drying drum, a second air supply duct which is connected to the first air supply duct and the hot air inlet duct to guide the hot air generated from the hot air supplier into at least one of the first air supply duct and the hot air inlet duct, and a third air supply duct which guides air discharged from the drying drum to the air condenser.
[0031] The composite washing system may further comprise a filter which is arranged in the third air supply duct to filter the air discharged from the drying drum, and thus, to remove foreign matter contained in the discharged air.
[0032] The laundry folder may include at least one folding rod which is detachably mounted in the cabinet dryer to fold a portion of the laundry, and a folding rod guide which is disposed in the cabinet dryer to hold the folding rod in a fixed state and to guide a movement of the folding rod.
[0033] The folding rod may include a seat member on which the laundry is seated, and a position fixing member which extends from one end of the seat member to fix a position of the folding rod.
[0034] The folding rod guide may include an insertion groove in which the position fixing member of the folding rod is insertable, a first guide which extends horizontally from the insertion groove to guide a horizontal movement of the folding rod, a second guide which extends vertically from the first guide to guide a vertical movement of the folding rod, and at least one fixing groove which is formed at one side of the second guide to fix a position of the folding rod.
[0035] The first guide may include a first guide groove which receives the position fixing member of the folding rod to allow the position fixing member to move along the first guide, and first separation preventing grooves which are formed along opposite edges of the first guide groove, respectively, to prevent the position fixing member from being separated from the first guide groove.
[0036] The second guide may include a second guide groove which receives the position fixing member of the folding rod to allow the position fixing member to move along the second guide, and second separation preventing grooves which are formed along opposite edges of the second guide groove, respectively, to prevent the position fixing member from being separated from the second guide groove.
[0037] The composite washing system may further comprise a laundry support which is disposed in the cabinet dryer to support the laundry in the cabinet dryer.
[0038] The laundry support may include at least one shelf detachably mounted in the cabinet dryer to support the laundry in such a manner that the laundry is laid on the shelf, and a hanger bar detachably mounted in the cabinet dryer at an upper portion of the cabinet dryer to support the laundry in such a manner that the laundry is hung on the hanger bar.
[0039] In accordance with another aspect of the present invention, a composite washing system comprises: a drum dryer which dries laundry to be dried, and includes a drying drum adapted to receive the laundry, a hot air supply path adapted to guide a flow of hot air, a hot air supplier arranged in the hot air supply path to generate the hot air, and an air condenser adapted to condense the hot air; a cabinet dryer which is coupled to one side of the drum dryer, and is defined with a laundry receiving compartment, the cabinet dryer including a hot air inlet duct adapted to receive the hot air flowing through the hot air supply path; at least one folding rod which is detachably mounted in the cabinet dryer to fold a portion of the laundry; a folding rod guide which is disposed in the cabinet dryer to hold the folding rod in a fixed state and to guide a movement of the folding rod; and a weight which prevents the laundry seated on the folding rod in a folded state from being separated from the folding rod.
[0040] The hot air supply path may include a first air supply duct which guides the hot air into the drying drum, a second air supply duct which is connected to the first air supply duct and the hot air inlet duct to guide the hot air generated from the hot air supplier into at least one of the first air supply duct and the hot air inlet duct, and a third air supply duct which guides air discharged from the drying drum to the air condenser.
[0041] The composite washing system may further comprise a valve which is arranged in a portion of the second air supply duct connected to the first air supply duct and the hot air inlet duct, and selectively guides the hot air flowing through the second air supply duct into at least one of the first air supply duct and the hot air inlet duct.
[0042] The composite washing system may further comprise a filter which is arranged in the third air supply duct to filter the air discharged from the drying drum, and thus, to remove foreign matter contained in the discharged air.
[0043] The folding rod may include a seat member on which the laundry is seated, and a position fixing member which extends from one end of the seat member to fix a position of the folding rod.
[0044] The folding rod guide may include an insertion groove in which the position fixing member of the folding rod is insertable, a first guide which extends horizontally from the insertion groove to guide a horizontal movement of the folding rod, a second guide which extends vertically from the first guide to guide a vertical movement of the folding rod, and at least one fixing groove which is formed at one side of the second guide to fix a position of the folding rod.
[0045] The first guide may include a first guide groove which receives the position fixing member of the folding rod to allow the position fixing member to move along the first guide, and first separation preventing grooves which are formed along opposite edges of the first guide groove, respectively, to prevent the position fixing member from being separated from the first guide groove.
[0046] The second guide may include a second guide groove which receives the position fixing member of the folding rod to allow the position fixing member to move along the second guide, and second separation preventing grooves which are formed along opposite edges of the second guide groove, respectively, to prevent the position fixing member from being separated from the second guide groove.
[0047] The composite washing system may further comprise a laundry support which is disposed in the cabinet dryer to support the laundry in the cabinet dryer.
[0048] The laundry support may include at least one shelf detachably mounted in the cabinet dryer to support the laundry in such a manner that the laundry is laid on the shelf, and a hanger bar detachably mounted in the cabinet dryer at an upper portion of the cabinet dryer to support the laundry in such a manner that the laundry is hung on the hanger bar.
[0049] It is to be understood that both the foregoing general description and the following detailed description of the present invention are exemplary and explanatory and are intended to provide further explanation of the invention as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0050] The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this application, illustrate embodiment(s) of the invention and together with the description serve to explain the principle of the invention. In the drawings:
[0051] FIG. 1 is a schematic view illustrating an inner configuration of a conventional drum dryer;
[0052] FIG. 2 is a front view schematically illustrating a configuration of a composite washing system according to an exemplary embodiment of the present invention;
[0053] FIG. 3 is a block diagram schematically illustrating the configuration of the composite washing system according to the exemplary embodiment of the present invention;
[0054] FIG. 4 is a perspective view illustrating a structure of a laundry folder according to an exemplary embodiment of the present invention;
[0055] FIG. 5 is a cross-sectional view taken along the line I-I of FIG. 4 ;
[0056] FIG. 6 is a cross-sectional view taken along the line II-II of FIG. 4 ; and
[0057] FIG. 7 is a perspective view illustrating a state in which laundry is hung on the laundry folder according to the exemplary embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0058] Reference will now be made in detail to the preferred embodiments of the present invention, examples of which are 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.
[0059] FIG. 2 is a front view schematically illustrating a configuration of a composite washing system according to an exemplary embodiment of the present invention. FIG. 3 is a block diagram schematically illustrating the configuration of the composite washing system according to the exemplary embodiment of the present invention.
[0060] FIG. 4 is a perspective view illustrating a structure of a laundry folder according to an exemplary embodiment of the present invention. FIG. 5 is a cross-sectional view taken along the line I-I of FIG. 4 . FIG. 6 is a cross-sectional view taken along the line II-II of FIG. 4 .
[0061] FIG. 7 is a perspective view illustrating a state in which laundry is hung on the laundry folder according to the exemplary embodiment of the present invention.
[0062] As shown in FIGS. 2 and 3 , the composite washing system according to the exemplary embodiment of the present invention mainly includes a drum dryer 100 , a cabinet dryer 200 , a laundry folder, and a controller 600 .
[0063] The drum dryer 100 performs an operation to dry laundry.
[0064] The drum dryer 100 may include a drying drum 110 which can perform a rotating operation and a stirring operation, a hot air supply path, a hot air supplier 130 , and an air condenser 140 .
[0065] The hot air supply path is a path to guide a flow of hot air. The hot air supply path communicates with an inner space defined in the system among the drying drum 110 , air condenser 140 , and cabinet dryer 200 .
[0066] For example, the hot air supply path may include a first air supply duct 121 which supplies hot air into the drying drum 110 , and a second air supply duct 122 which receives air emerging from the air condenser 140 , and guides the received air into the first air supply duct 121 or a hot air inlet duct 241 of the cabinet dryer 200 . The hot air supply path may further include a third air supply duct 123 which receives air emerging from the drying drum 110 , and guides the received air into the air condenser 140 .
[0067] A filter 124 may also be arranged in the third air supply duct 123 to filter air passing through the third air supply duct 123 , and thus, to remove foreign matter contained in the air.
[0068] The hot air supplier 130 is arranged in the second air supply duct 122 to produce hot air.
[0069] For example, the hot air supplier 130 may include a drying heater 131 which heats air passing through the second air supply duct 122 , and a blowing fan 132 which forcibly blows the air heated in the second air supply duct 122 .
[0070] Preferably, the blowing fan 132 is arranged in a portion of the second air supply duct 122 upstream from the drying heater 131 , in order to minimize any damage to the blowing fan 132 caused by hot air.
[0071] The air condenser 140 condenses air flowing through the third air supply duct 123 , and radiates heat from the air. The air condenser 140 may include a condenser 141 and a condensing fan 142 .
[0072] The condenser 141 is configured to receive hot air from the third air supply duct 123 of the hot air supply path. The condenser 141 may include a pipe having a plurality of bent portions, and cooling fins arranged around the pipe.
[0073] The condensing fan 142 is adapted to blow external air toward the condenser 141 .
[0074] Accordingly, humid air passing through the condenser 141 is condensed as it heat-exchanges with the external air supplied in accordance with the operation of the condensing fan 142 while passing through the pipe of the condenser 141 .
[0075] The cabinet dryer 200 is defined with a laundry compartment to receive a large amount of laundry. The cabinet dryer 200 may be coupled to a portion of the drum dryer 100 . In the exemplary embodiment of the present invention, the cabinet dryer 200 is illustrated as being coupled to the top of the drum dryer 100 .
[0076] In this case, in addition to the hot air inlet duct 241 , the cabinet dryer 200 mainly includes a body 210 , a laundry support 220 , an opening/closing door 230 , and an air outlet duct 242 .
[0077] The body 210 defines an appearance of the cabinet dryer 200 , and is open at the front thereof.
[0078] The laundry support 220 is mounted in the body 210 . The laundry support 220 may include a plurality of shelves 221 , and a hanger bar 222 .
[0079] Each shelf is detachably mounted in the body 210 . The hanger bar 222 is detachably mounted to the body 210 in an upper space of the body 210 .
[0080] The opening/closing door 230 is mounted to the front of the body 210 to open/close the open front of the body 210 .
[0081] The hot air inlet duct 241 has one end connected to the second air supply duct 122 of the drum dryer 100 , and the other end communicating with the interior of the body 210 . Accordingly, the hot air inlet duct 241 receives hot air from the second air supply duct 122 , and guides the received hot air into the body 210 .
[0082] Preferably, a valve 125 is arranged in the second air supply duct 122 to guide the air flowing through the second air supply duct 122 toward the first air supply duct 121 and/or the hot air inlet duct 241 .
[0083] The air outlet duct 242 has one end communicating with the body 210 , and the other end connected to the third air supply duct 123 of the hot air supply path. Accordingly, the air outlet duct 242 functions to discharge hot and humid air passing through the laundry in the body 210 .
[0084] A separate discharge fan (not shown) may be arranged in the air outlet duct 242 .
[0085] The laundry folder according to the exemplary embodiment of the present invention is adapted to enable laundry having a long length to be received in the cabinet dryer without being wrinkled.
[0086] FIG. 4 illustrates the structure of the laundry folder according to the exemplary embodiment of the present invention. FIG. 5 illustrates a cross-sectional structure of a first guide included in the laundry folder. FIG. 6 illustrates a cross-sectional structure of a second guide included in the laundry folder.
[0087] The laundry folder will be described in detail with reference to FIG. 4 .
[0088] The laundry folder may include at least one folding rod 300 which is detachably mounted in the body 210 of the cabinet dryer 200 to fold a portion of laundry, and a folding rod guide which is provided at the body 210 of the cabinet dryer 200 to hold the folding rod 300 in a fixed state and to guide movement of the folding rod 300 .
[0089] The folding rod 300 includes an elongated seat member 310 , and a position fixing member 320 which extends from one end of the seat member 310 .
[0090] The seat member 310 supports a portion of laundry in a state in which the laundry portion is wrapped around or laid on the seat member 310 without being wrinkled.
[0091] Preferably, the seat member 310 has a circular cross-section in order to allow laundry to be seated on the seat member 310 without being wrinkled.
[0092] The position fixing member 320 functions to fix the seat member 310 at a desired position in the body 210 of the cabinet dryer 200 while allowing the seat member 310 to be movable.
[0093] The position fixing member 320 also functions to prevent the seat member 310 from being unintentionally separated from the fixed position.
[0094] The laundry folder may include one or more folding rods 300 in accordance with the length of the laundry to be folded by the laundry folder. Where the laundry folder includes two folding rods 300 , namely, a first folding rod 300 a and a second folding rod 300 b , as shown in FIG. 7 , the first folding rod 300 a folds a portion of laundry in a state in which the laundry portion is wrapped around the first folding rod 300 a , and the second folding rod 300 b folds another portion of the folded laundry portion in a state in which the laundry portion is laid on the second folding rod 300 b.
[0095] Meanwhile, the folding rod guide includes an insertion groove 410 , a first guide 420 , a second guide 430 , and a plurality of fixing grooves 440 .
[0096] Preferably, the insertion groove 410 has the same shape as that of the position fixing member 320 in order to allow an easy insertion of the position fixing member 320 through the insertion groove 410 . More preferably, the insertion groove 410 has a size allowing the position fixing member 320 to be inserted through the insertion groove 410 .
[0097] The first guide 420 extends horizontally from the insertion groove 410 . The first guide 420 functions to guide a horizontal movement of the position fixing member 320 of the folding rode 300 inserted in the insertion groove 410 .
[0098] As shown in FIG. 5 , the first guide 420 includes a first guide groove 421 which extends horizontally to allow a horizontal movement of the position fixing member 320 along the first guide 420 , and first separation preventing grooves 422 which are formed along opposite longitudinal edges of the first guide groove 421 , respectively, to prevent the position fixing member 320 from being separated from the first guide groove 421 .
[0099] The second guide 430 extends vertically from the first guide 420 , and functions to guide a vertical movement, namely, an upward or downward movement, of the folding rod 300 which has been horizontally moved along the first guide 420 .
[0100] As shown in FIG. 6 , the second guide 430 includes a second guide groove 431 which extends vertically to allow a vertical movement of the position fixing member 320 along the second guide 430 , and second separation preventing grooves 432 which are formed along opposite longitudinal edges of the second guide groove 431 , respectively, to prevent the position fixing member 320 from being separated from the second guide groove 431 .
[0101] Each fixing groove 440 is formed at one longitudinal edge of the second guide 430 in order to fix the folding rod 300 which has moved along the second guide 430 .
[0102] Meanwhile, in accordance with the exemplary embodiment of the present invention, it is preferred that the laundry folder further include a weight 500 which prevents the laundry supported by the folding rod 300 in a seated state from being separated from the folding rod 300 , and smoothes out wrinkles on the laundry during the drying operation.
[0103] As shown in FIG. 7 , it is preferred that the weight 500 be provided, at one end thereof, with a nipper, in order to allow the weight 500 to be easily attached to a lower end of the laundry.
[0104] Thus, the weight 500 applies a load to the laundry seated on the seat member 310 of the folding rod 300 in a gravity direction, thereby preventing the laundry from being separated from the seat member 310 while smoothing out wrinkles on the laundry during the drying operation.
[0105] The controller 600 according to the exemplary embodiment of the present invention controls the operations of the drum dryer 100 and cabinet dryer 200 .
[0106] The controller 600 may be equipped in one of the drum dryer 100 and cabinet dryer 200 , or may be equipped in either the drum dryer 100 or the cabinet dryer 200 . In the exemplary embodiment of the present invention, the controller 600 is illustrated as being equipped in the drum dryer 100 .
[0107] Where two controllers 600 are equipped in the drum dryer 100 and cabinet dryer 200 , respectively, it is preferred that the two controllers 600 be connected by a data cable (not shown), for information transfer therebetween.
[0108] Meanwhile, the controller 600 may be configured to control the drum dryer 100 and cabinet dryer 200 in an independent manner or in a linked manner.
[0109] Hereinafter, the drying operation and functions of the composite washing system provided with the laundry folder in accordance with the exemplary embodiment of the present invention will be described.
[0110] First, laundry is laid on the shelves 221 , or is hung on the hanger bar 222 in the body 210 of the cabinet dryer 200 .
[0111] If the laundry to be hung on the hanger bar 221 has a long length, the folding rods 300 a and 300 b are mounted.
[0112] In this case, the position fixing member 320 of the second folding rod 300 b is first inserted into the insertion groove 410 of the folding rod guide. In this state, the position fixing member 320 of the second folding rod 300 b is moved along the first guide groove 421 of the first guide 420 .
[0113] Thereafter, the position fixing member 320 of the second folding rod 300 b is vertically moved along the second guide groove 431 of the second guide 430 to a fixing level at which the laundry does not come into contact with the bottom of the cabinet dryer 200 . The fixing level may be appropriately determined in accordance with the length of the laundry. Subsequently, the position fixing member 320 of the second folding rod 300 b is firmly fitted in the fixing groove 440 corresponding to the fixing level. As described above, the fixing groove 440 is formed at one longitudinal edge of the second guide 430 . Thus, the second folding rod 300 b is fixedly mounted to the body 210 of the cabinet dryer 200 .
[0114] Thereafter, the first folding rod 300 a is inserted into the insertion groove 410 of the folding rod guide, and is then moved along the first guide 420 to a desired position.
[0115] In this state, a portion of the laundry is wrapped around the bottom of the first folding rod 300 a such that the laundry is folded. Thereafter, the laundry is seated on the top of the second folding rod 300 b.
[0116] Meanwhile, if the laundry is likely to slip off the second folding rod 300 b , the weight 500 is attached to the lower end of the laundry in order to prevent the laundry from slipping off the second folding rod 300 b.
[0117] After the hanging of the laundry is completely achieved in the above-described manner, electric power is supplied to the hot air supplier 130 , thereby causing hot air to be supplied to the second air supply duct 122 of the hot air supply path.
[0118] Thereafter, the valve 125 is controlled to guide the hot air flowing through the second air supply duct 122 into the hot air inlet duct 241 of the cabinet dryer 200 .
[0119] The hot air introduced into the hot air inlet duct 241 is discharged into the body 210 of the cabinet dryer 200 . Thus, the laundry is dried.
[0120] The air which has become humid after being used to dry the laundry is guided through the condenser 140 , so that the air is dried while being condensed to remove moisture therefrom. The dried air is then heated to a high temperature while passing through the drying heater 131 . The resultant hot air is then re-supplied to the body 210 of the cabinet dryer 200 .
[0121] Thus, the laundry is dried as the above-described air flow is repeated for a predetermined time.
[0122] The above-described composite washing system according to the present invention has various advantages as follows.
[0123] First, air flowing in the drum dryer and cabinet dryer is continuously circulated without being discharged out of the dryers in accordance with the present invention. Accordingly, the air used in the drying cycle has no influence on the indoor environment. Therefore, the present invention can provide a composite washing system having a suitable built-in structure.
[0124] Second, in accordance with the present invention, humid air discharged from the drum dryer and cabinet dryer is condensed by the air condenser, so that moisture contained in the air is removed. Accordingly, it is possible to effectively dry laundry.
[0125] Third, in accordance with the present invention, the cabinet dryer is equipped with the laundry folder. Accordingly, it is possible to dry laundry having a long length in a state of receiving the laundry in the cabinet dryer without wrinkling the laundry, and thus, to enhance the reliability of the composite washing system.
[0126] It will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the spirit or scope of the inventions. Thus, it is intended that the present invention covers 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 composite washing system is disclosed which is capable of continuously circulating laundry-drying air through dryers while obtaining a more efficient drying effect, so that the composite washing system has a suitable built-in structure having minimal influence on the indoor environment. The composite washing system includes a drum dryer which dries laundry to be dried, and includes a drying drum adapted to receive the laundry, a hot air supply path adapted to guide a flow of hot air, a hot air supplier arranged in the hot air supply path to generate the hot air, and an air condenser adapted to condense the hot air, a cabinet dryer which is coupled to one side of the drum dryer, and is defined with a laundry receiving compartment, the cabinet dryer including a hot air adapted to receive the hot air flowing through the hot air supply path, and a laundry folder which is disposed in the cabinet dryer to receive laundry having a long length without wrinkling the laundry.
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[0001] This application claims the benefit of U.S. Provisional Patent Application No. 62/184,961 filed on Jun. 26, 2015. The disclosure of the referenced application is hereby incorporated herein in its entirety by reference.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to the field of safety and accuracy in crude oil and natural gas well drilling, particularly the use of thermodynamic principles in order to develop a new method for safely and accurately conducting crude oil and natural gas well drilling.
[0003] Well blowouts are caused by the uncontrolled release of crude oil or natural gas well after a well's pressure control systems have failed. Given the threat to life and adverse impact on property and environment that a blowout can have, significant planning and precautions are undertaken when drilling the well. As part of safe drilling practices, persons who drill wells must consider several factors when planning a well, including pore pressure determination. The Pre-drill estimation of pore pressure and fracture gradient analysis is the bedrock of the well-planning process. Optimal pore pressure and fracture gradient estimates rely on the accuracy of overburden gradient calculations, which signify the characteristics of a given basin. If overburden or vertical stress gradient calculations are off, then pore pressure and fracture gradient estimates may be grossly underestimated or overestimated, both of which can result in severe wellbore instability and/or well control issues.
[0004] “Geopressure” refers to a subterranean earth formation where the fluid pressure of the pores exceeds hydrostatic. More specifically, Terzaghi's Principle states that all quantifiable changes in stress to a soil (e.g., compression, deformation, shear resistance) are a direct result of a change in effective stress. The effective stress σ′ is related to total stress σ and the pore pressure u by the relationship σ=σ′+u reading that total stress is equal to the sum of effective stress and pore water pressure.
[0005] Subsequently, the above authors defined the effective stress of a system as the difference between the total overburden of overlying sediments and the pressure of fluids occupying the pores of rock material. Later the oil and gas industry defined the “normal” pressure as the Salt water gradient or 0.465 psi/ft for the Gulf of Mexico and any pressure in excess of normal gradient as “abnormal” pore pressure.
[0006] Yet, an inherent weakness in Terzaghi's Principle is that it fails to incorporate additional thermally induced pressure into the equation. In addition, this theory does not relate the thermal properties of the rock formation and heat flow—that is specific to shale and sandstone formations—to the location and magnitude of Formation Pore Pressures. Terzaghi's approach to the compaction-dominated system does not need to take into account the effect of “high” Temperature and Thermal Conductivity of rock material but it would have been appropriate to have included the cold and low temperatures. This is because unusual pressures are often seen to affect the freeze-thaw cycles which in turn affect the shape of pores and in places such as Alaska affects certain surface pressures. For example, the contribution of temperature or geochemical reactions to the effective stress gradient is not represented in either Terzaghi's equation or the publications by the above mentioned authors.
[0007] Although thermodynamic or related properties associated with temperature are recognized by the petroleum industry; the experts, especially those engaged in serious basin modeling, have not used it in conjunction with the existing pore pressure estimation model. Because failure to properly calculate pore pressure can threaten the health and safety of workers and the environment, a method to properly mitigate these concerns and aid in the economic recovery of natural resources is desirable.
SUMMARY OF THE INVENTION
[0008] The disclosed invention describes a method for determining the pressure at various depth points in a proposed oil or gas well location that considers certain thermodynamic properties. These properties now considered include thermal conductivity at different points within the proposed well and the heat flux at those points. These different data sets provide more information that can lead to a more effective, efficient and safe drill of the well.
[0009] In this method, the user creates several plots of data that is related to the depth of the proposed well. Included charts include the depth of the well against temperature, resistivity, and pressure. The pressure of the various points is analyzed using both the Eaton method and the DWC method. Using the pressure and resistivity, the thermal conductivity and heat flux can be determined for different depths. Based upon the generated graphs, the user can more accurately estimate the location of the Top of Geopressure (TOG), changes in pressure mechanism dominance below the TOG, as well as the possible location of hydrocarbons within the proposed well location.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a pressure versus temperature plot of three wells that were previously drilled. Said wells are used as examples throughout this disclosure.
[0011] FIG. 2 is a consolidated pressure versus temperature plot for all three wells that were previously drilled. There is also an enlargement of the “Transition Zone”, demonstrating the change from normal to abnormal pressure.
[0012] FIG. 3 is resistance versus depth plot for one of the three wells.
[0013] FIG. 4 is an exemplary Drilling Well Control (DWC) resistivity overlay plot.
[0014] FIG. 5 is an exemplary geothermal gradient chart.
[0015] FIG. 6 is a composite plot of formation thermal conductivity, heat flux through formation, and the normalized plot of dP/dT using Eaton's and DWC methods, side by side for well # 1 in the described field example.
[0016] FIG. 7 is a structural map of the field for the three wells, showing the three wells and the fault.
[0017] FIG. 8 is a basin simulator generated chart that compares pore pressure, excess pressure, heat flow, and geological age in millions of years for well # 1 in the field.
DETAILED DESCRIPTION OF THE INVENTION
[0018] The method described herein is a new method for analyzing pore pressure during pre-drilling planning for crude oil and natural gas wells in order to perform higher accuracy basin modeling. This novel method first develops and applies the concept of thermal equilibrium in the pressure-temperature space. Basin modeling is then used to analyze pore pressures along the depth of the interest and evaluate the effectiveness of seals as a barrier to heat flux. Data has suggested that an effective seal ideally prevents the leakage of pressure and temperature simultaneously from the system.
[0019] Eaton's work is used as the foundation for correlating the Resistivity Log (ohm-meter) values in normal and abnormal pressures across the SP 9-mv) values of shale through the following, known equation (hereinafter “Eaton's Correlation”):
[0000] P/D=S/D− 0.535(observed shale resistivity/normal resistivity) 1.2
[0000] In Eaton's Correlation, P/D, S/D, and 0.535 represent pressure gradient, overburden gradient, and normal effective stress value, respectively. Eaton's work developed a simple relationship that predicts the formation pore pressure by knowing the normally pressured compaction treadline, the observed resistivity/conductivity data and a relationship for formation overburden stress. Eaton's Correlation is also another form of Terzaghi's effective stress theory, which is correlated to Normal and Abnormal resistivity values. Because those having skill in the art are familiar with Eaton's Correlation and its simplicity, and resistivity values give better estimates of normal/abnormal pressures (as compared to other log data), this equation was selected to represent the Gulf Coast compaction process.
[0020] The temperature-depth relationship suggests that temperature gradient increases with depth in a linear fashion. Pressure is a function of depth and increases at deeper levels, thus this method considers that an over-pressured region in a field could exhibit high temperatures. This linear relationship between pressure and temperature defines the equilibrium of the system and is used to draft a pressure-temperature plot.
[0021] The earth, containing various materials (e.g., shale, sandstone, salt, clays, minerals, limestone, dolomite, and chert), is subject to a variety of temperatures and pressures to such a degree that the earth acts like a reactor. A number of different reactions may occur, including processes that lead to abnormal Formation Pore Pressure to develop. In these processes, the reactions obey the following fundamental law:
[0000] Δ G=ΔH−TΔS=ΔVP−TΔS (“Equation 1”)
[0000] In this equation, ΔG (Gibbs free energy) is the energy available to perform work. If ΔG is negative, the reaction will be instantaneous. If ΔG is positive, the reaction will not be instant, but will require a supply of additional energy in order to create a reaction. If ΔG equals zero, the reaction is considered to be at its “equilibrium state.” ΔH represents the change in enthalpy, or total heat content, of a system, wherein ΔH is equal to the sum of the internal energy and the product of pressure multiplied by the volume. T represents the temperature at any formation depth, and ΔS represents the change in entropy of the system. Entropy is the thermodynamic quality that represents the unavailability of a system's thermal energy for conversion into mechanical work, which is often interpreted as the degree of disorder or randomness in the system. As those having skill in the art will recognize, Δ represents the difference between two conditions. In order to determine the changes in the differences, those skilled in the art would perform the derivative of the above Equation 1, while keeping ΔV and ΔS constant, producing:
[0000] dΔG=dPΔV−dTΔS (“Equation 2”)
[0022] At Equilibrium Conditions, where there is no change in the ΔG, dΔG equals zero. Thus at Equilibrium Conditions, dPΔV−dTΔS=0. Expanding this equation results in: dPΔV=dTΔS. Dividing both sides of this equation by dT results in: (dP/dT) ΔV=ΔS. Then, when dividing both sides of the equation by ΔV, those skilled in the art will recognize that the result is Clapeyron's Equation:
[0000] ( dP/dT )=Δ S/ΔV
[0023] A careful examination of Clapeyron's Equation indicates that a plot of pore pressure versus temperature generates a curve whose slope is equal to dP/dT, and that slope is also equal to ΔS/ΔV, indicating that the slope is a measure of energy per unit volume—or, pressure. This pressure is the additional pore pressure that is induced by temperature. This disclosed invention tracks the deviations from equilibrium conditions as the user drills from the surface to any desired depth. As a demonstrative of this method, understood to be an example alone, the thermal equilibrium of three wells were studied in the field. FIG. 1 shows an example of a P-T plot for the field wells.
[0024] Next, this method consults the resistivity log for the site where the well is being planned. For oil and gas well drilling, resistivity logging is often used to assist in determining how porous the rock materials are. Resistivity logging is a known method of well logging that characterizes the rock or sediment by measuring its electrical resistivity. Most rock materials, especially those where oil and gas wells are drilled, are natural insulators, while their enclosed fluids are conductors (with the exception of hydrocarbon fluids). When a formation is porous and contains salty water, the overall resistivity will be low. However, if the formation contains hydrocarbon, or contains very low porosity, the resistivity will be high. This logging alerts the user as to whether the formation is permeable or not, as well as additional data that can be used to calculate the temperature at a given depth. In an additional embodiment, the relativity log and entire well log is already available from outside sources.
[0025] After the resistivity data is collected, a plot must be made of the resistivity versus the depth, an example of which is seen in FIG. 3 . Using the resistivity logs, at the bottom of the tangent (slope line), the user will establish shale baseline for the depth interval of interest on the spontaneous (“SP”) track. For the normal compaction region, the user selects any shale resistivity point on the shale baseline where the slope of the SP increased downward to its lowest point and the corresponding slope on the resistivity track reduces towards the bottom of the shale resistivity, as shown in FIG. 3 . This process is repeated for the rest of the points selected by the user from the resistivity log. Using these data points, a plot of resistivity v. depth graph similar to that seen in FIG. 3 is produced. On that same graph, the user plots the normal compaction trend line (“NCTL”) to indicate deviation from the normal compaction at sections below the normal trend. The NTCL represents the sonic and resistivity values if the pore pressure was normal (hydrostatic), and methods for calculating the NCTL are known in the art. The resistivity value (R(sh normal)), represent the normal shale resistivity values. The plotted resistivity values that deviate from the normal values represent the observed shale resistivity values.
[0026] Using the information obtained through available well logs or by performing well logging, the user will then identify the Top of Geopressure by locating and estimating the magnitude of pressure at depth in the normal and transition to abnormally pressured zones. Using Equation 1, the resistivity points from the previous chart can be used to determine the pressure measured in psi. The user then applies the pressure calculations and the ratio of observed shale resistivity in abnormally compacted zones and the shale resistivity in the normally compacted zones to Eaton's Correlation. For the field example, the “normally” compacted zone was defined as shale resistivity where the mud weight is 9.0 ppg, and the pressure versus depth plot for the field wells can be seen at FIG. 2 . In FIG. 2 , the Transition Zone is shown as residing between the two horizontal lines indicating the Top of Geopressure and Base of Geopressure. In that Transition Zone, there is present a double slope, indicating the existence of at least two different pressure regimes within the same Transition Zone. Discovering the actual pore pressure content and the corrected fracture pressure of the Transition Zone is an important step, as the accurate prediction of the pore pressures and fracture gradients is necessary for proper drilling of wells.
[0027] Next, it must be understood that resistivity or conductivity is related to thermal energy (i.e., Gibbs free energy), through the following relationship, known to those skilled in the art as the “Nerst Equation”:
[0000]
E
=
E
s
-
(
RT
nF
)
Ln
(
R
1
R
2
)
[0000] In the above equation, E is the cell potential energy (voltage energy, measured in Joules/Coulomb) at any given state in the earth, E s is the standard state potential energy (voltage energy) at standard pressure and temperature, R=8.314 is the universal gas constant in Jules/mol-degree Kelvin, n is moles of flowing electrons, F or Faraday's constant equals 96,485 Coulombs per moles of electricity, and Q represents the reaction quotient in the earth reactor. The Nearst Equation can be rewritten in terms of its thermodynamic energy equivalent:
[0000]
E
=
E
s
-
(
RT
nF
)
LnQ
Δ
G
=
Δ
G
s
-
(
-
RT
nF
)
LnQ
Δ
G
=
Δ
G
s
+
(
RT
nF
)
LnQ
[0000] By multiplying both sides of the above equation by nF, the user obtains (hereinafter Equation $):
[0000] nFΔG=nFΔG s +( RT ) LnQ
[0000] Comparing the Nearst Equation to the above thermodynamics energy form of the equation, it is noted that ΔG=−nFE and ΔG s =nFE s .
[0028] The user then takes the thermodynamic equilibrium condition as the normally pressured zone and the conditions which deviate from equilibrium as the abnormally pressured zone. This invention incorporates the thermally induced abnormal pressure locations—the Top of Geopressure and Base of Geopressure positions along the depth—as accurately as the data allows, and calculate, as accurately as the data will permit, the magnitude of the pore pressure and the fracture pressure at each depth. In order to find the equilibrium, the above Equation $ to consider that at equilibrium, ΔG=0. Consequently, the term Q (reaction quotient) becomes K, the equilibrium constant, indicating that the system is in equilibrium or a normally pressured zone.
[0000]
Δ
G
=
Δ
G
s
+
(
RT
nF
)
LnQ
=
0
at
equilibrium
[0000] Then Q=K, or the standard normal condition of the thermal energy:
[0000] Δ G s =−RTLnK
[0029] To then augment the P-T plot process, the known DWC method of calculating formation pore pressure is used. Using a DWC composite resistivity trend line overlay, an example of which can be seen at FIG. 4 , the user plots the resistivity points on three cycle semi-log graph paper. In the preferred embodiment, the resistivity points are plotted using the middle cycle on the semi-log paper. Construction of the DWC overlay, shown in FIG. 4 , is based on assumed Gradients of G=0.465 Psi/ft salt water at depth and temperature, 1.0 psi/ft overburden, and a data base that includes temperature effect provided by the following equation (hereinafter “Equation 2”):
[0000]
R
a
R
n
=
1.87
(
1.0
-
G
)
[0030] Next, the user draws the mud weight lines on the same semi-log paper, and then determines the associated mud weight of each resistivity point using the following equation. The mud weight is the density of the drilling fluid and is normally measured in pounds per gallon (“ppg”). The mud weight is then converted from ppg to equivalent pressures in psi. This pressure will be referred to as the Drilling Well Control (“DWC”) Pressure. The conversion is performed using the following equation:
[0000] DWC Pressure=0.052(Mud Weight)(Depth)
[0031] To construct the P-T equilibrium diagram, the user must estimate the temperature gradient. This estimate can be done using thermal logs, logging while drilling, by using standard charts available in the industry, such as that seen in FIG. 5 , or by using the following equation and the information recorded on the resistivity log heading:
[0000]
T
Z
100
ft
=
T
2
-
T
1
X
2
-
X
1
[0000] In this equation, dT/dZ is the temperature gradient (° F./100 ft), X 2 is the depth (in feet) of the interest whose temperature is being calculated, X 1 is the depth whose temperature is already known, T 1 is the temperature at X 1 depth, and T 2 is the temperature at X 2 depth.
[0032] To generate the P-T plot, it is necessary next to establish the thermal equilibrium of the particular interest location. The user plots the DWC pressure versus temperature three times, one each for the normal, transition zone, and abnormal pressure regions. An equation is then fit to each region by fitting a trend line to the individual curves on the graph. Then the user chooses an equation with the highest R 2 (Coefficient of Determination or R squared) value as the “best-fit” equation.
[0033] Then the Eaton's and DWC results are both plotted, along with the thermodynamic properties of the formation (e.g., thermal conductivity and heat flux (flow) at each depth point, in one diagram, as shown in FIG. 6 . To make the data from the Eaton's correlation and the DWC method compatible, the data must be normalized before generating the P-T plots, specifically the slopes of each segment in the normal (equilibrium), transition (deviation from equilibrium), and abnormal (deviation from equilibrium) zones. In the preferred embodiment, the Z-score normalization method is used; however, those having skill in the art will recognize that other normalization methods can be applied. To normalize the data using the Z-score method, the mean (M) of the dP/dT values is calculated. Then the standard deviation for all of the dP/dT values is determined using the following equation:
[0000] Standard deviation={Σ( Y n −M ) 2 /( N− 1)} 1/2
[0000] In the above equation, N is equal to the number of data sets and Y n , represents the particular dP/dT value. To calculate the Z-score, the following equation is used:
[0000]
[
Z
]
n
=
Y
(
n
)
-
M
SD
[0000] The Z-score values represent the normalized dP/dT values. The user then plots the normalized Eaton's gradient and the DWC Pressure gradient on the same plot in order to identify the depth that compaction induced pressure is significant and how much thermally induced pressure is present. This change in induced pressure dominance, occurs after the system achieves “Thermal Equilibrium” i.e. where the Eaton's gradient and the DWC Pressure gradient plot cross each other (Crossover Point or Equilibrium Point) as seen in FIG. 6 . Each segment of the normalized slope (dP/dT) is fit using a best fit equation. By plotting both the normalized Eaton's dP/dT and DWC dP/dT side by side, the user pinpoints where at depth and by how much the thermally induced pressure dominates and determines where and by how much the compaction induced pressure dominates.
[0034] With the data normalized, the user determines the lithology composition of the location of interest. Lithology composition is determined visually by estimating how much sand and shale the rock is made from at any depth of interest, and can be determined using a spontaneous (SP) log using the following steps. First, the user establishes a baseline for clean sand and shale. Next, using the SP track on the resistivity log, the user visually estimates how much reduction in shale content is present. The user then plots the shale resistivity values on a sheet of semi-log paper against the dept. Mud weight lines, in pounds per gallon, are then drawn on the semi-log paper using the DWC resistivity overlay. These mud weight values are then converted into the equivalent pressure in PSI. In an alternative embodiment, lithology compositions are instead gathered from cores or cuttings data.
[0035] To calculate the thermal conductivity, known vertical thermal conductivity values for standard shale and sand values are reviewed alongside the lithology compositions. For ease of calculation, temperatures are converted from degrees Fahrenheit to Kelvin with the exception of the dP/dT plot, which will remain in degrees Fahrenheit. Feet are also converted to meters, with the exception for P-T and the normalized dP/dT plots. Then, using the percentages of the rock composition, the thermal conductivity can be determined. For example, the thermal conductivity for typical shale is 1.64 Watts/meter-Kelvin and sandstone is 3.95 Watts/meter-Kelvin. For a 60 percent shale and 40 percent sand composition, the following thermal composition is found:
[0000] (1.64×0.6)+(3.95×0.4)=2.564 Watts/meter-Kelvin
[0000] To calculate heat flow, the following equation can be used:
[0000]
q
=
-
λ
(
T
Z
)
[0000] In the above equation, q represents heat flow (flux), λ is the thermal conductivity, and dT/dZ represents the Geothermal gradient. The negative sign indicates heat flow is from the hotter to the colder region.
[0036] The user then places the graphs for thermal conductivity, heat flow, and the combined normalized equilibrium dP/dT next to each other as seen in FIG. 6 . Reviewing the normalized equilibrium dP/dT plot, the normally pressured zone (at equilibrium), show the DWC dP/dT is significantly void of noise; however, the Eaton's dP/dT shows some noise in the normally compacted zone. Consequently, the DWC signal can be used to filter noise from Eaton's dP/dT through convolution. In the normal compaction section of the formation, the dP/dT trend indicates that the effect of temperature is weak and the effect of compaction in generating pore pressure is dominant and strong.
[0037] The first crossover of the DWC dP/dT and Eaton's dP/dT lines (hereinafter “First Crossover”) provide the exact location of the Top of Geopressure, which is 10,137 ft in the present field example. Below this depth of crossover point, the user discovers that in the upper part of the Transition Zone, the effect of temperature becomes stronger and dominant in generating abnormal pore pressure as the DWC plot deviates to the right.
[0038] In the Transition Zone, at least three slopes are present, indicating to the user that each one requires a specific mud weight to balance the formation pore pressure, and correctly estimate the fracture pressure without exceeding the Formation Fracture Pressure. In the Transition Zone, the majority of the upper part of the zone is dominated by thermally induced pore pressure. After the second crossover of the DWC dP/dT and Eaton's dP/dT lines (hereinafter “Second Crossover”), the user can see that the compaction trend becomes the dominant force in developing the formation of pore pressure and formation fracture pressure.
[0039] The thermal conductivity and the heat flux plots demonstrate non-events in the normally compacted segment of the formation, which is at equilibrium. This behavior confirms the behavior of the dP/dT plot in the “normally compacted zone.” In contrast to the neutral behavior in this segment, significant changes can be seen in the Transition Zone, where the user can observe a number of incidents. First, the heat flux shows a significant change in amplitude at the Top of Geopressure, which is located exactly at the point of First Crossover. Second, at the point of First Crossover, the thermal conductivity of the formation, especially within the upper part of the Transition Zone exhibits a significant change in amplitude. Thus, the invention permits the user to see that both observations of the dP/dT confirm the effect of thermal properties in generating the thermally induced pore pressure and consequently formation fracture pressure in the upper part of the Transition Zone. The user can now take thermal conditions into account when planning the well drilling.
[0040] An additional incident evident on the heat flux and thermal conductivity plot is that the amplitude gradually diminishes after the Second Crossover. This observation demonstrates that in the lower part of the transition zone, the compaction induced pore pressure becomes dominant and the thermally induced pore pressure becomes weaker.
[0041] Further, in FIG. 6 , the plot of thermal conductivity at point “a” and the heat flux at point “b” indicate another useful feature of this inventive method—the formation at these points is a “gas producing” formation. When the amplitude of these two plots increases together on the right, in the same direction, it is an indication of the existence of a hydrocarbon reservoir, since gases cool sand much differently than liquids. In short, the cooling effect of the reservoir fluids, the type of reservoir fluids, and the maturity of the hydrocarbons within the specific thermal windows control the amplitude of the two thermal property plots in FIG. 6 .
[0042] Now that the above properties of the well have been determined, the user inputs these features into a geological basin simulator. In one embodiment, a one dimensional simulator, such as BasinMod (a commercial simulator developed and marketed by Platt River Associates (PRA)) is used. However, as heat flow can be in both vertical and horizontal directions in the earth's subsurface, a three dimensional simulator could also be used. Those having skill in the art will recognize that a basin could be simulated without the use of software, or through other software available in the art currently or in the future. Continuing with the field example, the structural map of the field is shown in FIG. 7 , including a ground fault present in the land, and the outcome of the simulation is shown in FIG. 8 .
[0043] The simulation results seen in FIG. 8 for well # 1 , which was drilled near the fault depicted in FIG. 7 reveals several key pieces of information that would have been unavailable without the method disclosed herein. First, the start of the increase in pore pressure is synonymous with heat flow out of the system, as seen between 40-25 MY (Point A). This indicates the storing of more heat in the formation at Point A. The rise in excess pressure plot is synonymous with the decreasing heat flow out of the system (Point B). This is additional evidence of storing heat and buildup of thermally induced pore pressure at Point B.
[0044] 40 MY is the age when Jackson formation formed (Point C). The Jackson formation is a “geological seal” in the example field. The formation of the seal happens at approximately 170° F., indicating that an appropriate temperature window for the continued precipitation of limestone (referred to as “het limestone”). In addition to the shale formation, the limestone seal location is very close in depth to the Top of Geopressure seen in FIG. 2 .
[0045] Heat energy builds up until 24 MY and a temperature of approximately 190° F. At this point, heat flow out of the system rises. This indicates that the seal leaked at that temperature and time due to excess pore pressure build up. This is analogous to a relief valve opening automatically to relieve a thermally induced pressure.
[0046] The relief valve seen in FIG. 7 is a fault. The fault and broken seal open the pathway to migration of fluids to the other parts of the structure.
[0047] As demonstrated in this disclosure, by mapping the temperature increase at deeper depths within the subsurface along with considerations for the enabling conditions of the environment present, excess pressure is induced and can now be accounted for in planning well drilling. Hydrocarbon bearing formations analyzed in wells in the field example indicate a potential economic benefit by using this method to identify hydrocarbon flow to the surface. Considering this, it is understood that this approach can be used to locate hydrocarbon reservoirs, similar to how the formation petrophysical properties such as resistivity and porosity, combined with biomarkers, are used today in formation evaluation.
[0048] The described features, advantages, and characteristics may be combined in any suitable manner in one or more embodiments. One skilled in the relevant art will recognize that the varying components of this design may be practiced without one or more of the specific features or advantages of the particular embodiment. In other instances, additional features and advantages may be recognized in certain embodiments that may not be present in all embodiments.
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This inventive method provides a novel way of modeling basins in planning the drilling of crude oil and natural gas wells by accounting for thermodynamic considerations in tracking the pore pressure of a location of interest. By plotting the energy gradients, heat flux, and thermal conductivity of the location of interest, the user can more accurately identify the location of the Top of Geopressure and additional pertinent information during the well drilling planning process that can reduce costs and increase the safety of the process.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of priority under 35 U.S.C. §120 to U.S. application Ser. No. 11/056,021 filed Feb. 11, 2005, which claims the benefit of priority to U.S. Provisional Application No. 60/544,286 filed on Feb. 12, 2004, both of which are hereby incorporated by reference in their entirety.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not applicable.
BACKGROUND
Surgeons have identified and studies have shown, laparoscopic techniques require greater concentration and place greater mental and physical stress on surgeons than open surgery. The tools that laparoscopic surgeons must use are difficult to use and because of suboptimal design, they may actually be doing harm to the highly trained physician. Additionally, poor laparoscopic tools increase physician fatigue, creating potential for errors that may harm the patient.
Specialized instruments are required for laparoscopic surgery due to the small ports. The design of these instruments is critical to the result of the surgery. Current laparoscopic instruments have been found to be very poorly designed ergonomically and it is likely that ergonomics were not considered at all. Some practicing laparoscopic surgeons frequently experience post operation pain or numbness. This is generally attributable to pressure points on the laparoscopic tool handle. Furthermore, four different handle designs used on laparoscopic tools (shank, pistol, axial, and ring handle) have been found to result in either painful pressure spots or caused extreme ulnar deviation.
Compared to general surgery, laparoscopic surgery is a new practice. Therefore, the tools available to perform the procedures are not yet perfected. Limited work has been done by others to improve both the tools and procedures used in laparoscopy; however, an optimized tool, based on task analysis of laparoscopic surgery and sound ergonomic principles has not been prototyped and tested fully to date.
Furthermore, non-ergonomic tool handles often cause pain and discomfort and also result in painful pressure spots. It would be beneficial to have a laparoscopic tool with an ergonomic handle, an intuitive hand/tool interface, such as a control sphere, and an articulating end effector. It would also be beneficial to have an ergonomic tool handle with an intuitive hand/tool interface for use with other types of tools.
SUMMARY
In one embodiment, the present invention relates to a laparoscopic apparatus. The apparatus comprises a handle having a body portion, a top surface, opposite bottom surface, a proximal and distal end and a shaft projecting from the distal end of the handle, the shaft having a proximal and distal end. The apparatus further comprises a control sphere located on the handle and an end effector located at the distal end of the shaft, wherein the end effector is connected to the control sphere such that movements made to the control sphere control movement of the end effector.
In another embodiment, the present invention relates to an ergonomic handle apparatus for use with a tool. The handle apparatus comprises a base having a body portion, a top surface, opposite bottom surface, a proximal and a distal end, where the top surface of the base being contoured to compliment the natural curve of the palm. The handle apparatus further comprises a control sphere located on the base, wherein the control sphere can be moved by one or more of a user's fingers to indicate direction and at least one lever projecting from the bottom surface, wherein the lever may be actuated by a user.
In yet another embodiment, the present invention relates to a laparoscopic apparatus. The apparatus comprises a handle having a body portion, a top surface, opposite bottom surface, a proximal and distal end, where the top surface of the base is contoured to compliment the natural curve of the palm. The apparatus further includes a shaft projecting from the distal end of the handle, the shaft having a proximal and distal end and a control sphere located on the handle. The control sphere can be moved by one or more of a user's fingers to indicate direction. An end effector is located at the distal end of the shaft and the end effector is connected to the control sphere such that movements made to the control sphere control movement of the end effector.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a laparoscopic apparatus in accordance with an embodiment of the present invention;
FIG. 2 is a side perspective view of an ergonomic handle in the closed position in accordance with an embodiment of the present invention;
FIG. 3 is a side perspective view of an ergonomic handle in the open position in accordance with an embodiment of the present invention;
FIG. 4 is a longitudinal cross sectional view of an ergonomic handle with a slip lock in accordance with an embodiment of the present invention;
FIG. 5 is an enlarged side perspective view of an ergonomic handle in accordance with an embodiment of the present invention;
FIG. 6 is an enlarged perspective view of a portion of a laparoscopic apparatus in accordance with an embodiment of the present invention;
FIG. 7 is top perspective view of a control sphere of an ergonomic handle in accordance with an embodiment of the present invention;
FIG. 8 an enlarged perspective view of graspers of a laparoscopic apparatus in accordance with an embodiment of the present invention;
FIG. 9 is a perspective view of an ergonomic handle used with a laparoscopic apparatus displaying the internal components in accordance with an embodiment of the present invention;
FIG. 10 is side perspective view of a laparoscopic apparatus with a cutaway showing the internal control cables in accordance with an embodiment of the present invention;
FIG. 11 is a view of a reverse use position of a laparoscopic apparatus in accordance with an embodiment of the present invention;
FIG. 12 is an exploded perspective view of an end effector and graspers of a laparoscopic apparatus in accordance with an embodiment of the present invention;
FIG. 13 is a side perspective view of an internal portion of the ergonomic handle in accordance with an embodiment of the present invention; and
FIG. 14 is a side perspective view of the internal portion of a left half of an ergonomic handle in accordance with an embodiment of the present invention.
DETAILED DESCRIPTION
With reference to FIG. 1 , an ergonomic laparoscopic tool ( 10 ) is shown. Laparoscopic tool ( 10 ) comprises of five main components: an ergonomic handle ( 12 ), several controls, a shaft ( 14 ), an articulating end effector ( 16 ), and graspers ( 18 ). The graspers ( 18 ) may be any effectors such as cutting forceps and jawed end effectors or may be powered for cauterizing. The cauterizing may include electrosurgical cutting and coagulation of tissue.
In one embodiment, the shaft ( 14 ) is a 10 mm shaft. In this embodiment, the shaft is about 10 mm in diameter and about 40 cm long. The shaft houses the wire guides and actuation cables, described later. However, one of skill in the art will appreciate that the shaft, wire guides and actuation cables are scalable and may be any size, including, but not limited to, about 3 mm and about 5 mm in diameter and about 35-55 cm long.
With reference next to FIG. 2 , the tool handle ( 12 ) is a smooth, contoured shape. It is designed ergonomically for comfort and usability. In one embodiment, the handle ( 12 ) is about 155 mm (length) by about 35 mm (height) by about 45 mm (width). In another embodiment, the handle ( 12 ) may be about 150-165 mm in length, about 30-40 mm in height and about 40-50 mm in width. The handle has a top and bottom surface and a proximal and distal end. The proximal end of the handle is located nearest a user and the distal end is the end located farthest from a user. The top surface of the handle is contoured to compliment the natural curve of the palm.
In one embodiment, the handle circumference is about 5 cm and tapered in shape. A preferred range of handle circumference is from about 4 cm to 6.5 cm. The distal end of the handle is also curved such that the tool shaft ( 14 ) is angled at about 135 degrees to increase the accuracy of pointing with the tool. However, the distal end of the handle may be curved to at any variety of angles depending on the tool that the handle is used with. The handle is designed to fit hand sizes ranging from about the 5th percentile female to about the 95th percentile male. The tool handle is described in relation to a laparoscopic instrument, however, it will be appreciated that the ergonomic tool handle ( 12 ) may be used with any variety of tools including a homeland security device, such as a sensing device, or a laser pointer for presentations.
The handle ( 12 ) is designed for comfortable use with three different hand orientations. The first hand position is such that the thumb controls the sphere, and the fingers are wrapped around the handle and squeeze the grip ( 20 ). The second hand position uses the thumb to squeeze the grip ( 20 ), and the fingers are wrapped across the top of the handle ( 12 ) with the index finger controlling the sphere ( 26 ). The third is a reverse grip shown in FIG. 11 . In the reverse position, the fingers are wrapped around the handle ( 12 ) so that the index finger squeezes the grip ( 20 ), the control sphere ( 26 ) is moved with the user's thumb and the collet mechanism ( 24 ) is controlled with the user's pinky finger. The collet mechanism ( 24 ) may include a swivel collet or rotating grip. The first two positions allow comfortable control of the tool without straining a user's arm, wrist, or fingers. And the third reduces the reach and awkward postures that many users, such as surgeons, encounter while performing their tasks, especially from a reverse position.
Referring next to FIG. 3 , there are six controls located on the tool handle ( 12 ) including a squeeze grip ( 20 ), slip lock trigger ( 22 ), a collet mechanism ( 24 ), a control sphere ( 26 ), and sphere lock ( 28 ). In one embodiment, the controls are placed so they are reachable by the thumb or index finger. However, it will be appreciate that the tool handle ( 12 ) may be used in a variety of ways such that the controls can be reached by other fingers.
The squeeze grip ( 20 ) actuates the graspers ( 18 ) at the end of the tool ( 10 ). When the grip ( 20 ) is squeezed closed, the graspers ( 18 ) close (the closed position is shown in FIG. 2 ). The grip ( 20 ) is sprung such that when released the graspers ( 18 ) will open if the slip lock is disengaged (the open position is shown in FIG. 3 ). In one embodiment, the grip pivots ( 46 ) are located toward the distal end of the handle such that the stronger, more dexterous index and middle fingers can squeeze the grip in some of the grip positions. In one embodiment, the pivot angle between the body of the handle and the squeeze grip ( 20 ) when the squeeze grip is open is about 4-18 degrees, preferably about 17 degrees and the pivot angle when the squeeze grip is closed is about 0 degrees.
With reference to FIGS. 4 and 5 , in one embodiment, when the squeeze grip ( 20 ) is closed (as shown in FIG. 2 ), a slip lock ( 48 ) prevents the squeeze grip ( 20 ) from opening. A ratcheting mechanism is used to perform this action. However, one of skill in the art will appreciate that any variety of mechanisms or methods may be used to prevent the squeeze grip ( 20 ) from opening. The slip lock ( 48 ) allows smooth motion while still preventing the squeeze grip ( 20 ) from reopening. The slip lock trigger ( 22 ) will disengage the slip lock ( 48 ), allowing the squeeze grip ( 20 ) to open. The slip lock trigger ( 22 ) locks in position when pulled back disengaging contact between the slip lock ( 48 ) and squeeze grip ( 20 ). In one embodiment, the slip lock ( 48 ) is located about 2-3 cm, preferable, about 2.7 cm, from the collet mechanism ( 24 ) and is substantially centered along the lateral axis of the handle ( 12 ). In this embodiment, the actuation force needed to for the sliplock ( 48 ) to rotate the shaft ( 14 ) is between about 0.5 and 1.0 lbs, preferably about 0.6 lbs.
With reference to FIG. 6 , a collet mechanism ( 24 ) is located on the front of the handle ( 12 ). When rotated, a collet mechanism ( 24 ) turns the end effector ( 16 ) about the axis of the tool shaft ( 14 ). The collet mechanism ( 24 ) is free to rotate 360 degrees. In one gripping position, the collet mechanism ( 24 ) is reached with the index finger for one-handed operation. However, depending on the grip position, the collet mechanism ( 24 ) may be reached with a user's thumb or other finger.
With reference to FIGS. 1 , 7 and 8 , the control sphere ( 26 ) actuates the pitch and yaw of the end effector ( 16 ). The control sphere ( 26 ) can also be used to rotate to end effector ( 16 ) in the same manner as the collet mechanism ( 24 ). A small tactile element ( 50 ) on the top the sphere ( 26 ) aligns with the tool shaft ( 14 ) when the end effector ( 16 ) is aligned with the shaft ( 14 ). The tactile element ( 50 ) provides a sense of touch for location of the end effector ( 16 ). The tactile element ( 50 ) is an inward element or an outward bump to orient a user as to the position of articulation. Control is intuitive where moving the tactile element ( 50 ) forward/up ( 52 ) moves the tip of the end effector up ( 60 ), and moving the tactile element ( 50 ) backward/down ( 54 ) moves the end effector down ( 62 ). Likewise, moving the tactile element ( 50 ) left ( 56 ) or right ( 58 ) moves the end effector left ( 64 ) or right ( 66 ), respectively.
In one embodiment, the control sphere is located in at or near the center of the lateral axis of the handle and about 3-4 cm from the collet mechanism ( 24 ). In one embodiment, the control sphere is located about 3.6 cm from the collet mechanism ( 24 ) and is substantially inline with the shaft ( 14 ). In this embodiment, the actuation force needed to move the control sphere such that it moves the end effector properly between about 2 and 5 lbs, preferably about 3 lbs.
With reference to FIG. 4 , the sphere lock ( 28 ) is an internal mechanism involving a wave spring ( 82 ). When in the released position, the wave spring ( 82 ) pushes the control sphere ( 26 ) into contact with the inside of the handle shell ( 68 ) which locks the sphere ( 26 ) in place which in turn prevents articulation of the end effector ( 16 ). Also, because the sphere ( 26 ) and collet mechanism ( 24 ) both rotate the shaft ( 14 ), the sphere lock ( 28 ) prevents rotation of the end effector ( 16 ) but allows independent rotation of the shaft while the end effector remains in the locked position. When the control sphere ( 26 ) is depressed, the wave spring ( 82 ) is flattened and the control sphere ( 26 ) is released, leaving it free to move. The sphere lock ( 28 ) allows the articulating end effector ( 16 ) to be placed in one position and the digit (thumb or finger) removed from the sphere ( 26 ) which locks the articulation in place. To move the articulating end effector ( 16 ), pressure from the digits is required. Thus, the articulation is stationary once the sphere ( 26 ) is not under digital pressure and can move freely once unlocked, after the digit (thumb or finger) engages the control sphere ( 26 ).
With reference to FIG. 12 , in one embodiment the actuating end effector ( 16 ) is based on a spherical shape. It will be appreciated that the articulating end effector may take any shape, however. The spherical end effector ( 16 ) may be of any size proportional to the graspers ( 18 ) and shaft ( 14 ). In one embodiment, the end effector ( 16 ) is approximately about 10 mm in diameter, scaled to the size of the shaft ( 14 ). Attached to the front of the spherical end effector ( 16 ) is a protrusion with two wings ( 36 ) that hold the graspers ( 18 ) via a pin ( 37 ). Small wings ( 36 ), similar to those found on the current rigid tools, are attached to the spherical end effector ( 16 ) to hold the graspers' ( 18 ) pivot point from the end effector's ( 16 ) center. A slot ( 38 ) between the wings ( 36 ) is also used to allow grasper movement.
In one embodiment, a portion of the spherical end effector ( 16 ) is removed leaving approximately ½-¾ of a sphere. However, it can be appreciated that different amounts of a spherical end effector may be removed. A small hole ( 40 ) extends through the end effector to allow the grasper cable to pass. In the embodiment having a spherical end effector ( 16 ) that is approximately about 10 mm in diameter, the small hole ( 40 ) is approximately about 2 mm in diameter. The spherical end effector ( 16 ) is split across the equator for attachment of control cables ( 42 ) described in more detail below. Four attachment mechanisms, such as screws, hold the end effector ( 16 ) together and secure the control cables ( 42 ) to the end effector ( 16 ).
With reference to FIG. 10 , the pitch and yaw of the end effector ( 16 ) are actuated by the control sphere ( 26 ). In one embodiment, four inextensible control cables ( 42 ) connect the control sphere through the shaft ( 14 ) to the end effector ( 16 ). It will be appreciated that the control cables may be wires or the like and that any number of control cables may be used to connect the control sphere ( 26 ) to the end effector ( 16 ). The control cables are fed through four wire guides ( 44 ) internal to the shaft ( 14 ) to prevent end-effector ( 16 ) and control sphere ( 26 ) from having shaft-independent rotation.
In one embodiment, the control sphere ( 26 ) is about three times larger than the end effector ( 16 ). For example, if the spherical end effector ( 16 ) is about 10 mm in diameter, the control sphere ( 26 ) is about 30 mm diameter. The difference in size enables the user to have more precise control over the end effector ( 16 ). Also, in one embodiment, the control sphere ( 26 ) is in-line with the actuating effector ( 16 ).
In one embodiment, the control cables ( 42 ) running through the shaft ( 14 ) are rotated a total of about 180° when passed through the wire guides ( 44 ). This rotation ensures that when the control sphere ( 26 ) is moved left, the end effector ( 16 ) will move left, and when the control sphere ( 26 ) is moved forward, the end effector ( 16 ) will move up.
The four control cables ( 42 ) have swaged balls attached to each end. In the embodiment with an end effector ( 16 ) having a diameter of about 10 mm, the swaged balls and each end of the four control cables ( 42 ) are approximately about 2 mm. Both the end effector and control sphere are split along their equators. The swaged ends of the control cables ( 42 ) seed into depressions ( 39 ) in each hemisphere of the end effector ( 16 ). Four attachment mechanisms, such as screws, hold the two hemispheres of the end effector ( 16 ) together and secure the control cables ( 42 ). The control cables ( 42 ) connect to the control sphere ( 26 ) also seed into depressions ( 37 ) in the control sphere ( 26 ). One attachment mechanism, such as a screw, holds the top half of the control sphere ( 26 ) in place and secures the control cables ( 42 ). A screw cover may be used to hide the screw and has a small tactile element for tactile feedback.
The tool shaft ( 14 ) is able to rotate 360°. Normally, rotation of the control ball would cause the control cables to become tangled; consequently, control of the end effector ( 16 ) would be lost. The tool ( 10 ) allows the shaft ( 14 ) and actuating end effector ( 16 ) (along with the cables ( 42 )) to rotate about the tool handle ( 12 ) without becoming entangled.
With continued reference to FIG. 10 , the graspers ( 18 ) are opened and closed by the movement of an actuator rod ( 70 ) located within shaft ( 14 ). The internal mechanism was designed to allow an external forward and backward movement to control the graspers ( 18 ), while allowing rotation that does not twist or bind the internal control cables ( 42 ). The actuator rod ( 70 ) extends through the shaft ( 14 ) and wire guides ( 44 ). At the control sphere ( 26 ) end, two halves of a pull cylinder ( 72 ) are connected to the actuator rod ( 70 ) by two pins that extend through the actuator rod ( 70 ) perpendicular the axis of the actuator rod ( 70 ). The pull cylinder ( 72 ) is free to move forward and backward along the shaft ( 14 ). At the actuating end, a flexible cable (not shown) extends from the shaft and connects to an eyelet that opens and closes the graspers ( 18 ) when the actuator rod ( 70 ) moves forward and backward. When the pull cylinder ( 72 ) is moved back toward the control sphere ( 26 ), the graspers ( 18 ) close. When the pull cylinder ( 72 ) is pushed forward, the graspers ( 18 ) open.
With reference to FIG. 9 , four-piece assembly of cylinder ( 72 ) allows the pull cylinder ( 72 ) to rotate with the shaft ( 14 ) while the outer covers ( 74 ) are stationary. A rotary cylinder ( 76 ) slides over the outer covers ( 74 ) such that the posts on the outer covers ( 74 ) feed through inclined tracks on the rotary cylinder ( 76 ). When the rotary cylinder ( 76 ) is turned, the outer covers ( 74 ) are forced forward and backward actuating the graspers ( 18 ). The control sphere ( 26 ) rests in a cradle ( 78 ) that has four ball bearings embedded in it for smooth operation. Extending from the bottom of the cradle ( 78 ) is a short shaft (not shown) that mates with the shaft ( 14 ) of the tool ( 10 ). This maintains the rotation of the control sphere ( 26 ) with the end effector ( 16 ) so the control cables ( 42 ) do not become tangled. A TEFLON bearing ( 80 ) allows the cradle ( 78 ) to rotate smoothly with the shaft ( 14 ) and a wave spring ( 82 ) for the sphere lock ( 28 ).
With reference to FIG. 13 , rotary cylinder ( 76 ) is connected to the squeeze grip ( 20 ) by an actuating cable (not shown). It will be appreciated that the actuating cable may be any type of cable including a pull cable and push-pull cable. The cable has two swaged ball ends that fit into a protrusion ( 86 ) on the squeeze grip ( 20 ) and a recess on the rotary cylinder ( 76 ). The cable runs through a groove ( 84 ) in the left side of the handle ( 90 ). The squeeze grip ( 20 ) is spring-loaded such that the graspers ( 18 ) open when the squeeze grip ( 20 ) is released.
The handle ( 12 ) can comprise multiple components or may be one component. In one embodiment, the handle ( 12 ) comprises a right half of handle ( 88 ), left half of handle ( 90 ) and a handle grip ( 90 ). One of skill in the art will appreciate that the handle ( 12 ) may be made up of any number of components or may be a unitary handle.
From the foregoing, it will be seen that this invention is one well adapted to attain all the ends and objects hereinabove set forth together with other advantages which are obvious and which are inherent in the structure. It will be understood that certain features and subcombinations are of utility and may be employed without reference to other features and subcombinations. This is contemplated by and is within the scope of the claims. Since many possible embodiments may be made of the invention without departing from the scope thereof, it is to be understood that all matter herein set forth or shown in the accompanying drawings is to be interpreted as illustrative and not in a limiting sense.
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The present invention relates to a laparoscopic apparatus. The apparatus includes a handle having a body portion, a top surface, opposite bottom surface, a proximal and distal end. The top surface of the base is contoured to compliment the natural curve of the palm. The apparatus further includes a shaft projecting from the distal end of the handle. The shaft has a proximal and distal end. A control sphere is located on the handle. The control sphere can be moved by one or more of a user's fingers to indicate direction. An end effector is located at the distal end of the shaft. The end effector is connected to the control sphere such that movements made to the control sphere control cause movement (articulation) of the end effector.
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This application is a division of application Ser. No. 566,288 filed Dec. 28, 1983 now abandoned.
INTRODUCTION
The present invention relates to a non-cyanide molten salt bath composition and process for the carburization of objects made of ferrous metals or alloys. More particularly, the present invention relates to a non-cyanide molten salt bath comprising: alkali metal chloride, an oxygen containing strontium or barium salt, which can be calcined to the corresponding oxide, and a graphite cover. The process involves immersing ferrous metal parts in the bath at a temperature in the range of 900° C.-1050° C. for a period of time to achieve the desired result.
BACKGROUND OF THE INVENTION
Carburization of ferrous metal parts in molten salt baths has been known for many years. The conventional method involves using a substantial amount of a cyanide salt in a molten chloride bath. Although metal parts treated in the cyanide baths exhibit a high degree of surface hardness when quenched, the difficulty of safe handling and waste disposal have presented severe problems.
Many attempts have been made to develop non-cyanide carburizing processes. For example, Freudenberg, U.S. Pat. No. 1,796,248, describes a process using a mechanically agitated fused chloride salt bath with soda and finely divided carbon to introduce carbon into ferrous metal parts immersed therein. Leininger et al., U.S. Pat. No. 2,568,860, describes a similar bath using fused chloride and a carbonate; and instead of mechanical agitation, carbon monoxide or a gas forming carbon monoxide is bubbled through the bath. Further, Newell, U.S. Pat. No. 3,488,233, describes the use of molten lithium carbonate as the active carburizing ingredient. However, these methods using carbonates, generally tend to de-carburize initially and require a long interval of induction, or heating at high temperatures.
Other types of non-cyanide carburizing processes are described in Holt U.S. Pat. No. 2,049,806; Muller, U.S. Pat. No. 3,194,696 and Jakubowski et al U.S. Pat. No. 4,268,323. These processes involve the addition of organic nitrogen compounds such as urea, cyanates and dicyanodiamide. Such baths introduce both carbon and nitrogen into the treated parts, and in many applications, nitriding is not desired.
Other non-cyanide carburizing baths using metal carbides in molten salt are described in Albrect, U.S. Pat. No. 1,992,931; Solakian, U.S. Pat. No. 2,249,581; Steigerwald, U.S. Pat. No. 2,254,328 and British Patent No. 1,223,952. Among the metal carbides described, silicon carbide is preferred for good carburization. However, silicon carbide reacts with alkaline salts to form a silicate which is corrosive to steel and further gives rise to the objectionable formation of sludge or scum.
A further method is described in Leininger U.S. Pat. No. 2,492,803 which uses boron or silicon oxide in combination with carbonates and carbon to achieve carburizing. However, this method suffers from the same disadvantages as methods using silicon carbide.
More recent attempts to carburize by a non-cyanide liquid process are described in Foreman et al., U.S. Pat. No. 4,153,481 and Fox et al., Canadian Patent No. 944,665. Both of these patents describe processes using molten chloride and carbonate salt mixtures and graphite. However, as in prior attempts using carbon in the form of finely divided graphite, mechanical agitation is needed to disperse the graphite into the molten salt. This requires the modification of existing equipment used in cyanide baths, and requires large capital expenditures. Further, as stated previously for carbonate baths, a long interval of induction is required before carburization can by effected. For example, Foreman et al. U.S. Pat. No. 4,153,481 disclosed in Example 1 that about 5 hours of induction is needed. For the above reasons, cyanide processing is still the generally used molten salt carburizing method despite its many obvious disadvantages.
Therefore, it is the object of the present invention to develop a non-cyanide molten salt bath capable for producing a uniform depth of carbon casing free of nitrogen on ferrous metal surfaces.
Another object of the present invention is to provide a non-cyanide carburizing process capable of carburizing at a rate equal to or faster than the conventional cyanide process.
A further object of the invention is to provide a carburizing process employing readily available materials which are economical, require no special handling and create no waste disposal problems.
Yet another object of the present invention is to provide a carburizing process which can utilize equipment currently employed in cyanide processing.
BRIEF DESCRIPTION OF THE INVENTION
In accordance with the present invention, a molten salt bath for carburizing ferrous metal surfaces is provided. The molten salt bath, maintained at a temperature of 900° C. to 1050° C., comprises, based on the weight of the bath:
(a) about 85-99% by weight of an alkali metal chloride or a mixture of alkali metal chlorides;
(b) about 0.25-8% by weight of an activator, consisting of an oxygen containing compound of strontium or barium; and
(c) sufficient amount of finely divided graphite to provide a continuous cover on the surface of the molten salt mixture.
The process according to the present invention comprises:
(a) melting and heating the salt bath composition to a temperature in the range of about 900° C. to about 1050° C.;
(b) maintaining the bath at this temperature for about 1 hour; and
(c) immersing a ferrous metal article in the bath.
DETAILED DESCRIPTION OF THE INVENTION
In accordance with the present invention, a noncyanide carburizing molten salt bath operated at a temperature in the range of 900° C.-1050° C. may be prepared, based on the total weight of the bath, to comprise:
(a) about 85-99% by weight of an alkali metal chloride or a mixture of alkali metal chlorides;
(b) about 0.25-8% by weight of an activator consisting of an oxygen containing compound of barium or strontium; and
(c) sufficient amount of a finely divided graphite material to provide a continuous cover on the surface of the molten salt mixture.
The alkali metal chloride may be sodium, potassium or lithium chloride used individually or in combination with one another. Preferably, the alkali metal chloride is a mixture of sodium and potassium chlorides, and most preferably, a 50:50 by weight mixture of sodium and potassium chlorides.
Compounds useful as an activator are selected from oxygen containing compounds of barium or strontium. The oxygen containing compound of barium or strontium suitable as activators should produce the corresponding oxides of barium or strontium on being calcined, such as: the oxides, the hydrated chlorides, or carboxylates of barium and strontium. The preferred compounds suitable as activators are the oxides or oxalates of barium or strontium, especially preferred is strontium oxalate.
The graphite used in the process according to the invention should be of standard industrial quality and finely divided, i.e. with a particle size between about 80 mesh and about 300 mesh. Especially preferred is a graphite known as Carbon 1264 available from Asbury Graphite Mills, Inc., New Jersey. The amount of graphite according to the present invention, should be sufficient to provide a continuous cover over the molten salts. Generally, about 1% is sufficient initially. However, for a newly prepared molten salt mixture, during the induction period, more graphite may need to be added to maintain a continuous cover on the surface of the molten salt mixture. It has been found that about 3% to about 8% by weight of additional graphite has been found to be satisfactory. Further, during carburizing, the graphite is consumed and more graphite is needed to continuously cover the molten salt mixture with a layer of graphite such that no molten salt surface is exposed. In a typical work day, approximately 1-3% by weight, based on the weight of the bath, of additional graphite is required,
It was found that the bath can be continuously used for about 9-10 working days as long as more graphite, about 1% to 3% by weight, is added every day. The bath can then be reactivated by adding another allotment of the activator.
The bath should be operated at a temperature in the range of about 900° C.-1050° C. It has been found that for efficient and effective, i.e. optimum, carburization, the temperature of the bath is critical, and is dependent on the type of chloride and amount of activator in the bath. If potassium chloride is used together with about 2% strontium oxalate, the temperature of the bath may be lower. At about 900° C., it takes approximately 6 hours of immersion to achieve a Rockwell hardness of Rc 60-67; at 925° C., it takes about 4 hours of immersion to achieve a Rockwell hardness of Rc 64-67; and at 950° C., it takes about 2 hours of immersion to achieve a Rockwell hardness of Rc 63-67. However, if the molten salt is a mixture of sodium and potassium chloride, in particular a 50-50 mixture with about 1% strontium oxalate, then the temperature of the bath should be higher, the optimum temperature being 950° C. It has been observed at times that when the bath is operating optimally, the gases on the surface of the bath tends to flare into flame, similar in appearance to that observed in conventional cyanide baths.
It has been found, surprisingly, that in a bath according to the present invention, the need of agitation, to disperse the graphite particles in the bath to obtain satisfactory carburization, has been eliminated.
The present invention is described in further detail in the following examples. It will be understood that the examples are included for illustrative purposes only and no limitation is intended or implied therein.
EXAMPLE 1
A mixture of the following was prepared:
______________________________________ % by weight______________________________________Sodium chloride 48.89Potassium chloride 48.83Strontium oxide 1.34%Graphite 1.00%______________________________________
The above mixture was heated in an Inconel pot to 950° C., and held at this temperature for about an hour. Six panels, 2"×3"×x3/64", of SAE 1010 steel, cleaned and weighed were immersed in the bath. Two of the panels were immersed for 1 hour, removed and immediately cold water quenched. These panels were reweighed and showed an average gain in weight of 82.9 mg and an average Rockwell hardness of Rc 40. The other four panels were immersed for 2 hours, removed and immediately cold water quenched. These four panels were also reweighed and showed an average gain in weight of 200.5 mg and an average Rockwell hardness of Rc 66. The amount of graphite added to provide a continuous cover on the bath was about 7% over a 6 hour period. One of the panels was etched with 10% hydrochloric acid with 0.2% diethylthiourea. The solution was analyzed by atomic absorption and the presence of strontium was indicated.
EXAMPLE 2
A mixture of the following composition was prepared and heated to 950° C. in an Inconel pot, and held at this temperature for about an hour.
______________________________________ % by weight______________________________________sodium chloride 24%potassium chloride 74%strontium oxalate 1%graphite 1%______________________________________
The amount of graphite added over a period of 6 hours was about 4%. Six SAE 1010 panels with the same dimension as Example 1 were cleaned and weighed and immersed in the bath. Two panels were removed after 1 hour and immediately water quenched. These two panels showed an average gain in weight of 94 mg and an average Rockwell hardness of Rc 45. Four panels were removed after two hours and water quenched. These four panels showed an average weight gain of 187.8 mg. and an average Rockwell hardness of Rc 65.
EXAMPLE 3
A mixture of the following composition was prepared:
______________________________________ % by weight______________________________________potassium chloride 97%sodium chloride 1%strontium oxalate 1%graphite 1%______________________________________
The mixture was molten and heated to a temperature of 900° C. in an Inconel pot and held at this temperature for one hour. A total of 4% graphite was added over a period of 6 hours. Four panels of SAE 1010 steel with the same dimensions were cleaned and weighed and immersed in the bath. One panel was removed after 1 hour, one panel was removed after 2 hours, one panel was removed after 4 hours and the last panel was removed after 6 hours. All of the panels were immediately quenched with cold water. The results obtained are as follows: the first panel after one hour immersion showed a weight gain of 24.5 mg. and a Rockwell hardness of Ra 47-75. The second panel with two hours immersion showed a weight gain of 53.7 mg. and a Rockwell hardness of Ra54-85. The Rockwell hardness on the C scale could not be measured. The third panel with four hours immersion showed a weight gain of 107.6 mg and a Rockwell hardness of Rc 35-66. The fourth panel with six hours immersion showed a weight gain of 179.9 mg and a Rockwell hardness of Rc 60-67.
EXAMPLE 4
A mixture of the following composition was prepared and heated to 950° C. in a mild steel pot. The molten salt mixture was held at this temperature for 1 hour.
______________________________________ % by weight______________________________________sodium chloride 49%potassium chloride 49%strontium oxalate 1%graphite 1%______________________________________
The amount of graphite added over a period of 6 hours was about 2%.
An object made of SAE 1018 steel was immersed in the bath at 950° C. for 2 hours and brine quenched. The results showed a case depth of 0.024" microscopically and a Rockwell hardness of Rc 62.
EXAMPLE 5
A mixture of the following composition was prepared and heated to 950° C. in an Inconel pot and held at this temperature for about 1 hour.
______________________________________ % by weight______________________________________Sodium chloride 49%potassium chloride 49%barium oxide 1%graphite 1%______________________________________
2% more graphite was added over a 5 hour period. Two SAE 1010 steel panels, 2"×3"x3/64", immersed in the bath for 1 hour and then water quenched, showed an average weight gain of 109 mg. and an average Rockwell hardness of Rc 53. Two identical panels immersed in the bath for 2 hours showed an average weight gain of 180 mg. and an average Rockwell hardness of Rc 65.
EXAMPLE 6
A mixture of the following composition was prerared and heated to 950° C. in an Inconel pot and held at this temperature for about 1 hour.
______________________________________ % by weight______________________________________sodium chloride 48.75%potassium chloride 48.75%barium oxalate 1.5%graphite 1.0%______________________________________
3% of graphite was added over a period of 4 hours.
Two SAE 1010 steel panel, 2"×3"×3/64", immersed in the bath at 950° C. for 1 hour followed by a cold water quench showed an average gain in weight of 104.8 mg. and an average Rockwell hardness of Rc 49-53. Two identical panels, immersed for 2 hours followed by a cold water quench showed an average gain in weight of 179.5 mg. and an average Rockwell hardness of Rc 65.
EXAMPLE 7
A mixture of the following composition was prepared for comparison:
______________________________________ % by weight______________________________________sodium chloride 49%potassium chloride 49%calcium carbonate 1%graphite 1%______________________________________
The bath was heated to 950° C. and held at this temperature for about 1 hour. Five soft steel panels were immersed in the bath for 2 hours followed by a cold water quench. These showed an average weight gain of 147.5 mg. and an average Rockwell hardness of Rc 56. Further, the readings were widely scattered in the range of Rc 39-67.
EXAMPLE 8
A mixture of the following composition was prepared for comparison purposes.
______________________________________ % by weight______________________________________sodium chloride 49.16%potassium chloride 49.16%sodium carbonate 0.68%graphite 1.00%______________________________________
The composition was heated to 925° C. and held at this temperature for about 1 hour. Four panels, SAE 1010 steel, 2"×3"×3/64", were cleaned and weighed and immersed in the bath for 2 hours. The panels were removed and quenched in cold water. The treated panels showed an average weight loss of 48.1 mg. with an average Rockwell hardness of Rc 26, the readings being widely scattered in the range of Rc 18-32.
EXAMPLE 9
For comparison purposes, two test bars, one made of 1117 steel and one made of 1018 steel, were treated in a conventional cyanide bath at 950° C. Two identical test bars were treated by the process using strontium oxalate according to the present invention, also at a temperature of 950° C. all of the test bars were immersed for 2 hours, removed, cooled, and the depth of carburization measured. The depth of carburization was measured by making successive 0.005" cuts of the surface of the test bars. Each 0.005" layer was analyzed for percent by weight of carbon. The results obtained are as follows:
______________________________________Depth of % CarbonCarburization Cyanide Process Present ProcessPass No. 1117 Steel 1018 Steel 1117 Steel 1018 Steel______________________________________1 0.731 0.687 0.796 0.6742 0.665 0.750 0.794 0.5753 0.545 0.644 0.630 0.4834 0.464 0.625 0.537 0.3745 0.371 0.436 0.365 0.3276 0.300 0.349 0.319 0.2677 0.247 0.303 0.278 0.2518 0.207 0.292 0.221 0.229______________________________________
The above data indicates that the molten bath composition and process according to the present invention is far superior to the known non-cyanide molten baths using carbonate. Further, the results obtained for Example 9 also shows that the non-cyanide process according to the present invention is comparable or better than the conventional cyanide process.
All of the percentages in the claims are in % by weight based on the total weight of the composition.
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A non-cyanide molten salt bath composition and process for the carburization of objects made of ferrous metals or alloys are provided. The composition comprises a molten salt mixture, at a temperature in the range of 900° C. to 1050° C., of an alkali metal chloride or a mixture of alkali metal chlorides; an activator consisting of an oxygen containing strontium or barium salt; and a graphite cover. The process comprises immersing the ferrous metal or alloy part in the molten mixture at a temperature in the range of 900° C. to 1050° C.
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[0001] This application claims priority to U.S. Patent Application No. 60/631,766, filed on Nov. 30, 2004.
FIELD OF THE INVENTION
[0002] The invention is directed to a method to regenerate sorbents used in decontamination processes, minimizing solid waste disposal volume.
BACKGROUND
[0003] Liquid streams containing non-toxic and toxic contaminants may be decontaminated by contact with a sorbent to which the contaminants bind. The spent sorbent must then pass the Toxicity Characteristic Leaching Procedure (TCLP) to meet regulatory and other requirements to be classified as a non-hazardous waste.
[0004] To improve the economics of decontaminating a liquid stream, spent sorbents are typically regenerated so that they can be reused. The spent sorbents may be treated with an alkaline solution that will strip all contaminants (toxic and non-toxic) from the sorbent. The inert, non-toxic contaminants that are also released may be at concentrations several orders of magnitude greater than the toxic contaminants released. The waste stream resulting from sorbent regeneration therefore contains relatively low (e.g., mg/L) concentrations of toxic contaminants in comparison to the relatively high (e.g., g/L) concentrations of non-toxic contaminants, but is still classified as hazardous waste.
[0005] Decontaminating this hazardous waste stream by contact with an ion exchange resin or other sorbent to remove all of the contaminants in solution is not cost effective. Most of the available capacity of the resin will be occupied by the non-toxic contaminants, which are present at higher concentrations in the waste stream. This process requires a greater volume of resin to remove all the toxic contaminants and to render the waste stream non-hazardous.
[0006] Other methods are thus desirable.
SUMMARY OF THE INVENTION
[0007] Spent sorbents to which toxic contaminants (e.g., arsenic) are bound more strongly than non-toxic contaminants (e.g., sulfates) are regenerated. These sorbents are used to decontaminate potable water and other liquids.
[0008] In one embodiment, the spent sorbent is contacted with a first wash solution that selectively removes less strongly bound non-toxic contaminants from the sorbent. This results in a non-hazardous waste stream that is readily disposed of by conventional disposal methods, and a partially treated sorbent. The partially treated spent sorbent is then contacted with a second wash solution that removes substantially all the remaining contaminants, which includes the more strongly bound toxic contaminants. This results in a hazardous waste stream that can be treated with a lower volume of material (e.g., ion exchange resin) for hazardous waste decontamination because the bulk of contaminants (the non-toxic contaminants) were removed in the first waste stream. This in turn reduced the volume of solid waste for ultimate disposal and minimized hazardous waste disposal costs.
[0009] In another embodiment, spent sorbents that bind toxic contaminants more strongly than non-toxic contaminants are regenerated by treating with a first wash solution under conditions to selectively elute less strongly bound non-toxic contaminants, then treating with a second wash solution under conditions to selectively elute more strongly bound contaminants. Additional second wash solutions may be applied to the sorbent to selectively concentrate toxic contaminants in a specific waste stream. The toxic contaminants may be retained on a solid support, reducing the volume of hazardous solid waste for disposal.
[0010] In another embodiment, a spent hydrous metal oxide sorbent or a spent hybrid sorbent is first contacted with a carbonate containing solution that has been buffered to a pH in excess of the point of zero charge (PZC) of the sorbent. At such a pH, the charge on the sorbent changes from positive to negative, causing the less strongly bound contaminants to be released into the wash solution. The more strongly bound contaminants (toxic contaminants) remain on the sorbent, and can be selectively removed using a solution that is more alkaline than the first solution.
[0011] These and other advantages will be apparent in light of the following detailed description and examples.
DETAILED DESCRIPTION
[0012] Toxic contaminants include, but are not limited to, arsenic, vanadium, molybdenum, uranium, and selenium. Non-toxic contaminants include, but are not limited to, sulfate, bicarbonate, and silicate. A contaminated stream is broadly defined as any liquid stream containing any contaminants (non-toxic and/or toxic). One example is potable water. Another example is cooling water, e.g., water used as a coolant in manufacturing processes. Another example is industrial effluents. These examples are non-limiting, and other examples are known to one skilled in the art.
[0013] A sorbent is a material that removes a contaminant by one or more ion exchange, adsorption, absorption, chemisorption, chelation, and precipitation process(es). Sorbent is a general term for materials used to decontaminate liquid streams. The inventive selective elution process is applicable to a wide range of sorbents, including metal oxides and ion exchange resins. A spent sorbent is one that has been used in a decontamination process, regardless whether its full sorption or binding capacity has been utilized. The methods may be used to regenerate any sorbent that selectively binds one species (e.g., toxic contaminants) more strongly than another species (e.g., non-toxic contaminants). Examples of such sorbents include, but are not limited to, a hydrous metal oxide sorbent (e.g., Bayoxidee® 33, Bayer Chemicals AG, Germany), a hybrid sorbent (e.g., a hydrous metal oxide on the surface of, or throughout, a polymer matrix; ArsenX nP (SolmeteX, Northboro Mass.)).
[0014] A spent sorbent to be regenerated is first contacted with a first wash solution under conditions sufficient to remove or strip the less strongly bound contaminants from the sorbent. The contaminants removed in the resulting waste stream are non-toxic contaminants, due to the sorbent's stronger binding of the toxic contaminants. In one embodiment, a chloride-containing solution is used. Examples include ammonium chloride, Group I alkali metal chlorides, and/or Group II alkaline earth metal chlorides (e.g., sodium chloride, potassium chloride, lithium chloride, rubidium chloride, cesium chloride, magnesium chloride, calcium chloride, beryllium chloride, strontium chloride, barium chloride, etc.). The concentration of the chloride-containing solution ranges from about 1% w/v to about 25% w/v .
[0015] In another embodiment, a nitrate-containing solution is used. Examples include ammonium nitrate, Group I alkali metal nitrates, and/or Group II alkaline earth metal nitrates (e.g., sodium nitrate, potassium nitrate, lithium nitrate, rubidium nitrate, cesium nitrate, magnesium nitrate, calcium nitrate, beryllium nitrate, strontium nitrate, or barium nitrate). The concentration of the nitrate-containing solution ranges from about 1% w/v to about 25% w/v .
[0016] In another embodiment, sodium bicarbonate and sodium carbonate buffered at a pH greater than the point of zero charge (PZC) of the sorbent is used. The PZC can be determined experimentally, or an approximate value can be found in the appropriate scientific literature. PZC is a value of the negative logarithm of the activity in the bulk of the charge-determining ions. A surface charge of the sorbent is at its PZC when the surface charge density is zero. At a pH greater than PZC, the charge on the sorbent changes from positive to negative, causing the more weakly bound anionic contaminants (e.g., sulfate, bicarbonate, silicate) to be released into the wash solution. The more strongly bound contaminants (e.g., arsenic, vanadium, molybdenum, selenium) are then selectively removed, as is subsequently described, using a wash solution that is more alkaline than the first wash solution.
[0017] In another embodiment, a Group I alkali metal bicarbonate/carbonate buffered solution is used at a concentration of about 0.1% w/v to about 20% w/v .
[0018] The first wash solution selectively removed the less strongly bound non-toxic contaminants, resulting in a first waste stream containing substantially non-toxic contaminants, and a partially treated sorbent. The first waste stream is classified as non-hazardous waste. It can be disposed of by simple and economic methods known to one skilled in the art; there are no hazardous waste precautions, disposal requirements, etc. Alternatively, it can be reused to treat additional spent sorbent.
[0019] The partially treated sorbent is then contacted with a second wash solution. The second solution is sufficiently strong to strip contaminants that were strongly bound to the sorbent, which included the toxic contaminants and any residual non-toxic contaminants that were not removed in the first waste stream. In one embodiment, a Group I alkali metal hydroxide solution is used (e.g., lithium hydroxide, sodium hydroxide, potassium hydroxide, etc.). In another embodiment, a slurry of a Group II alkaline earth metal hydroxide is used (e.g., beryllium hydroxide, magnesium hydroxide, calcium hydroxide, strontium hydroxide, etc.). In another embodiment, ammonium hydroxide is used. The concentration of the hydroxide-containing second wash solution ranges from about 0.1% w/v to about 20% w/v . Treatment with the second wash solution results in a second hazardous waste stream containing these toxic contaminants.
[0020] In one embodiment, the second wash solution may additionally contain a chloride- and/or nitrate-containing first wash solution. This facilitates conditioning of the regenerated sorbent prior to reuse.
[0021] The second waste stream is treated with an ion exchange material to immobilize the toxic contaminants onto a solid substrate. The ion-exchange material may be contained on a column, it may be a powder, etc. Examples of ion exchange materials include high capacity anion exchange materials such as hydrotalcite (Alcoa) or similar layered double hydroxides (LDHs) of the general formula [M 2+ (1−x) M 3+ x (OH) 2 ][ x / n A n− .mH 2 O] where M 2+ and M 3+ are divalent and trivalent cations, respectively; x is equal to the ratio M 3+ /(M 2+ +M 3+ ) and A is an anion of charge n (e.g. Metall:X (SolmeteX, Inc., Northboro Mass.)). Because the bulk of the contaminants (non-toxic species) were removed in the first waste stream, the volume of the ion exchange material needed to retain contaminants (mostly toxic species) in the second waste stream was reduced.
[0022] The invention will be further appreciated with reference to the following illustrative, non-limiting examples using a sample of ArsenXnP that had been used to treat a groundwater contaminated with arsenic and vanadium.
EXAMPLE 1
[0023] Six bed volumes of 15% w/v NaCl solution were passed through a column of spent sorbent at a flow rate of about five bed volumes/hour or less. This process removed less strongly bound sulfate and carbonate non-toxic contaminants from the liquid. The waste stream was analyzed and contained 0.2 mg/l of arsenic, 0.2 mg/l of vanadium, 6.5 mg/l of silicon, and 3390 mg/l of sulfate. This first waste stream was thus classified as non-hazardous.
[0024] Six bed volumes of 2% w/v NaOH/1% w/v NaCl solution were then passed through the same column of partially treated sorbent at a flow rate of about two bed volumes/hour. This process removed the bulk of the more strongly bound contaminants (e.g., arsenic, vanadium). This second waste stream was thus classified as hazardous.
[0025] The waste stream was then adjusted to pH 7.1 with hydrochloric acid and filtered to remove any precipitated silica. The neutralized waste stream was analyzed and contained 65 mg/l of sulfate, 13 mg/l of vanadium, 80 mg/l of arsenic, and 130 mg/l of silicon.
[0026] The neutralized hazardous waste stream was passed through a column of anion exchange material to sequester the arsenic and vanadium ions. The resultant waste stream was non-hazardous, simplifying its disposal. The anion exchange material containing the toxic contaminants was configured to pass TCLP requirements as known to one skilled in the art, making it suitable for direct disposal.
EXAMPLE 2
[0027] The method of Example 1 was followed except that the second wash solution was 2% w/v NaOH.
EXAMPLE 3
[0028] The method of Example 1 was followed except that the first wash solution was 5% w/v sodium bicarbonate which had been adjusted to pH 10 with sodium hydroxide to produce a sodium carbonate/sodium bicarbonate buffered solution. Six bed volumes of this solution were then passed through a column of ArsenX nP , a hybrid sorbent of hydrous iron oxide impregnated into a porous polymer bead. A pH 10 was greater than the PZC (or isoelectronic point) of ArsenX nP . This treatment removed the bulk of the less strongly absorbed silicon and sulfate contaminants, but left the more strongly bound contaminants (arsenic and vanadium) on the resin beads. Consequently, the wash solution was classed as non-hazardous. More strongly bound contaminants, i.e., toxic contaminants, were then removed from the sorbent using the second wash solution as described in Example 1.
EXAMPLE 4
[0029] The method of Example 1 was followed except that sufficient powdered sorbent or anion exchange material, e.g. Metall:X, was added to the neutralized waste to sorb all of the contaminants. The mixture was then stirred for up to six hours, filtered, and the resultant liquid was discharged as non-hazardous waste. The sorbent was selected so as to pass TCLP regulations.
[0030] Other variations or embodiments of the invention will also be apparent to one of ordinary skill in the art from the above description and examples. Thus, the forgoing embodiments are not to be construed as limiting the scope of this invention.
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Contaminated drinking water and other liquids are decontaminated by contact with sorbents to remove toxic contaminants such as arsenic, as well as non-toxic contaminants. In regenerating the spent sorbents, the waste stream contains both toxic and non-toxic contaminants but only toxic components must be treated as hazardous waste and subjected to strict regulations for disposal. The inventive method regenerates spent sorbents in a process that minimizes the amount of hazardous waste for disposal. The bulk of contaminants are non-toxic and are first selectively removed from the spent sorbent, generating a non-hazardous waste stream. Toxic contaminants are then removed from the sorbent, generating a hazardous waste stream. Because the bulk of contaminants was removed in the first waste stream, the lower concentration of toxic contaminants in the second waste stream requires less material (e.g., ion exchange resin) for hazardous waste decontamination and disposition.
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FIELD OF THE INVENTION
This invention relates generally to the field of sports equipment, and more particularly to hockey equipment of the sort worn by a player to provide comfort and protection during the rough and tumble play of the game of hockey.
BACKGROUND OF THE INVENTION
Ice hockey is one of the most popular team sports played in Canada and the USA. It is a fast-paced game that combines players of many sizes together on the rink with high skating speed and fast, furious action.
Hockey is known as a hard-hitting, collision sport. Players risk injury from high-impact collisions with each other, the rigid boards that mark the boundary of the playing surface, and the goal posts. Impact with a skate blade, long sticks, and pucks traveling more than 100 MPH also add to the risk.
Lacerations (cuts) to the head, scalp and face have been reduced by the use of helmets and face shields but sadly, more serious cuts still continue to cause physical trauma to players at all levels in minor and major league hockey, including ringette, recreational and pick-up hockey games and practices.
While newer protective equipment is lighter, stronger and offers more protection, it has also been modified to make hockey movement easier. In particular, hockey gloves are now shorter and expose players to more wrist and arms injuries than before. Likewise, there is no equipment to protect the underarms, sides of torso and armpits from serious cuts.
What is required is not only protection for the body parts susceptible to injury from skate blades, but protection that is lightweight, inexpensive and doesn't impede range of motion, particularly wrist and shoulder movement.
SUMMARY OF THE INVENTION
According to one aspect of the present invention, there is provided a protective undergarment worn for ice skating sports comprising a torso portion having a front, a back and a neck opening, said torso portion comprising a jersey fabric, and first and second sleeves which extend from and are joined to or integral with said torso portion, each sleeve including a flexible, high performance fabric, resistant to cutting; wherein at least a part of said front and back of said torso portion between opposed sides thereof comprises said jersey fabric without any flexible high performance fabric resistance to cutting.
According to the present invention, there is provided a protective undergarment comprising a torso portion having a front, a back and a neck opening, left and right arm sleeves which extend from and are directly joined to or integral with said torso portion such that the torso portion and said sleeves form a unitary undergarment, wherein, when the protective garment is laid flat, the upper arm portion of each sleeve has a front and a back, and opposed upper and lower edges, wherein each sleeve has a forearm portion comprising a flexible, high performance fabric, resistant to cutting by skate blades and at least part of the torso portion between opposed sides thereof comprises jersey fabric.
Advantageously, this arrangement provides an undergarment for ice hockey and other ice skating sports which provides arm protection from skate blade lacerations while providing comfort to the wearer by reducing chaffing, itching and other discomforts that might arise if the entire undergarment were made from high performance material only. Furthermore, the invention provides a product which does not add to the list of clothing or equipment worn today by players, but replaces an existing item of apparel.
Also according to the present invention, there is provided a protective undergarment comprising a torso portion having a neck opening, first and second arm sleeves extending from said torso portion and including an upper arm portion for covering the upper arms of a wearer, each upper arm portion having an underside portion, and wherein each underside portion includes a high performance, flexible fabric, resistant to cutting.
According to the present invention, there is further provided a protective undergarment worn for ice skating sports comprising a torso portion having a front, a back and sides between the front and back, and a neck opening, first and second arm sleeves extending from said torso portion and a high performance flexible fabric, resistant to cutting by skate blades, extending from an underside of each sleeve to a respective side to provide underarm protection.
According to the present invention, there is further provided a protective undergarment comprising a torso portion having a neck opening, first and second arm sleeves extending from said torso portion, each sleeve including a lower arm portion for covering a lower arm of a wearer and wherein said lower arm portion comprises a high performance, flexible fabric resistant to cutting.
According to the present invention, there is further provided a protective undergarment comprising a torso portion having a front, a back and a neck opening, said torso portion comprising a jersey fabric, and a flexible, high performance fabric, resistant to cutting and forming first and second sleeves which are joined to said torso portion.
According to the present invention, there is further provided a protective undergarment comprising a torso portion having a neck opening, first and second arm sleeves extending from said torso portion, each sleeve being formed of a jersey fabric and a high performance, flexible fabric, resistant to cutting by skate blades and joined to said jersey fabric to thereby form an integral sleeve therewith.
Embodiments of the invention provide a simple and easy method for protecting arm and torso parts not covered by existing hockey equipment protection.
Embodiments of the invention provide a product that is easily maintained and laundered as it will be worn often and close to the skin.
Embodiments of the invention provide a product that improves the comfort of the wearer, such as by reducing chaffing, itching and other discomforts that might arise if the entire shirt were to be fabricated with the protective covering only.
Embodiments of the invention provide a product that does not inhibit range of motion, thereby maintaining a player's effectiveness.
Embodiments of the invention provide a product that can be mass produced.
Embodiments of the invention provide a product that is affordable.
Embodiments of the invention provide a product that can accommodate players of all sizes.
In one embodiment, the undergarment comprises an undershirt for use by hockey players, the undershirt comprising: a torso portion with a lower trunk opening; a pair of sleeves attached to the torso portion with protective covering on the forearms, underarms and armpit areas; a sleeve cuff assembly on each of said sleeves; and a head opening.
In one embodiment, the protective covering is made of an aramid fiber to guard against cuts and gashes between the hockey gloves and the elbow pads and shoulder pads; on the underside of the arms, in the armpit and on the sides of the torso.
In some embodiments, the protective covering is sewn, surged (interlock) or fused between a layer of garment fabric made of 50% polyester and 50% cotton (or tubular 100% cotton and other similar materials without affecting the integrity of the safety features) and a layer of rip-stock nylon on top. In some embodiments, the protective covering is 100% aramid fiber material. It is five times stronger than an equal weight of steel, has exceptional stretch resistance and is inherently flame resistant. This fibre is used extensively in Personal Body Armour, specialized gear for Correctional Officers and has many other uses in workplace safety. As well as providing protection against lacerations, it is light in weight, provides an extended-wear life and can be laundered.
BRIEF DESCRIPTION OF THE DRAWINGS
Examples of embodiments of the present invention will now be described with reference to the drawings, in which FIG. 1A shows a front view of an undershirt according to an embodiment of the present invention,
FIG. 1B shows a back view of the undershirt shown in FIG. 1A , and
FIG. 1C shows an enlarged view of a portion of the undershirt showing an assembly of garment material and aramid fibre material, used in embodiments of the invention.
DETAILED DESCRIPTION OF EMBODIMENTS
Referring to FIGS. 1A and 1B , an undershirt 1 according to an embodiment of the present invention comprises a torso portion 3 , having a front 5 , a back 7 , and two side portions 9 , 11 , and right and left arm sleeves 13 , extending from the torso portion 3 . The torso portion further includes a neck opening 17 , which may include a cuff 19 , and a lower trunk opening 21 .
The torso portion comprises a fabric, for example a combination of 50% polyester and 50% cotton. In other embodiments, the torso portion may be made of tubular 100% cotton or other similar materials without affecting the integrity of the safety features.
The sleeves 13 , 15 each comprises a first layer of fabric 23 , 25 which may comprise for example a combination of 50% polyester and 50% cotton, tubular 100% cotton or other similar materials. The sleeves 13 , 15 further include a second layer of material, shown by broken lines, comprising a high performance, flexible fabric, which is resistant to cutting by skate blades and which overlays the first layer of fabric 13 , 15 in the regions of an underside portion 27 , 29 of the upper arm of the sleeve, the lower arm portion 31 , 33 and a portion 28 , 30 of the undergarment which extends from the upper arm to the side portions 9 , 11 of the torso portion 3 .
In the particular embodiment shown in FIGS. 1A and 1B , the second layer, which may comprise 100% Kevlar, covers the lower arms, both front and back, the upper underarms, the armpits and the sides of the torso down to where the ribcage ends. However, in this embodiment, the protective layer does not cover a portion of the back of the upper arm of the sleeve proximate in the elbow region 32 and the upper edge 34 . Regions of the sleeves which include high performance flexible cut resistant fabric are shown in the figures by hatching. In this embodiment a layer of rip-stock nylon covers the protective layer and regions of rip-stock nylon are also shown by the hatching. The protective layer may be joined to the jersey fabric by for example stitching, as shown in FIG. 1C . FIG. 1C shows an enlarged view of a stitch in which reference numeral 36 indicates jersey fabric, for example 50% polyester and 50% cotton, 38 indicates high performance, flexible cut resistant fabric, and 40 indicates rip-stock nylon.
The undershirt may be manufactured in standard Canadian sizes for children and adults or could be custom made.
In this embodiment, the sleeves include a wrist cuff assembly 37 , 39 comprising a rib fabric (eg. a knitted rib fabric) to ensure a secure and comfortable fit for all wrist sizes. Likewise, the neck opening or cuff 19 may comprise a rib fabric (eg. a knitted rib fabric) designed to fit various neck sizes and to be comfortable.
Thus, in embodiments of the protective undergarment, a mixture of 50% polyester and 50% cotton, or other similar material is used for the non-protective parts of the garment. Rib knit or similar material may be used for the collar and cuffs. An aramid fibre material is used for protection in the underarms, cuffs and armpit areas. This material is sewn, surged (interlock), or fused between layers of the polycotton or other similar material and rip-stock nylon cover layer.
A particularly advantageous feature of embodiments of the present invention is the combination of an undershirt with a protective covering.
It can now be appreciated that the most preferred form of an embodiment of the present invention is to combine protection and undershirt into one product, providing essentially built-in protection. Instead of providing a 100% Kevlar undershirt protection as well as a regular hockey undershirt, two dressing room steps are reduced to a single one. All that is needed is to pull the undershirt on over the head and arms. When removing the undershirt it is just as easy. Further, the whole undershirt can be easily put into the wash, meaning that the sweat accumulated is eliminated. In this way this equipment can be kept clean and fragrant.
Various modifications and alterations are possible to the form of the invention, without departing from the scope of the broad claims as attached hereto. In particular, while reference has been made to a particular jersey material or rib fabric, it is possible to alter those fabrics without compromising the protective nature of the undershirt or its value to hockey players.
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A hockey shirt with a lower trunk opening, a neck opening and collar, including sleeves and cuff assembly. The shirt has special protective cover stitched, surged or fused on the lower sleeves, underarm parts and armpits to prevent against gashes, cuts and other injuries caused by skate blades.
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FIELD OF INVENTION
The present invention relates to tapping molten furnaces using a rotary percussion drill in general and to an drilling rod, poking rod and cage assembly for mounting the same to the drill in particular.
BACKGROUND OF THE INVENTION
Molten metal furnace have tap holes therein to empty the furnaces at the conclusion of the metal heat. These tap holes are plugged with anhydrous tap hole clay which becomes very hard. In order to empty the furnaces, the plugged tap holes must be bored through by a drill to allow the moltern metal to pass therethrough.
Rotary percussion drills are used to bore through the anhydrous tap hole clay. The rotary percussion drills have a long slide mechanism associated therewith mounting a drill rod and drill bit for both rotary movement and hammering or percussion movement. The drill bit is made from carbide or other hardened metal and the drill rod is made from drill steel. When the drill bit penetrates the clay plug, the molten metal passes over and around the drill bit and drill rod to destroy or severly damage the same. This destruction or damage results in the relatively expensive drill bit and drill rod having to be replaced for substantially every heat of the furnace.
SUMMARY OF THE INVENTION
The principal object of the present invention is to provide an apparatus and method for drilling the plugged tap hole of a molten metal furnace without destroying or damaging the expensive drill bit and drill rod. To this end, the drilling rod with drill bit is used to drill the plugged tap hole to the furnace skull. The drilling rod and drill bit are removed from the rotary percussion drill. A poking rod and poking bar, which are made from relatively inexpensive carbon steel, are then installed on the rotary percussion drill to break through the molten metal skull to tap the furnace. The poking rod and poking bar are then removed from the drill and the drilling rod and drilling bit are the reinstalled to drill the tap hole after the next furnace heat.
It is another object of the present invention to provide a cage assembly on the rotary percussion drill drive box to facilitate installation and removal of the drilling rod or poking rod. The cage assembly is pivotally mounted to the drive box to provide additional clearance and gauidance in installing or removing the rods. The cage assembly includes a front end abutment plate cooperating with an abutment on either the poking rod or drilling rod to assist in providing a percussion drive connection with the rotary percussion drill. The cage assembly also includes a removable bottom bolt to facilitate installation and removal of the poking rod or drilling rod and to preclude inadvertent rod removal when installed.
It is yet another object of the present invention to provide a mounting means for either the drilling rod or the poking rod to facilitate rod installation. The mounting means includes a drive head on the back end of the rod being received in the drive box for a rotary connection and a forwardly spaced abutment (shoulder or taper) on the rod being positioned in close proximity to the front abutment wall of the cage assembly to assist in providing the percussion connection.
It is still another object of the present invention to provide a three piece drilling rod assembly having a selectively replaceable drill section. To this end, the drilling rod assembly may consist of a drilling section with drill bit, a mounting section and an intermediate coupling threadedly joining the drill section to the mounting section. The mounting section has the spaced drive head and tapered wall section on a striking bar threaded to a hollow tube in turn threaded to the intermediate coupling to allow the mounting section or parts thereof to be repeatedly used even though the drilling section may have to be replaced from time to time.
These and other objects and advantages of the present invention will become apparent as the following description proceeds.
To the accomplishment of the foregoing and related ends the invention, then, comprises the features hereinafter fully described and particularly pointed out in the claims, the following description and the annexed drawings setting forth in detail certain illustrative embodiments of the invention, these being indicative, however, of but a few of the various ways in which the principle of the invention may be employed.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1A is a perspective of a rotary percussion drill having the cage assembly and drilling rod assembly with drill bit mounted thereon;
FIG. 1B is a perspective of the rotary percussion drill having the cage assembly and poking rod assembly with poking bar mounted thereon;
FIG. 2 is a side elevation of the cage assembly pivotally mounted on the flange;
FIG. 3 is a top plan view of the cage assembly and flange taken generally along the plane 3--3 in FIG. 2;
FIG. 4 is a rear end elevation of the flange and cage assembly taken generally along the plane 4--4 in FIG. 2;
FIG. 5 is a front end elevation of the cage assembly and flange taken generally along the plane 5--5 of FIG. 2;
FIG. 6 is a side elevation of the drilling rod assembly and drilling bit, partially broken away and partially in section, showing the coupling between the drilling section and mounting section of the drilling rod and also showing part of the cage assembly in phantom lines;
FIG. 7 is a side elevation of the poking rod assembly with poking bar, partially broken away and showing part of the cage assembly in phantom lines.
DETAILED DESCRIPTION OF THE INVENTION
Referring now in more detail to the drawings and intially to FIGS. 1A and 1B, a rotary percussion drill indicated generally at 1 includes an elongated inclined slide 2 supported at its forward and rear ends. A drive motor 3 is mounted on and extends upwardly from the rear end of the slide 2. The motor 3 drives the drilling rod or poking rod in both rotary and rectilinear or percussion movements through drive box 4 in conventional fashion. Drive box 4 is mounted on slide 2 for rectilinear reciprocal motion to provide the hammering or percussion movement of the drilling rod or poking rod. The percussion drill forms no part of the applicant's invention bu ti is the perferred equipment with which applicant's apparatus and method are used as described below.
Apparatus for Drilling the Plugged Hole
To assist in mounting the drill rod or poking rod, a cage assembly, which is indicated generally at 5, is pivotally mounted to the front end of drive box 4. The cage assembly includes two side walls 7 and 8 joined at their front end by front abutment wall 9. As best shown in FIG. 5, the front end abutment wall has an inverted U-shaped groove 10 therein to allow the drilling rod or poking rod to pass therethrough as described in more detail below. A top guide plate 11 is supported by the front end abutment wall 9 and extends backwardly to cross brace 12, which extends between side walss 7 and 8. The top guide plate 11 is inclined slightly upwardly from its forward end to its rear end as best shown in FIG. 2. Two longitudnally aligned ears 13 and 14 are respectively mounted on and extend downwardly from side walls 7 and 8. Ears 13 and 14 have aligned holes adjacent their bottom ends selectively to receive a containment bolt 15. The containment bolt 15 has a head 16 at one end thereof and a hole through its shank at the other end thereof selectively to receive cotter pin 17 to retain containment bolt 15 in position during operation.
The rear end of cage assembly 5 is pivotally mounted on the forward end of drive box 4. To this end, a flange 19 has a plurality of circumferentially spaced peripheral holes 20 receiving fasteners to secure the flange 19 to the drive box 4. The flange has diametrically opposed threaded pivot arms 21 and 22 extending horizontally outwardly therefrom. The threaded pivot arms 21 and 22 are respectively received in aligned holes 23 and 24 in the side walls 7 and 8 adjacent their respective rear ends. Nuts 25 are threaded onto the two pivot arms 21 and 22 to complete the pivotal connection between the flange 19 and the cage assembly 5.
The pivotal movement of the cage assembly is limited by stop members 27 and 28 welded to and extending horizontally outwardly from flange 19. Stop members 27 and 28 are respectively engaged by side walls 7 and 8 to limit their pivotal movement and thus the pivotal movement of the cage assembly 5 away from slide 2. The pivotal movement of the cage assembly is provided to assist in mounting the drilling rod or poking rod on the rotary percussion drill 1, and a central hole 29 is provided in flange 19 to allow the rear end of the drilling rod to pass therethrough.
The drilling rod assembly, which is indicated generally at 31, is preferably made in three sections including drill section 32, mounting section, indicated generally at 33, and coupling 34. The drilling section 32 includes a hollow drill steel tube having a carbide or other hard metal drill bit 35 on its front end. The rear end of the drill pipe forming the drilling section is threaded as shown at 36.
The threaded part 36 of drill pipe section 32 is screwed into a tapped hole 37 in one end of coupling 34. The other end of coupling 34 has a tapped hole 38 in axial alignment with tapped hole 37. Tapped hole 38 threadedly receives the forward end 39 of mounting section 33 of the drilling rod, which is formed of hollow drill steel or carbon steel tube. The two aligned tapped holes 37 and 38 in coupling 34 have bore 40 extending therebetween to provide air flow from the mounting section 33 through coupling 34 to drilling section 32 as will be described in more detail below.
The mounting section 33 of drilling rod assembly 31 includes a hollow tube 41 and a mounting means of its rear end selectively to couple the drilling rod assembly 31 to the drive box 4. The mounting means includes a striking bar 42 having a drive head 43 at its rear end. The drive head 43 has a polygonal peripheral configuration for receipt in a complementary polygonally configured socked 44 in drive box 4 to provide the rotary drive connection. The front end of striking bar 42 has a tapered wall section 45. The tapered wall section 45 is spaced forwardly from the drive head 43 and has a radial extent larger than the U-shaped opening in front abutment wall 9 of cage 5 forming a shoulder selectively abutting the front wall 9 of cage 5 to provide the percussion connection with the drill box 4, as best shown in FIG. 6. The front end of the striking bar 42 has a tapped hole 47 threadedly to receive the threaded male shank 48 on the rear end of hollow tube 41. The mounting section 33 of drill rod 31 can thus be disassembled by unthreading the rear end of tube 41 from the front end of striking bar 42.
Turning now to FIG. 1B and FIG. 7, the poking rod assembly, indicated generally at 50, includes an elongated one piece carbon steel rod 51 having a poking bar 52 welded to its forward end at right angles. The poking rod 51 may be solid or hollow. The rear end of poking rod 51 includes a mounting means selectively to connect the poking rod to the drive box 4.
Specifically, the mounting for poking rod assembly 50 includes a polygonal drive head 53 at its rear end and an annular washer forming shoulder 54 fixed to the poking rod 51 forwardly from the drive head 53. The spacing between the drive head 53 and annular shoulder 54 conforms to the spacing between the socket 44 in drive box 4 and the front wall abutment 9 of cage assembly 5. Thus, when the drive head 53 is received in the drive socket 44 of drive box 4, the shoulder 54 on poking rod 51 is in engagement with or in close proximity to the front end abutment wall 9 of cage assembly 5, as best shown in FIG. 7. The engagement between shoulder 54 and front wall abutment 9 precludes longitudnal movement of the poking rod assembly 50 relative to the drill 1 and thus provides the percussion connection to the drive box 4 of the rotary percussion drill 1. As thus mounted, the pushing rod extends through the U-shape groove 10 in the front end abutment wall. The pushing rod assembly 50 is supported at its rear end by the drive head connection and is supported at its forward end by a J-hook 56. The J-hook encircles approximately 270° of the poking rod 51 (or the drilling rod) and thus provides support for the same while permitting facile installation and removal of the rods.
Method of Tapping the Plugged Tap Hole
The description of the method for using the apparatus just described begins with the drilling rod mounted on the drill as shown in FIG. 1A. The rotary percussion drill is then actuated to rotate and reciprocate the drill bit 35. The reciprocal movement of the drill bit to provide the hammering effect is provided by drive box 4 being reciprocally driven on slide 2 in known fashion. The drill bit 35 is rotated and advanced through the hardened clay in the tap hole, with air being blown through the hollow drill rod and coupling bore to remove dust and debris from the drill bit during drilling. The advancement of drill bit 35 is continued until sparks are observed. At this time, air is contacting the molten metal to form a parially solidified or oxidized skull layer. The drill bit 35 is then retracted from the tap hole, and drilling rod assembly 31 is removed from the rotary percussion drill 1.
To obtain removal, the lower containment bolt 15 of cage assembly 5 is removed after withdrawing cotter pin 17. The forward end of drilling rod assembly 31 is then lifted off J-hook 56. The drilling rod assembly 31 is then pulled forwardly to withdraw the draw head 43 from the drive box 4 through hole 29 in flange 19. When the drive head 43 clears flange 19, the drilling rod assembly 31 can be removed from cage assembly 5 and placed in a convenient storage location before installing the poking rod assembly 50.
To install poking rod assembly 50, the forward end of rod 51 is first inserted in J-hook 56. The drive head 53 of poking rod assembly 50 is longitudinally rearwardly advanced toward hole 29 in flange 19. The cage assembly 5 can pivot upwardly out of the way around pivot arms 21 and 22 to provide additional clearance for inserting drive head 53 in drive box 4. The top guide plate 11 of the cage assembly assists in directing the drive head 53 toward the hole 29 in flange 19 by acting as a lead-in ramp. A washer or collar 58 mounted in drive box 4 can also be used to assist in guiding drive head insertion. When the drive head 53 is received in drive socket 44 of the rotary percussion drill, the shoulder 54 has cleared the front wall abutment 9 of cage assembly 5 allowing the cage assembly to pivot downwardly under gravity to the position resting on stops 27 and 28 as best shown in FIG. 1B. In such position, the rotary connection with the rotary percussion drill is obtained by drive head 53 being received in the drive socket 44 and the percussion connection with the drill is formed by shoulder 54 engaging the front wall abutment 9 of cage assembly 5. The bottom containment bolt 15 of cage assembly 5 may then be reinstalled and held in place by cotter pin 17 to preclude the poking rod assmbly 50 from inadvertently falling out of the cage assembly 5.
With the poking rod assembly 50 thus mounted, the poking bar 52 on poking rod 51 is then advanced by actuating drill 1 to push through the furnace skull. This allows the molten metal to pass through the bored tap hole clay to tap the furnace. When the skull is punctured or broken, the poking bar 52 is quickly withdrawn from the tap hole. The poking bar assembly 50 is then removed from the rotary percussion drill, and the drilling rod assembly 31 reinstalled to prepare for drilling the replugged tap hole after the next furnace heat.
By drilling the tap hole only to the furnace skull with the drilling rod assembly 31, the drill bit 35 and drill steel section 32 can be reused several times before being replaced. The drill bit 35 and drill rod steel 32 have minimum exposed to and are not submerged in molten metal which allows the reuse of these relatively expensive components. When replacement is necessary, the drill rod 32 with attached drill bit 35 can be screwed out of coupling 34 and a new drill section screwed into place on coupling 34. This allows the coupling 34 and mounting section 33 to be continually reused without replacement.
Similarly, the poking rod 51 with attached poking bar 52 are only penetrating the relatively soft furnace skull. Therefore, even though the poking rod and poking bar may be exposed to or submerged in the molten metal, any damage to the same is not as important since reuse will be possible for at least a few heats and since the poking rod and poking bar are made of relatively inexpensive and easily replaced carbon steel.
By using the foregoing apparatus and process, the drilling rod assembly and poking rod assebly are easily removed from and installed on the rotary percussion drill. The expensive drill bit and drill steel used on the drilling rod section of the drilling rod asssembly have increased operational life since they can be reused for multiple furnace heats. The less expensive poking rod can also be reused for several heats because of the ease with which the furnace skull can be penetrated by the poking bar.
It will be apparent from the foregoing that changes may be made in the details of construction and configuration without departing from the spirit of the invention as defined in the following claims. For example, the drilling rod assembly could be provided with a shoulder, such as shoulder 54, cooperatively to form the percussion connection with cage assembly 5 instead of the tapered wall section 45 on striking bar 42.
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An apparatus and process for tapping molten metal furnaces using a rotary percussion drill include a drilling rod assembly having a replaceable drilling section initially to drill the plugged tap hole to the furnace skull before being removed from the drill and being replaced by a one piece poking rod assembly to break the skull to tap the furnace. A cage assembly is pivotally mounted to the drive box of the drill to assist in alternately mounting the drilling rod assembly or poking rod assembly to the drive box and in cooperating with the drive box to provide the drive connection to the drill.
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[0001] This application claims the benefit of U.S. provisional patent application No. 61/470,771 filed Apr. 1, 2011, the disclosure of which is incorporated herein by reference in its entirety.
FIELD OF THE DISCLOSURE
[0002] The present disclosure relates to lighting modules.
BACKGROUND
[0003] In recent years, a movement has gained traction to replace incandescent light bulbs with lighting fixtures that employ more efficient lighting technologies. One such technology that shows tremendous promise employs light emitting diodes (LEDs). Compared with incandescent bulbs, LED-based light fixtures are much more efficient at converting electrical energy into light and are longer lasting, and as a result, lighting fixtures that employ LED technologies are expected to replace incandescent bulbs in residential, commercial, and industrial applications.
[0004] As such, there is need for LED based lighting fixtures that are capable of being employed in an efficient and economical manner in residential, commercial, and industrial applications.
SUMMARY
[0005] The present disclosure relates to a lighting module wherein a DC-DC converter and an LED module are provided as an integral part of the lighting module, and an AC-DC module is provided separately from the lighting module. The AC-DC module is effectively a remote power supply that can be easily replaced without having to replace, reconfigure, or otherwise modify the lighting module. With this configuration, the DC-DC module may be tuned for the particular LED module of the lighting module, and in the case of a failure of the AC-DC module, the AC-DC module can be replaced without having to replace or retune the DC-DC module.
[0006] In one embodiment, a lighting module is mounted within a mounting housing and receives DC power from a remote AC-DC module that is mounted outside of the mounting housing. The lighting module includes an LED module comprising a plurality of LEDs and a DC-DC module. The DC-DC module is configured to receive a DC power signal from the remote AC-DC module and provide at least one drive signal to drive the plurality of LEDs of the LED module.
[0007] In this embodiment, the lighting module may be configured to receive from the remote AC-DC module an output dimming signal based on a desired level of dimming for the plurality of LEDs, wherein the DC-DC module is configured to control the at least one drive signal based on the output dimming signal. The LED module is configured to provide a feedback signal to the DC-DC module, which is further configured to control the at least one drive signal based at least in part on the feedback signal. For example, the LED module is configured to detect a fault or temperature associated with the LED module and the feedback signal relates to the fault or temperature associated with the LED module.
[0008] In another embodiment, the DC-DC module is configured to provide a feedback signal to the remote AC-DC module, which is further configured to control the DC power supply based at least in part on the feedback signal. The DC-DC module is configured to detect a fault or temperature associated with the DC-DC module and the feedback signal relates to the fault or the temperature associated with the DC-DC module.
[0009] In another embodiment, the remote AC-DC module is configured to generate and provide to the DC-DC module an output dimming signal based at least in part on the feedback signal, and the DC-DC module is configured to control the at least one drive signal based on the output dimming signal. The remote AC-DC module may be configured to generate the output dimming signal based on an input dimming signal that is separate from the AC power signal. Alternately, the remote AC-DC module may be configured to generate the output dimming signal based on a characteristic of the AC power signal.
[0010] In yet another embodiment, a lighting assembly is provided that includes a lighting module and an AC-DC module that is located remotely from the lighting module. The lighting module includes an LED module having a plurality of LEDs and a DC-DC module. The DC-DC module may be configured to receive a DC power signal and to provide at least one drive signal to drive the plurality of LEDs of the LED module. The AC-DC module may be configured to convert an AC power signal to the DC power signal for the DC-DC module. The lighting module is configured to be mounted inside of a mounting housing and the AC-DC module is configured to be mounted outside of the mounting housing. The resultant lighting assembly may include a mounting frame, wherein the mounting housing is mounted to the mounting frame and the lighting assembly forms a recessed lighting fixture for ceilings. The lighting assembly may further include a junction box mounted on the mounting frame and outside of the mounting housing, wherein the AC-DC module is mounted inside the junction box and the lighting module is mounted inside the mounting housing.
[0011] Those skilled in the art will appreciate the scope of the disclosure and realize additional aspects thereof after reading the following detailed description in association with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The accompanying drawings incorporated in and forming a part of this specification illustrate several aspects of the disclosure, and together with the description serve to explain the principles of the disclosure.
[0013] FIG. 1 is a block diagram of electronics employed for a lighting fixture according to one embodiment of the disclosure.
[0014] FIG. 2 illustrates a mounting assembly in which the lighting fixture of FIG. 1 is provided.
[0015] FIGS. 3A through 3G are various views of a lighting module for the lighting fixture of FIG. 1 according to one embodiment of the disclosure.
[0016] FIGS. 4A through 4G are various views of a lighting module for the lighting fixture of FIG. 1 according to one embodiment of the disclosure.
[0017] FIGS. 5A and 5B are isometric views of the heat sinks for the embodiments illustrated in FIGS. 3A through 3G and FIGS. 4A through 4G , respectively.
[0018] FIGS. 6A and 6B are isometric views of the housings for the embodiments illustrated in FIGS. 3A through 3G and FIGS. 4A through 4G , respectively.
DETAILED DESCRIPTION
[0019] The embodiments set forth below represent the necessary information to enable those skilled in the art to practice the disclosure and illustrate the best mode of practicing the disclosure. Upon reading the following description in light of the accompanying drawings, those skilled in the art will understand the concepts of the disclosure 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.
[0020] It will be understood that relative terms such as “front,” “forward,” “rear,” “below,” “above,” “upper,” “lower,” “horizontal,” or “vertical” may be used herein to describe a relationship of one element, layer or region to another element, layer or region as illustrated in the figures. It will be understood that these terms are intended to encompass different orientations of the device in addition to the orientation depicted in the figures.
[0021] With reference to FIG. 1 , the electronics for one embodiment of the disclosed lighting fixture are illustrated. As shown, the electronics include an AC-DC (alternating current-direct current) module 10 , a DC-DC (direct current-direct current) module 12 , and an LED (light emitting diode) module 14 . The DC-DC module 12 and the LED module 14 cooperate to form a light engine 16 , wherein the DC-DC module 12 generates the requisite drive currents I N to drive corresponding strands of LEDs provided by the LED module 14 . The DC-DC module 12 is powered and controlled in part by the AC-DC module 10 .
[0022] The AC-DC module 10 is configured to receive an AC power supply signal P AC and a input dimming signal S DIM , and based on these signals, provide a DC power supply signal P DC and an output dimming signal S D to the DC-DC module 12 . The AC-DC module 10 includes circuitry to step down and rectify the AC power supply signal P AC to a desired DC voltage, which represents the DC power supply signal P DC . The DC power supply signal P DC is used to power the DC-DC module 12 .
[0023] The input dimming signal S DIM is an analog or digital control signal that represents a desired level of dimming relative to a maximum desirable lumen output of an LED module 14 . The input dimming signal S DIM may be provided from an appropriate remote control module or lighting switch (not shown), as will be appreciated by those skilled in the art. The AC-DC module 10 provides the necessary circuitry to process the input dimming signal S DIM and generate a corresponding output dimming signal S D based on the desired level of dimming. As will be appreciated by one skilled in the art, the output dimming signal S D is generally a pulse width modulated (PWM) signal wherein the duty cycle of the output dimming signal S D is effectively a function of the input dimming signal S DIM . Since the input dimming signal S DIM corresponds to a desired level of dimming, the duty cycle of the output dimming signal S D is a function of the desired level of dimming.
[0024] In an alternative embodiment, the AC power supply signal P AC may be provided with the use of a dimmer for lighting control. The dimmer may be leading or trailing edge controlled. The portion of the AC waveform received in the AC power supply signal P AC corresponds to the desired level of dimming. As such, the AC-DC module 10 is configured to analyze the AC power supply signal P AC and generate the output signal S D based thereon.
[0025] The DC-DC module 12 includes a DC-DC converter and multiple current sources that are supplied by the DC-DC converter. The current sources generate the individual drive currents I N , which are illustrated as I 1 , I 2 , and I 3 , and are used to respectively drive three different strands of LEDs of the LED module 14 . The DC-DC converter of the DC-DC module 12 is configured to drive the current sources to control the drive currents I 1 , I 2 , and I 3 such that the respective strands of LEDs output light at a desired color as well as a desired intensity based on the output dimming signal S D . In one embodiment, one or more strands may be formed from red LEDs, while one or more of the other strands may be formed from blue-shifted yellow LEDs. The different strands are driven by the drive currents I 1 , I 2 , and I 3 such that the light emitted from the strands mixes to form light at a desired color temperature as well as at a desired intensity based on the desired level of dimming.
[0026] The DC-DC module 12 may be configured to provide one or more feedback signals F DC to the AC-DC module 10 . The feedback signals F DC may provide temperature, fault, or other information bearing on the operation of the DC-DC module 12 , and the AC-DC module 10 may be configured to respond to the feedback signals F DC and adjust or control the output dimming signal S D , the DC power supply signal P DC , or both, in a desired manner. Similarly, the LED module 14 may be configured to provide one or more feedback signals F LED to the DC-DC module 12 . The feedback signals F LED may provide temperature, fault, or other information bearing on the operation of the LED module 14 , and the DC-DC module 12 may be configured to respond to the feedback signals F LED and adjust or control the drive currents I N in a desired manner.
[0027] For the present disclosure, the DC-DC module 12 and the LED module 14 of the light engine 16 are provided in a lighting module 18 , while the AC-DC module 10 is designed to be mounted apart from the lighting module 18 , as shown in FIG. 2 . As illustrated, the lighting module 18 is mounted inside of a mounting housing 20 , while the AC-DC module 10 is mounted outside of the mounting housing 20 . In particular, the AC-DC module 10 is mounted to or inside a junction box 22 . The mounting housing 20 and the junction box 22 may be coupled together via a mounting frame 24 to form a mounting assembly 26 . For example, the mounting frame 24 of the mounting assembly 26 may be configured as a recessed lighting assembly, which mounts between adjacent ceiling joists such that the mounting housing 20 is suspended at a location where the lighting module 18 is desired. A cable 28 is used to connect the AC-DC module 10 and the DC-DC module 12 . The cable 28 is shown running from the AC-DC module 10 to the lighting module 18 through an upper portion of the mounting housing 20 . The cable 28 may be provided in a conduit in select embodiments.
[0028] The DC-DC module 12 and the LED module 14 are mounted to or in portions of the lighting module 18 . In addition to the DC-DC module 12 and the LED module 14 , the lighting module 18 comprises a heat sink 30 , a support bracket 32 , a mixing chamber 34 having a reflective interior, a diffuser 36 , and a lens 38 . In the illustrated embodiment, the heat sink 30 provides for a compartment 40 in which the DC-DC module 12 is mounted. As such, the DC-DC module 12 is mounted within the confines of the outer boundaries of the heat sink 30 .
[0029] In this embodiment, the LED module 14 is mounted to the heat sink 30 wherein a thermal pad (not shown) may be used to thermally couple the LED module 14 to the heat sink 30 . The thermal pad may be formed from any thermally conductive material, such as metal or thermally conductive resins. Bolts or other fastening mechanisms may be used to attach the LED module 14 and the thermal pad to a forward surface of the heat sink 30 . Notably, the LED module 14 is illustrated as a printed circuit board (PCB) having the LEDs of the different strands of LEDs arranged in an array. A cable assembly is used to connect the LED module 14 to the DC-DC module 12 .
[0030] The support bracket 32 is a primary structural component for the lighting module 18 . The support bracket 32 has a bottom rim, which forms a rear opening and mounts to the heat sink 30 with bolts, such that at least the array of LEDs of the LED module 14 are exposed though the rear opening. In the illustrated embodiment, the rear opening of the support bracket 32 is sized and shaped to correspond to and receive the PCB of the LED module 14 . The support bracket 32 also has a forward opening, which receives the mixing chamber 34 . The mixing chamber 34 may take various forms. In the illustrated embodiment, the mixing chamber 34 has a conical or parabolic body with a rear opening that is sized and shaped such that the array of LEDs of the LED module 14 remains exposed. The mixing chamber 34 also has a forward opening formed by a forward flange. The mixing chamber 34 concentrically resides inside the support bracket 32 wherein the rear surface of the forward flange of the mixing chamber 34 rests on the forward surface of the support bracket's forward flange.
[0031] A planar diffuser 36 , which generally corresponds in shape and size to the outside periphery of the forward flange of the mixing chamber 34 , may be placed on the forward surface of the forward flange of the mixing chamber 34 , and thus cover the forward opening of the mixing chamber 34 . The degree and type of diffusion provided by the diffuser 36 may vary from one embodiment to another. Further, color, translucency, or opaqueness of the diffuser 36 may vary from one embodiment to another. Diffusers 36 are typically formed from a polymer or glass, but other materials are viable. Similarly, a planar lens 38 , which generally corresponds to the shape and size of the diffuser 36 as well as the outside periphery of the forward flange of the mixing chamber 34 , may be placed over the diffuser 36 . As with the diffuser 36 , the material, color, translucency, or opaqueness of the lens 38 may vary from one embodiment to another. Further, both the diffuser 36 and the lens 38 may be formed from one or more materials or one or more layers of the same or different materials. While only one diffuser 36 and one lens 38 are depicted, the lighting module 18 may have multiple diffusers 36 or lenses 38 ; no diffuser 36 , no lens 38 , no diffuser 36 or lens 38 , or an integrated diffuser and lens (not shown) in place of the illustrated diffuser 36 and lens 38 .
[0032] A retention ring may be provided to hold the mixing chamber 34 , diffuser 36 , and lens 38 in place. In operation, light emitted from the array of LEDs of the LED module 14 is mixed inside the mixing chamber 34 and directed out through the lens 38 in a forward direction to form a light beam. As noted, the array of LEDs of the LED module 14 may include LEDs that emit different colors of light. For example, the array of LEDs may include both red LEDs that emit red light and blue-shifted yellow or green LEDs that emit bluish-yellow or bluish green light, wherein the red and bluish-yellow or bluish-green light is mixed to form “white” light at a desired color temperature. For a uniformly colored light beam, relatively thorough mixing of the light emitted from the array of LEDs is desired. Both the mixing chamber 34 and the diffuser 36 play a role in mixing the light emanated from the array of LEDs of the LED module 14 .
[0033] Certain light rays, which are referred to as non-reflected light rays, emanate from the array of LEDs of the LED module 14 and exit the mixing chamber 34 through the diffuser 36 and lens 38 without being reflected off of the interior surface of the mixing chamber 34 . Other light rays, which are referred to as reflected light rays, emanate from the array of LEDs of the LED module 14 and are reflected off of the reflective interior surface of the mixing chamber 34 one or more times before exiting the mixing chamber 34 through the diffuser 36 and lens 38 . With these reflections, the reflected light rays are effectively mixed with each other and at least some of the non-reflected light rays within the mixing chamber 34 before exiting the mixing chamber 34 through the diffuser 36 and the lens 38 . The diffuser 36 functions to diffuse, and as result mix, the non-reflected and reflected light rays as they exit the mixing chamber 34 , wherein the mixing chamber 34 and the diffuser 36 provide sufficient mixing of the light emanated from the array of LEDs of the LED module 14 to provide a light beam of a consistent color. In addition to mixing light rays, the diffuser 36 is designed and the mixing chamber 34 shaped in a manner to control the relative concentration and shape of the resulting light beam that is projected from the diffuser 36 and the lens 38 . For example, a first lighting module 18 may be designed to provide a concentrated beam for a spotlight, wherein another may be designed to provide a widely dispersed beam for a floodlight. Notably, finishing trim (not shown) may also be provided to further contribute to light mixing, beam shaping, or both. The interior surface of the finishing trim may range from a highly reflective metal coating to a matte black finish, depending on the desired aesthetics and functionality.
[0034] FIGS. 3A through 3G and FIGS. 4A through 4G respectively illustrate various views of two embodiments of the disclosure. In these embodiments and as described in further detail below, the side(s) of the heat sink 30 may be formed to have recessed portions 30 R that extend from the forward surface of the heat sink 30 to the rear surface of the heat sink 30 . A compartment 40 may be provided in and along one of the recessed portions 30 R of the heat sink 30 , such that the compartment 40 does not extend past the overall lateral dimensions of the heat sink 30 . As clearly depicted in FIGS. 3F and 3G , the compartment 40 may be provided by a separate housing that mounts to the heat sink 30 and resides substantially or entirely within a recessed portion 30 R. The housing may optionally have a bottom and a detachable lid, such that the DC-DC module 12 is protected from the elements. FIGS. 3F , 3 G, and 4 E illustrate the lid being in place on the compartment 40 . FIGS. 3F and 4E illustrate the DC-DC module 12 being located inside of the compartment 40 through a cut-away provided in the lid of the compartment 40 . Alternatively, the main body of the compartment 40 may be formed as an integral part of the heat sink 30 and be configured to receive the optional lid.
[0035] As illustrated in FIGS. 4A through 4G , the cable 28 , as well as any conduit in which the cable 28 is run, may also be configured to exit the support bracket 32 adjacent a recessed portion 30 R of the heat sink 30 . As such, the cable 28 may run through the recessed portion 30 R and within the outer periphery of the heat sink 30 .
[0036] In select embodiments, the support bracket 32 is configured to form an air gap between the fins of the heat sink 30 and the main body of the support bracket 32 to provide for additional airflow through the fins of the heat sink 30 .
[0037] FIGS. 5A and 5B illustrate the heat sinks 30 and the respective recessed portions 30 R for the respective embodiments. The heat sinks 30 include radial fins 44 that are substantially parallel to a central axis of the substantially cylindrical heat sink 30 . In the illustrated embodiments, shorter fin sections have a group of adjacent radial fins 44 , which radially extend to a first distance relative to the central axis of the heat sink 30 . The shorter fin sections that correspond to the recessed portion 30 R are provided among or between one or more longer fin sections. As illustrated, the embodiment of FIG. 5A has two shorter fin sections, and thus, two recessed portions 30 R. The embodiment of FIG. 5B has one shorter fin section, and thus one recessed portion 30 R. The number of shorter and longer fins sections may vary from one embodiment to the next.
[0038] The longer fin sections have a group of adjacent radial fins, which radially extend to a second distance relative to the central axis of the heat sink 30 , wherein the second distance is greater than the first distance. Relative to the longer fin sections, the shorter fin sections effectively form the recessed portions 30 R. While only longer and shorter fin sections are illustrated, one or more intermediate fin sections (not illustrated) may be provided wherein the intermediate fin sections (not shown) have a group of adjacent radial fins, which radially extend to a third distance relative to the central axis of the heat sink 30 , wherein the third distance is between the first and second distances.
[0039] As noted above, the recessed portions 30 R of the heat sink 30 provide channels in which the compartment 40 for the DC-DC module 12 may be formed or mounted. The recessed portions 30 R may also act as cable chases.
[0040] As illustrated in FIGS. 5A and 5B , the heat sink 30 may include a solid, generally cylindrical core 46 , wherein the center axis of the heat sink 30 generally corresponds to the center axis of the core 46 . The radial fins 44 effectively extend outward from the outer surface of the cylindrical core 46 , wherein the cylindrical core 46 and the radial fins 44 form the heat sink 30 . In alternate embodiments, the core 46 may be hollow or have one or more openings or cavities therein. Threaded mounting holes may be formed on the forward and rear surfaces or the fins of the heat sink 30 to facilitate attaching elements, such as the support bracket 32 , LED module 14 , the compartment 40 , and the like. In one embodiment, the entirety of the heat sink 30 is extruded as a single integrated component from highly thermally conductive metal, such as aluminum, copper, gold, or the like. As noted, the compartment 40 that may be used to house the DC-DC module 12 may by integrally formed with the heat sink 30 or may be formed in a separate housing that is mounted to the heat sink 30 , and perhaps in a recessed portion 30 R provided therein.
[0041] FIGS. 6A and 6B illustrate exemplary support brackets 32 for the respective embodiments.
[0042] Those skilled in the art will recognize improvements and modifications to the embodiments of the present disclosure. For example, although the above embodiments are directed to a lighting module 18 and a remote AC-DC module 10 wherein the primary components of the lighting module 18 are substantially cylindrical in nature; however, any one or all of these components may take on other forms, such as rectangular, triangular, elliptical, and the like. As another example, the DC-DC module 12 may be integrated with the LED module 14 . All such improvements and modifications are considered within the scope of the concepts disclosed herein.
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The present disclosure relates to a lighting module wherein a DC-DC converter and an LED module are provided as an integral part of the lighting module, and an AC-DC module is provided separately from the lighting module. The AC-DC module is effectively a remote power supply that can be easily replaced without having to replace, reconfigure, or otherwise modify the lighting module. With this configuration, the DC-DC module may be tuned for the particular LED module of the lighting module, and in the case of a failure of the AC-DC module, the AC-DC module can be replaced without having to replace or retune the DC-DC module.
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BACKGROUND OF THE INVENTION
Field of the Invention
This invention relates to a modular decking system that can be assembled and disassembled for reconfiguration, relocation, and expansion; and more particularly relates to a modular decking system comprised of panels that assemble to form a deck, anchors that uniformly bear the weight from the panels, and fastening components that rotatably lock the panels to the anchors and to the surface to restrict lateral movement therebetween.
Description of the Related Art
Installation of permanent decking requires a specialized skill set and is labor intensive, sometimes requiring footings to be dug or other construction. Traditional decks are often constructed to be a fixed in place and cannot be relocated and can only be removed or relocated through destructive means. Although modular decking kits having attachable members are known in the art, they are often fabricated from wooden members which may warp, splinter, or rot. Most modular decking comprises rectangular decking members affixed together on a subgrade, joists, beams or framing to form a larger deck. These members are not easily secured, transported and detached. Maintenance may be required to protect wooden decking from the elements and seal the surface from moisture. Variations in temperature and humidity cause them to expand and contract, which loosens the metal connection hardware. Lumber used in constructing traditional decking is also susceptible to deterioration by mildew, mold, and infestation.
In many instances, modular decking is not efficient or easily assembled in the construction of a decking. What is needed in the art is a multipurpose, lightweight decking, which does can be easily assembled, disassembled and transported; and which is suitable to withstand inclement weather, harsh environments, heavy foot traffic, and is resilient when exposed to harsh cleaning chemicals. This modular decking should also provide lateral support, comfort, and reduction of fatigue during walking or standing by users of the tile.
It is therefore desirable that a multi-configurable modular decking system be provided which overcomes these difficulties.
SUMMARY OF THE INVENTION
From the foregoing discussion, it should be apparent that a need exists for a modular decking system having unique and multi-configurable panels, anchors, locking components.
Beneficially, such a system would overcome many of the difficulties of the prior art by providing a modular decking system comprised of panels that assemble to form a deck, anchors that uniformly bear the weight from the panels while anchored into a ground or wall surface, and fasteners that rotatably lock the panels to the anchors to restrict lateral movement therebetween. The system leverages the weight of the panels, frictional forces, and fastening components to restrict lateral movement between the panels, the anchor, and a surface.
The present invention has been developed in response to the present state of the art, and in particular, in response to the problems and needs in the art that have not yet been fully solved by currently available apparatii and methods. Accordingly, the present invention has been developed to provide a modular decking apparatus that assembles to form a deck, the deck being disassemblable and portable, the decking system comprising: a plurality of hexagonal panels having a planar top surface, each panel defining six recesses circumscribing the top surface at evenly-spaced intervals, wherein each recess is shaped as a circular sector, each recess for receiving a fastener; wherein each panel further defines a plurality of apertures on the top surface; the panel further comprising an anchor affixed to a bottom surface of the panel, the anchor comprising: a plurality of fastener receptacles, each fastener receptacle having a foot for engaging a ground surface which protrudes downwardly, each fastener receptacle circumscribing an outside edge of the anchor at evenly-spaced intervals, each fastener receptacle disposed beneath a recess; a plurality of reinforced ribs disposed beneath the bottom surface, the plurality of reinforced ribs configured to enhance structural integrity of the panel; each fastener receptacle comprising an upwardly-protruding locking protrusion for engaging a fastener, the locking protrusion defining at least one locking hole; and a plurality of fasteners, each fastener for interconnecting a plurality of panels, each fastener locking over locking protrusions on separate panels.
The apparatus of claim 1 , wherein each fastener comprises a cylindrical base configured to abut a fastener receptacle, the at least one fastener further comprising a cap configured to overlay the base, the cap defining at least one cap hole, wherein the at least one cap hole is configured to align with the at least one locking hole of the locking protrusion from the fastener receptacle for at least partially fastening the at the at least one anchor to the at least one panel.
The plurality of apertures in the at least one panel may be drainage holes for liquid accumulating on the top surface. In some embodiments, the top surface of the anchor engages and contour a bottom surface of the panel.
The panel and anchor may be formed as an integrated piece. The plurality of reinforced ribs may comprise perpendicularly crossing beams. The base may comprise a plurality of detents configured to frictionally engage the locking protrusion of the fastener receptacle.
The cap may be substantially circular in some embodiments. The at least one cap hole may have a hexagonal shape.
The apparatus may further comprise at least one cap fastener configured to pass through the at least one cap hole and the at least one locking hole.
The at least one cap fastener is a bolt in some embodiments. The at least one cap fastener may comprise a cap fastener hole configured to receive an Allen wrench. The cap may define a plurality of teardrop-shaped locking hole.
These features and advantages of the present invention will become more fully apparent from the following description and appended claims, or may be learned by the practice of the invention as set forth hereinafter.
BRIEF DESCRIPTION OF THE DRAWINGS
In order that the advantages of the invention will be readily understood, a more particular description of the invention briefly described above will be rendered by reference to specific embodiments that are illustrated in the appended drawings. Understanding that these drawings depict only typical embodiments of the invention and are not therefore to be considered to be limiting of its scope, the invention will be described and explained with additional specificity and detail through the use of the accompanying drawings, in which:
FIG. 1 is a top perspective view of a panel in accordance with the present invention;
FIG. 2 is a top perspective view of a panel mated with an anchor in accordance with the present invention;
FIG. 3 is a bottom perspective view of a panel in accordance with the present invention;
FIG. 4 is a top perspective view of a fastener locking the panel to the anchor in accordance with the present invention;
FIG. 5 is a top perspective view of a fastener having a base and a cap in accordance with the present invention;
FIG. 6 is a top perspective view of a cap for a fastener in accordance with the present invention;
FIGS. 7A and 7B are side perspective views of a cap fastener and an Allen screw in accordance with the present invention;
FIG. 8 is a top perspective view of a self-locking fastener with a self-locking cap removed from a self-locking base in accordance with the present invention; and
FIG. 9 is a top perspective view of a self-locking cap in accordance with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Reference throughout this specification to “one embodiment,” “an embodiment,” or similar language 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. Thus, appearances of the phrases “in one embodiment,” “in an embodiment,” and similar language throughout this specification may, but do not necessarily, all refer to the same embodiment.
Furthermore, the described features, structures, or characteristics of the invention may be combined in any suitable manner in one or more embodiments. In the following description, numerous specific details are provided to provide a thorough understanding of embodiments of the invention. One skilled in the relevant art will recognize, however, that the invention may be practiced without one or more of the specific details, or with other methods, components, materials, and so forth. In other instances, well-known structures, materials, or operations are not shown or described in detail to avoid obscuring aspects of the invention.
As referenced in FIGS. 1-9 , a modular decking system 100 comprises at least one panel 102 that assembles to form a deck; at least one anchor 114 that mates with the panel 102 to uniformly bear the dead and/or live load weight from the panel 102 while anchored into a ground or wall surface; and at least one fastener 132 that rotatably locks the panel 102 to the anchor 114 to restrict lateral movement therebetween.
The anchors 114 position at a panel periphery 108 on each panel 102 . The generally peripheral positioning of the anchors 114 and interconnections allow for a more uniform weight distribution of a load on the decking. Additionally, the fastener 132 creates a lock through frictional forces while also providing tactile feedback to indicate when the panel 102 and the anchor 114 are locked into place. The fastener 132 also requires minimal special tools or skillset to lock or remove.
In some embodiments, the system 100 comprises at least one panel 102 and at least one anchor 114 that have substantially the same contour shape. The substantially same contour shape enables for intuitive and facilitated mating therebetween. The panel 102 and the anchor 114 interlock together at the panel periphery 108 and at an anchor periphery 122 through at least one fastener 132 . The fastener 132 uses a rotatable locking mechanism having a plurality of detents 140 . The detents 140 create frictional forces against the anchor and the panel to form a snug fit therebetween. The detents 140 also create tactile feedback during rotation of the fastener 130 to indicate when the locking is complete.
The fastener 132 has at least one cap hole 138 that can be aligned with at least one locking hole 130 in the anchor 114 . Once aligned, at least one cap fastener 152 can pass through the holes 130 , 138 to further secure the lock. In this manner, the interlocking connections are doubly secured while still maintaining their simplicity to form the interlocking interaction between panels 102 and anchors 114 .
In some embodiments, the at least one panel 102 forms a substantial portion of the deck's surface. The at least one anchor 114 uniformly supports the dead and/or live load weight from the panel 102 . The points of interconnection where the fasteners 132 lock the panels 102 and anchors 114 occur at the panel recessions 110 a - 110 f and the anchor recessions 124 a - 124 f . Because the interconnections with the anchor 114 occur at the peripheries 108 , 122 , the load on the decking is more uniformly distributed.
Additionally, each panel 102 is secured in place to the anchor 114 by at least one fastener 132 that engages the anchor 114 at a plurality of anchor recessions 124 a - 124 f on the anchor periphery 122 . The fasteners 132 rotatably lock the panel 102 to the anchor 114 through frictional engagement, detents 140 that snap together and provide tactile feedback, and additional fastening components that pass through at least one locking hole 130 at the anchor recessions 124 a - 124 f and at least one cap hole 138 at the fastener 132 . In one embodiment, six anchors 114 support a single panel 102 and any number of adjacent panels 102 . The use of six anchors 114 and six correlating fasteners 132 is consistent with the hexagonal shape of the panel 102 . However, in other embodiments, any number of anchors 114 and fasteners 132 may be used.
As referenced in FIG. 1 , the system 100 comprises at least one panel 102 . The panel 102 is configured to interlock with additional panels 102 to form the decking. In some embodiments, the decking may include a floor decking, a wall, a patio, a pier, or a boat deck. The panel 102 is defined by a panel bottom surface 104 and a panel top surface 106 . The panel 102 may have a generally flat, hexagonal shape. Though in other embodiments, other shapes for the panel 102 may include, without limitation, a pentagonal, cube, triangle, and rectangle shape. Suitable materials for the panel 102 may include, without limitation, composite lumber, polymeric resins, polyvinyl chloride, virgin polyvinyl chloride, virgin/reclaimed polyvinyl chloride mixtures, compression molded rubber, rigid polymers, hard wood, soft wood, and a combination of wood fiber, plastic, and binding agents.
The panel 102 is further defined by a panel periphery 108 having a plurality of panel recessions 110 a - 110 f . The panel recessions 110 a - 110 f may form a substantially half-circle shape at evenly-spaced sections of the periphery of the panel 102 . The at least one panel 102 also includes a plurality of apertures 112 a - 112 c that are efficacious for enabling water, ice, or debris to pass through. One example of the apertures 112 a - 112 c includes drainage or weep holes passing through the panel 102 serve to shed and disperse water from the deck. The plurality of apertures 112 a - 112 c can take any number of shapes, and may be pre-molded, pre-drilled, or otherwise pre-made with the panel 102 .
Turning now to FIG. 2 , the system 100 is shown to include at least one anchor 114 . The anchor 114 is defined by an anchor top surface 116 , an anchor bottom surface 118 , and a cavity (not shown). In some embodiments, the anchor 114 is configured to have substantially the same contour shape as the panel 102 , whereby the panel 102 mates with the anchor 114 . The anchor 114 receives the panel 102 at the anchor top surface 116 , thereby engaging the panel bottom surface 104 . An anchor periphery 122 aligns flush against a panel periphery 108 when the panel 102 and anchor 114 engage. The panel 102 may be secured, via adhesive, molded attachment, or other means, to the anchor 114 , concealing all of its fastening components and substantially all of the panel bottom surface 104 and the anchor top surface 116 .
The anchor 114 is designed to support the panel 102 , maximizing support for the panel 102 and uniformly distributing dead and/or live load weight onto a ground or wall surface. Because the anchor 114 attaches to the panel periphery 108 , specifically at the plurality of panel recessions 110 a - 110 f , the weight on the decking is uniformly distributed. Furthermore, since six anchors 114 may be used, the weight is further distributed, since it is known that the larger the number of supports, the more uniform is the weight distribution.
The anchor 114 fastens to a ground or wall surface at the anchor bottom surface 118 . In some embodiments, the anchor 114 rests on a grade or level surface and is considered a temporary structure, allowing the system 100 to be utilized by more than just building component.
As illustrated in FIG. 3 , the anchor 114 forms a cavity that enables it to be portable and lightweight. To further reinforce the anchor 114 without significantly increasing its weight, the cavity in the anchor 114 is filled with a reticulated structure, such as a plurality of reinforced ribs 120 . The plurality of reinforced ribs 120 are configured to enhance the structural integrity of the anchor 114 . The ribs 120 serve to further distribute the live and dead load weight from the panel 102 to the anchors 114 . The ribs 120 may include a crosslinking series of barriers that fill the cavity. The crosslinking configuration serves to resist lateral and compressive forces that tend to destabilize the anchor 114 .
Those skilled in the art, in light of the present teachings, will recognize that by creating structural integrity in the cavity of the anchor 114 through ribs 120 , rather than filling the cavity with a solid material, the weight of the anchor 114 is reduced while still maintaining strength and stability. Additionally, the reinforced ribs 120 establish an exact, consistently-spaced gap between adjacent panels 102 , allowing for water drainage and air circulation.
The anchor 114 is further defined by a plurality of anchor recessions 124 a - 124 f at the anchor periphery 122 . The anchor recessions 124 a - 124 f have substantially the same contour shape as the panel recessions 110 a - 110 f , thereby enabling a flush surface with the panel periphery 108 while the panel 102 and the anchor 114 are engaged.
Each anchor recession 124 a - 124 f has a fastener receptacle 126 that integrates therein. The fastener receptacle 126 forms a substantially wing shaped extension to the anchor recessions 124 a - 124 f . Due to this unique wing shaped configuration, the fastener receptacle 126 provides a locking surface for the various fastening components to engage. The fastener receptacle 126 forms a stable surface for receiving fastening components. Thus, frictional engagement works with the detents 140 in the fastening components to lock the fastener 132 into the fastener receptacle 126 .
In one embodiment, the fastener receptacle 126 includes a locking protrusion 128 that extends perpendicularly from the fastener receptacle 126 . The locking protrusion 128 provides yet another locking mechanism to secure the fastener 132 to the fastener receptacle 126 . At least one locking hole 130 is disposed to cross transversely across the locking protrusion 128 . The locking hole 130 enables passage of fastening components that help secure the panel 102 to the anchor 114 .
Each fastener receptacle 126 extends transversely across the anchor 114 . The fastener receptacle 126 is disposed to extend beyond the anchor bottom surface 118 . In this manner, the fastener receptacle 126 forms an extension that orients perpendicularly to the anchor 114 . The fastener can be used to penetrate the ground or wall surface for anchoring. For example, six fastener receptacles 126 on the anchor periphery 122 penetrate the ground surface until the anchor 114 is level and stable relative to the ground surface. However in other embodiments, the fastener receptacle 126 may attach to the ground or wall surface through other means, including, without limitation, screws, nails, magnets, ropes, and adhesives.
It is significant to note that the panel 102 and the anchor 114 have a lightweight construction, being made of lightweight plastic or another composite material, with each panel 102 and each anchor 114 manufactured as individual single pieces. One possible form of manufacturing may include injection molding, although compression molding or any other suitable technique for molding polymeric resin may also be used. Additionally, during fabrication, the panel 102 and the anchor 114 may be reinforced by pulling reinforced fibers through the resin.
Turning now to FIG. 4 , the system 100 further comprises at least one fastener 132 that is configured to rotatably fasten against the fastener receptacle 126 at the anchor recessions 124 a - 124 f and the panel recessions 110 a - 110 f . The fasteners 132 serve to restrict lateral movement between the panel 102 and the anchor 114 . The fastener 132 also works with the fastener receptacle 126 for anchoring to the ground or wall surface. In one embodiment, six fasteners 132 engage six fastener receptacles 136 .
FIG. 5 illustrates a perspective close-up view of the fastener 132 . The fastener 132 comprises a base 136 having an elongated shape that is configured to at least partially pass through the fastener receptacle 126 . The base 136 has a plurality of detents 140 configured on the outer surface of the base 136 to provide tactile feedback for when the fastener 132 is rotatably locked to the fastener receptacle 126 . The fastener 132 utilizes frictional engagement and the detents 140 to form a snug fit with the fastener receptacle 126 . In this manner, the panel 102 and the anchors 114 are securely held into place with minimal tools or skillsets needed.
Each fastener 132 passes through the panel recessions 110 a - 110 f and the anchor recession 124 a - 124 f , locking into place with the fastener receptacle 126 by means of a vertical 360° rotation. In one embodiment, detents 140 in the fastener 132 engage depressions in the fastener receptacle 126 . The detents 140 provide tactile feedback once the turn is complete and the fastener 132 is locked into place. In one embodiment, the system 100 utilizes six fasteners 132 to engage six fastener receptacles 126 . Additional fastening components may be used to further secure the fastener 132 to the anchor 114 and the panel 102 .
As shown in FIG. 6 , the fastener 132 comprises a cap 136 that is disposed to overlay the base 136 . The cap 136 comprising at least one cap hole 138 . The cap hole 138 may have a variety of shapes, including, without limitation, circles, tear drops, hexagons, pentagons, and cubes. For example, FIG. 6 illustrates a central hexagonal-shaped cap hole 138 concentric to outer circular and smaller hexagonal holes. The at least one cap hole 138 is configured to align with the locking hole 130 of the protrusion 128 from the fastener receptacle 126 .
Once the cap hole 138 aligns with the locking hole 130 in the locking protrusion 128 , then at least one cap fastener 152 ( FIG. 7A ), such as a screw, bolt, nail, and nut, can pass through the aligned cap hole 138 and the locking hole 130 to fasten the anchor 114 to both the panel 102 and the ground or wall surface. FIG. 7B illustrates an Allen screw 154 , which is an alternative embodiment of the cap fastener 152 . The cap fastener 152 comprises a cap fastener hole 156 that provides a grip for a wrench to rotatably fasten the cap fastener 152 or the Allen screw 154 . It is significant to note that while having small structural differences, both types of cap fasteners 152 , 154 enable rotatable tightening and loosening of the cap 136 relative to the base 136 , and also fasten the fastener 132 to the fastener receptacle 126 .
FIGS. 8 and 9 illustrate an alternative embodiment of a self-locking fastener 142 having a self-locking base 158 with an internal clip 144 to attach a self-locking cap 150 . The clip 144 is disposed inside the self-locking base 158 . As the self-locking cap 150 is rotated, the clip 144 clamps down on a teardrop cap hole 148 on the self-locking cap 150 through a clip slot 160 . The self-locking base 158 comprises a teardrop locking hole 146 that aligns with the teardrop cap hole 148 . Once aligned, the self-locking fastener 142 can be made to attach the fastener receptacle 126 with the cap fastener 152 . It is significant to note however, that the self-locking fastener 142 , though having slightly different mechanisms, operates in substantially the same manner as the fastener 132 discussed above.
In some embodiments, the system 100 utilizes components that are precut and assembled with minimal tools or skillset. The system 100 is efficacious for constructing a solid, yet easily detachable and portable surfaces, for a deck, floor, wall, ceiling, or roof. Those skilled in the art will recognize that the modular, portable capacity of the system 100 provides numerous solutions to decking.
For example, renters, condominium owners, and secondary residences, such as cottages or trailers, can benefit from the interlocking and modular decking system 100 . These users are ideally able to relocate, reconfigure, expand, or store the system 100 , as needed. Additionally, the components of the system 100 are designed to be easily packaged on and within the dimensions of standardized palettes traditionally used for shipping and storage purposes.
Additionally, the universal, interlocking design of the system 100 allows for the addition of accessory components, consisting of, but not limited to: stairways, umbrellas, benches, tables, railings, storage bins, light fixtures, gazebos, planters, and other accessories. The accessories can be supported on the same anchors 114 that support the panel 102 .
During installation of a deck utilizing the system 100 , the area where the installation will take place is preferably level. Where minor discrepancies occur, the length of the fastener receptacles 126 on the anchor recessions 124 a - 124 f can be increased or decreased, as needed. The fastener receptacles 126 from the anchors 114 may then penetrate the ground surface of the designated deck area for preparation to receive the panels 102 . The panel 102 is then attached to the anchors 114 at the panel periphery 108 using the fastener 132 to hold the panels 102 in place against the anchor 114 . The fasteners 132 are inserted into the fastener receptacles 126 of the anchor recessions 124 a - 124 f and rotated up to 360°. A plurality of detents 140 in the base 136 of the fastener 132 provide tactile feedback once the locking rotation is complete and the fastener 132 locked into place.
Additional fastening components, such as screws or bolts, are passed through the locking hole 130 and cap hole 138 to enhance the attachment. Additional anchors 114 may be placed on the ground to receive additional panels 102 . This installation process continues until the desired dimensions of the deck have been completed. The system 100 may be disassembled through simple removal of the fasteners 132 , without requiring excessive force or breakage of the panels 102 or anchors 114 .
The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope.
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A portable, modular, interlocking decking system or apparatus that can be assembled and disassembled for resizing, transport, relocation and expansion. The decking comprises a plurality of panels shaped and dimensioned to interlock with other panels via fastener, the fastener comprising an axially rotatable locking mechanism which have detents in some embodiments.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to U.S. Provisional Application No. 60/650,434, filed Feb. 4, 2005, which is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to a method of selecting structural components required to resist seismic forces and more particularly to a method directed to ascertaining such components for use when supporting pipe or other mechanical components such as duct work for example from an overhead structure.
BACKGROUND OF THE INVENTION
[0003] It is quite common when designing the support members of a structure to first calculate the overall loading on the structure and then work down from this overall loading to the forces on the individual support members comprising the structure. Often times the procedure to initially determine this overall loading on the structure is by taking into account all safety factors and other forces that the structure must resist. Afterwards, an appropriate support member that can resist the calculated force is ascertained from a table or chart for subsequent inclusion in the construction of the desired structure. Anchoring detail is also necessary to secure the individual support members together or to some other support.
[0004] In the case of a pipe support, the overall configuration of each individual supporting structure along the length of the pipe must first be conceived (top support, bottom support, side support, single hanger, dual hanger, etc.). Then, the spacing of these individual structures along the pipe must be estimated in order to find the load that each such structure is to resist. Once the individual structural loads are calculated, the size and bracing of the hanger elements must be computed. In the case of ceiling supported structures, the size of the hanger rod is to be computed and whether such rod or rods need to be braced must be ascertained. Presuming bracing is required under the anticipated seismic or other loading or to comply with code requirements, the individual bracing loading must be calculated. Also, the manner of attachment of the brace and the rod to the structure itself and to each other must be considered.
[0005] Once all these various components, materials and methods of attachment are selected, the assembly as a whole must be investigated to insure that it will withstand the desired loading and that it meets code. If not, then the process starts all over again with the selection of another of the eligible support members or another manner of attachment or another size brace or another brace spacing or another rod size, etc.
[0006] Each time and for each such selection, the characteristics of the various component parts of the assembly will need to be re-calculated, their characteristics re-compiled and their combination re-computed.
[0007] A key drawback of this iterative and circular method of calculation is that it is quite time consuming and may result in components that are over-designed for their intended purpose. For example, a beefier initial member might be selected when one that is more compact but with more bracing or closer spacing might do just as well and cost considerably less. Hence, a result of following the above method is the general acceptance of the first assembly whose calculations satisfy all the requirements, not necessarily the assembly that meets all structural requirements, and is least costly to produce or the easiest to install.
[0008] For these reasons, it is desirable to provide a method of selecting structural members for supporting mechanical components such as piping and duct work in an efficient method and one that does not require more than one iterative step to arrive at the optimum solution with respect to structural, cost and installation considerations.
SUMMARY OF THE INVENTION
[0009] The present invention provides a method of design and selection of a bracing system to support mechanical components in a building in a single iterative step to arrive at the optimum solution with respect to structural, cost and installation considerations.
[0010] The present invention solves the problems of the prior art systems by providing a method for designing a bracing and support system and selecting the required components in a linear workflow method that accounts for all design considerations during the workflow, allows for the selection of the proper components and component assemblies and verifies that the requirements are satisfied in an efficient manner.
[0011] It is therefore an object of this invention to provide a different method of using loading to calculate the required structural members to support a particular load. Another object of this invention is to eliminate the ‘circular’ method employed in the past such that in a single iterative step the method according to the present invention will result in the assembly of components that most efficiently satisfies structural, cost and installation considerations. In accordance with the method of the present invention, no re-calculations or re-designs are necessary, the best solution is determined in a single step.
[0012] Still another object of this method is to devise a system of selecting structural members from a series of tables that are organized in such a way that additional or further calculations based on these various members are eliminated. Another object of this invention is to pre-arrange the various components within these tables by such factors as seismic factor and load characteristic.
[0013] In the efficient attainment of these and other objectives, the present invention provides a method of selecting and positioning support components for a bracing system without calculating the forces in these components comprising, choosing a design configuration of the bracing system, determining the seismic coefficient of the design configuration, ascertaining a load rating for the design configuration, consulting one or more pre-engineered tables to select the support components, the spacing of the support components, and the anchor details and configuration of the support components.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is a design procedure flow chart showing the assembly design method in accordance with the current invention.
[0015] FIG. 2 discloses an exemplary graph of the value of z/h on the vertical axis and the seismic factor on the horizontal axis for use in accordance with the method of the current invention.
[0016] FIG. 3 shows an exemplary design table having a seismic factor of 0.25 for use when designing a single hanger pipe assembly to be secured to an overhead concrete support.
[0017] FIG. 4 shows an exemplary design table having a seismic factor of 0.75 for use when designing a single hanger pipe assembly to be secured to an overhead steel support.
[0018] FIG. 5 shows an exemplary design table having a seismic factor of 1.0 for use when designing a dual hanger or trapeze pipe assembly to be secured to an overhead wood beam supporting a medium load.
[0019] FIG. 6 illustrates an exemplary load category table.
[0020] FIG. 7 is an exemplary pipe anchorage selection table for concrete when employing a single hanger pipe assembly.
[0021] FIG. 8 discloses an exemplary trapeze anchorage selection table for wood.
[0022] FIG. 9 discloses exemplary anchoring details for the anchorage selection of FIG. 7 .
[0023] FIG. 10 discloses exemplary final assembly details for the anchorage selection of FIG. 7 .
[0024] FIG. 11 discloses exemplary longitudinal bracing details for the anchorage selection of FIG. 10 .
[0025] FIG. 12 an exemplary design table having a seismic factor of 1.5 for use when designing a dual hanger or trapeze pipe assembly to be secured to an overhead wood beam supporting a heavy load.
[0026] FIG. 13 discloses exemplary trapeze support details for the anchorage selection table set forth in FIG. 8 .
[0027] FIG. 14 discloses exemplary trapeze support details for the anchorage selection table set forth in FIG. 8 illustrating the use of double channels.
[0028] FIG. 15 discloses exemplary wood anchor details for the anchorage selection table set forth in FIG. 8 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0029] The following is a detailed description of the preferred embodiments of the present invention. The description is meant to describe the preferred embodiments, and is not meant to limit the invention in any way.
[0030] FIG. 1 shows a flow chart depicting the assembly design method in accordance with the present invention. The work flow depicted is a process that addresses the demand and capacities of a pre-designed assembly of specific components and anchorages. The method makes use of load groups and categorizes associated assembly and anchorages details within categories of “light”, “medium” and “heavy”. Furthermore, the method accounts and provides for anchorage into structures of concrete, steel or wood. Therefore, the user is able to select the appropriate anchorage for the project in question to provide the optimum solution for the bracing support structure in question.
[0031] In the work flow diagrams depicted, prior to beginning the new assembly design method in accordance with the present invention the user must first select or determine the seismic coefficient or seismic factor 100 for the structure to be assembled based on the loading that this structure is to incur. Determining the seismic coefficient or factor 100 in one embodiment can be accomplished in accordance with the graph 200 depicted in FIG. 2 indicated therein using the values provided. This graph 200 shown in FIG. 2 is based on seismic force design criteria as defined in the 2001 California Building Code (CBC) incorporated herein. The necessary coefficients should be acquired from the Professional of Record and applied to the seismic design requirement in Section 1632.2 of the 2001 CBC.
[0032] The graph of FIG. 2 is utilized by first establishing “hx/hr”, or “z/h” on the vertical axis 202 of the graph 200 where hx=anchorage height and hr=building height. For example for anchorage at 20 feet elevation (hx) in a 100 foot building (hr): hx/hr=20/100=0.2. Once the value of “hx/hr” is determined, in this example 0.2, the user finds the point corresponding to that value on the vertical axis 202 of graph 200 . In this example, at point 204 , the user then reads horizontally across the graph to the point of intersection with line 206 , which in accordance with the stated exemplary value of 0.2 occurs at point 208 . The seismic factor (g) is then determined by determining the value on the horizontal axis of graph 200 that corresponds to point 208 . In this example point 210 , which has a value of 0.48. When employing this seismic factor in accordance with the invention, it is always rounded up.
[0033] Referring back to FIG. 1 , once the seismic coefficient or factor (g) is determined in step 100 , the user proceeds to step 102 when using the system assembly design method of this invention. Step 102 includes selecting the design table having the appropriate seismic factor. Turning to FIG. 3 , there is shown an exemplary depiction of an assembly design table for use in accordance with step 102 when using the system assembly design method of this invention. In accordance with the exemplary seismic coefficient determined in step 100 , the user must select the appropriate design table. The design tables are produced to account for the differences in anchorage, i.e. wood, concrete or steel, and the type of hanger to be used. Specifically single or dual hanger, also known as a trapeze support. Therefore, the user must select the assembly design table for the anchorage and hanger in use for the calculated seismic coefficient. In the exemplary assembly design table 300 of FIG. 3 , there is a designation heading 302 , indicating that the exemplary table is intended for use with concrete anchorages. Furthermore, the table heading 304 indicates that the table is to be used in the design of a single hanger or single pipe assembly. Furthermore, the seismic factor 306 is indicated. Therefore, the design table 300 , depicted in FIG. 3 is the appropriate table for when the seismic factor or coefficient 306 is 0.25 or less; when the support structure is to be a single pipe assembly; and, when concrete is the final supporting material. Note also the symbol 310 in the upper right hand corner of FIG. 3 designating its use for a single hanger from concrete structure. Additional design tables would be provided to the user for different seismic factors as well as for wood and steel anchorage. Design table 300 , also includes sections for “Light” 312 , “Medium” 314 and “Heavy” 316 loading.
[0034] As can be seen, different design tables 300 are employed depending on the seismic factor, the type of support assembly and the material to which the assembly will be affixed. Each such design table 300 is itself specially calculated to provide information such as pipe size, support spacing and brace spacing. Thus, each design table 300 , has been pre-engineered or pre-determined so that the proper structural members can be selected without the user having to manually perform these calculations for each hanging system to be designed as would be the case when applying the component design method. By way of further example, another design table 300 is shown in FIG. 4 . This design table 300 is to be employed when the seismic factor 306 is 0.75 or less; when the support structure is to be a single pipe assembly; 304 and, when the material supporting the assembly is steel 302 . Note also the single pipe hanger or assembly symbol 310 in the upper right hand corner of FIG. 4 .
[0035] Yet another exemplary design table 300 is shown in FIG. 5 . This design table 300 is to be employed when the seismic factor 306 is 1.0 or less; when the support structure is to be of the trapeze type 304 ; and, when the assembly is affixed to wood 302 . Note also the tandem pipe hanger or assembly symbol 310 in the upper right hand corner of FIG. 5 . It should further be understood by one skilled in the art that in accordance with the present inventive method, the user will be presented with the appropriate assembly design tables to cover all permutations of design criteria.
[0036] Once the user has selected the appropriate assembly design table in step 102 , the user moves on to the next design step in accordance with the current invention. Turning again to FIG. 1 , the following step 104 includes selecting the appropriate category based on weight, that being “Light”, “Medium” or “Heavy”. This selection will direct the user to the appropriate section of design table 300 , that being 312 , 314 , 316 respectively. In order to select a weight category: light, medium or heavy, the user makes reference to FIG. 6 . Load category tables 600 shown in detail in FIG. 6 assist the user in making this selection by establishing some criteria, based on either pipe diameter 602 or load per linear foot (plf) 604 , upon which to make this selection. Obviously, a smaller pipe or a pipe that presents less loading characteristics will be in the ‘light’ category while larger or heavier pipes will be in the ‘heavy’ category. Those in-between will be deemed to be in the ‘medium’ category. There is considerable overlap between the various categories as seen in load tables 600 .
[0037] Referring once again to FIG. 1 , the next step in the method according to the present invention is to determine the appropriate support and bracing options 106 . Once the user has ascertained the load characteristic (i.e. light, medium or heavy) and has already determined seismic factor 306 , the material supporting the assembly (concrete, steel or wood) as well as whether the support is to comprise a single or a multiple hanger design, the user is ready to determine the appropriate support and brace spacing options 106 . By consulting the appropriate design table 300 such as that shown in FIG. 3 , the user determines the support spacing 318 and brace spacing 320 , by selecting the horizontal row corresponding to the pipe size to be installed under the appropriate load characteristics. In the example of a 3 inch pipe subject to a “light” loading, the proper support spacing is given as 12 feet 322 with a brace spacing of 24 feet transverse 324 and 48 feet longitudinal 326 .
[0038] The final step in accordance with the method of the current invention is set forth in FIG. 1 ; Select Suitable Anchor Type Detail 108 . Turning to FIG. 7 , step 108 can be fully explained.
[0039] FIG. 7 includes a Single Pipe Anchorage Selection Table 700 . Similar to table 300 previously detailed, table 700 is indicated for use with concrete anchorage 702 and 704 and for a seismic factor of 0.25 706 corresponding with that shown in FIG. 3 . As with table 300 of FIG. 3 , the user will be provided with a selection of anchorage selection tables 700 to cover the various permutations of design choices, that being; concrete, wood or steel anchorage, single pipe or multiple pipe (trapeze) hangers and a range of seismic values. By way of example, FIG. 8 presents an anchorage selection table 700 for a wood anchorage 702 and 704 for a seismic factor of 1.5 706 . It should further be understood by one skilled in the art that in accordance with the present invention method, the user will be presented with the appropriate tables to cover all permutations of design criteria. Different anchorage selection tables 700 are employed to account for the different design criteria present.
[0040] Turning again to FIG. 7 , anchorage selection table 700 includes specifications for “light” 708 , medium 710 and “heavy” 712 pipe sizes. Utilizing the same light-duty, 3″ pipe example as above, the user will find that any of five different pipe hanger options are suitable for use, as listed in field 716 pipe hanger option. Also, the user is informed that ⅜ inch diameter hanger rod and ⅜ inch diameter expansion anchors can be employed as shown in Anchor Detail Number 1 which will be described in greater detail below. For further purposes of explanation, presume the user selects pipe hanger option M-718 as listed in field 716 of FIG. 7 . A note in this FIG. 7 informs the user to proceed to one section, Section E for pipe hanger details and to proceed to another section, Section F for anchorage details.
[0041] Referring to anchorage details first, in FIG. 9 , difference is made whether the anchor is to be in a generally uniform concrete slab (lower details) 902 or in a concrete metal deck (upper details) 904 . The anchor details for the hanger rod are shown to the left 906 while the anchor details for the brace are shown to the right 908 . Whichever concrete flooring is used, the necessary anchoring details for this assembly is provided to safely secure a lightly loaded 3″ pipe in place against seismic loads.
[0042] Referring now to pipe hanger assembly option M-718, previously selected and as shown in FIG. 10 . Here, the ⅜″ diameter hanger rod 1002 , as previously selected with reference to Anchorage Selection Table 700 shown in FIG. 7 , is suspended from the concrete support 1004 along the run of the pipe 1006 with transverse bracing 1008 every 24 feet 324 , which the user finds in accordance with the brace spacing requirement previously given in table 300 of FIG. 3 . Details on the various hardware necessary to complete this support assembly are also provided in this FIG. 10 for pipe hanger assembly option M-718, including the coupler 1010 , and associated hex nut 1012 . The rod stiffener 1014 , hex nuts 1016 for attaching the split pipe ring 1018 to the transverse brace 1008 and angle fitting 1020 for attaching transverse brace 1008 to concrete support 1004 are also identified. There is also a note referencing the longitudinal bracing 1022 that is required at least every 48 feet, as previously determined with reference to FIG. 3 , in this example. Details on such longitudinal bracing can be found in FIG. 11 which provides hardware and assembly information regarding selected option M-718, such that such longitudinal bracing can be installed as needed.
[0043] Turning to FIG. 11 , there is shown a longitudinal bracing assembly detail for pipe hanger option M-718. Similarly to the transverse brace of FIG. 10 , there is shown a detail on the various hardware necessary to complete this longitudinal support assembly, including the coupler 1010 , and associated hex nut 1012 . Details on hex nuts 1016 for attaching the split pipe ring 1018 to the longitudinal brace 1102 and angle fitting 1104 for attaching longitudinal brace 1102 to concrete support 1004 are also provided.
[0044] For purposes of complete understanding, another example will be presented; this time pertaining to a trapeze support suspended from wood. Such trapeze support a would be employed when supporting two or more runs of a longitudinal member (although a trapeze design can also be used to support a single run of a longitudinal member if so desired). The example shown supposes the longitudinal member being a pipe, but it could just as easily be duct or tray or any other device requiring spaced supports.
[0045] The example that follows will pertain to the support of heavy piping having a loading of 70 pounds per linear foot and employing a seismic factor of 1.5. It should be noted that the above information is rather basic in nature and does not require much in the manner of calculation by the user. Thus in this example the user will proceed to step 106 of FIG. 1 to determine appropriate support and brace spacing option. From this initial criteria the user will consult the proper assembly design table as described above. Turning to FIG. 12 , there is show trapeze assembly design table 1200 satisfying the above criteria. For weight 70 plf 1202 , it will be seen that there is only one option (option ii) available, the vertical support 1204 is to be spaced 3 feet maximum; transverse bracing 1206 is to occur every 3 feet 1208 ; and longitudinal bracing 1208 is to occur every 6 feet.
[0046] Given the above design parameters, the user will consult the appropriate assembly design table. In this case the anchorage details for this assembly are provided on FIG. 8 as shown by reference 1210 on FIG. 12 . Turing now to FIG. 8 and recalling that this example is limited to option (ii) for heavy loading, the resultant maximum channel lengths for single B-900 channel is 48 inches 814 whereas the maximum channel length for double B-900-2A channel is 96 inches 816 , each supported by ⅝ inch rod 818 and eligible for anchor details 1-4820 as selected. The notes following the tables 822 on FIG. 8 indicate where to find trapeze support details and wood anchor details under the given design conditions.
[0047] Turning now to FIG. 13 which shows the trapeze support details identified in the notes of FIG. 8 for single channel length, B-900. It should be noted that depending on the type of trapeze desired the user is provided with assembly details for all of the trapeze support variations possible. For example, if single B-900 channel 814 is selected then the maximum length between ⅝ inch hanger rod is the above specified 48 inches. However, if double channel B-900-2A 816 is selected then the maximum length between ⅝ inch hanger rod is the above specified 96 inches and the assembly details for such channel are also shown in FIG. 14 .
[0048] Turning again to FIG. 13 , there is shown the assembly details for the selected trapeze support in accordance with the given design parameters. As described with respect to the previous example, the assembly details include and provide specifications for all component parts of the trapeze hanger. The assembly details are divided into a front elevation view 1302 and a side elevation view 1304 . The front elevation 1302 includes specifications for the coupler 1306 and associated hex nut 1308 , threaded rod 1310 , stiffener 1312 , U pipe clamp or pipe strap 1314 , and associated screw 1316 and nut. The screw 1316 and nut attach U pipe clamp 1314 to the single channel support 1318 . In addition, the hex nut and washer 1320 for attaching the rod 1310 to single channel support 1318 are also indicated. Finally, transverse brace 1322 and attachment hardware, angle fitting 1324 and hex head cap screw and channel nut 1326 are noted for the users reference. The side elevation view 1304 further include the reference for the appropriate longitudinal brace 1328 .
[0049] Turning again to FIG. 8 , note 822 further specifies the wood anchor details. Therefore, once the user has selected the appropriate components for the trapeze support details in accordance with the specification contained in FIG. 13 , the user is directed to select the suitable anchor type detail 824 . In order to complete this step, the user is directed to the appropriate anchor detail selection sheet. An exemplary version of which is reproduced as FIG. 15 . FIG. 15 depicts a brace connection detail 1502 and a hanger rod anchor detail 1504 . The brace connection detail 1502 includes the specification for the single channel brace 1506 , angle fitting 1508 for attachment to the wood beam 1510 and the hex head cap screw and channel nut 1512 . Likewise the hanger rod anchor detail includes the specifications for the threaded rod 1514 and hex nut 1516 and washer 1518 . The specification includes reference to the surrounding structure, such as the wood beam 1520 , blocking 1522 and joist hangers 1524 which are not part of the hanger system, but are provided as a reference to the user with respect to anchor placement and attachment points.
[0050] Obviously, and as evidenced above, the present assembly design method is quite capable and quite rapid at supplying the necessary assembly details and mounting hardware needed to construct these hanger supports. Very little, if any, manual calculations by the user are required unlike the prior art component design method which mandated often repeated calculations until the designer could ‘zero-in’ on the final assembly. The present method is an improvement on this prior method in that the selection of the necessary hardware and the calculation of the necessary bracing and spacing is now made very simple. The user need simply follow a flow chart and turn to the appropriate tables to find the necessary information.
[0051] While select preferred embodiments of this invention have been illustrated, many modifications may occur to those skilled in the art and therefore it is to be understood that these modifications are incorporated within these embodiments as fully as if they were fully illustrated and described herein.
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This invention pertains to a novel method of calculating seismic bracing and more particularly to a method of selecting and positioning support components for a bracing system without calculating the forces in these components comprising, choosing a design configuration of the bracing system, determining the seismic coefficient of the design configuration, ascertaining a load rating for the design configuration, consulting one or more pre-engineered tables to select the support components, the spacing of the support components, and the anchor details and configuration of the support components.
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BACKGROUND OF THE INVENTION
[0001] A number of alternative, general purpose attachment schemes and hardware designs have been developed for mounting MEDs within vehicles. These approaches have attempted to provide universal, fit-any-vehicle, MED mount designs. Suction cup installations have been used for securing MED docking holders to windshield, dashboard, or other mounting surfaces. This approach can provide some limited positioning flexibility but mounting surfaces need to be flat and smooth and, invariably, suction integrity degrades over time and the MED mount can fall from its mount installation surface. Suction based mounts positioned on the vehicle's smooth surface windshield can be reasonably durable but this MED placement, however, can seriously interfere with driver visibility in a small car like the classic Porsche 911, (Porsche® is a registered trademark of Dr. Ing. h.c. F. Porsche AG.). Adhesives and/or invasive fasteners have been used to secure MED mounting, but these approaches can irreversibly mar/damage vehicle mounting surfaces (e.g. the dashboard covering) with visible, conspicuous residues or holes. Velcro attachment of MEDs requires surface marring adhesive and installations can look, aesthetically, rather unfinished and crude. Clip based mounts are limited by available attachment points and often, what's workable ends up positioning the MED in an awkward location. Weighted, conformable bases have been used to secure MED mounting by friction to the top of a vehicle's dashboard but, this approach requires a large bulky base that can also seriously impede driver vision in a small car like the classic 911 Porsche. Under dashboard brackets have been tried in the classic Porsche 911 but, these installations generally place the MED too low in the cabin for acceptable device visibility and/or interactive convenience and furthermore, this positioning can compromise operating performance of the MED e.g. degraded GPS navigation capability or deficient phone functionality due to shielded signal strength. Vehicle-specific MED mounting brackets have been designed to attach onto the center dashboard vent in the classic Porsche 911, but this approach can impair cabin ventilation. Bracket insertion between the perimeter of this vent and the dashboard surface can result in cracking the plastic vent grille.
[0002] The Porsche 911 is an iconic example of excellence in automotive design. The basic shape and styling contours of today' latest version of the 911, the 2012 991, make it instantly recognizable as a worthy descendant of Ferry Porsche's original 1963 design (produced in 1964, commercialized in 1965). The nearly fifty year durability of the vehicle's aesthetics and underlying engineering framework are testimony to the market potency of good design, performance, and functionality.
[0003] While basic body form and power train layout have lasted throughout Porsche 911 production life, major advances and refinements were implemented with every new model along the way. Across the development history of the Porsche 911, a major styling and engineering demarcation took place in 1999 with the commercialization of the 996 model, the first generation water cooled engine powered Porsche 911. From 1965 through 1998, the air cooled, flat six engine defined the original or now “classic” phase of the vehicle.
[0004] The interior design of the classic 911 remained substantially unchanged for thirty three years finally giving way to major revision with the introduction of the 996 model.
[0005] Drivers of the earliest 911s would feel completely at home in the “end-of-era,” air cooled 993s of the late 1990s. Some ergonomic modifications of certain switch locations were implemented over the years and improved cabin ventilation was achieved with added air grilles to the dashboard structure, but driver-interaction with the readouts and controls of the car was grounded in preserved familiarity.
[0006] While dashboard form and instrument layout were kept intact throughout the evolutionary development of the air cooled 911, both active and passive functionality at the driver/car interface advanced, continuously, with new improved electronics, sensor readouts, and safety features such as integrated airbag systems. The simplicity of the classic Porsche 911 dashboard design carried some ergonomic quirks for new drivers with certain controls better managed by feel than sight. Nonetheless, a little drive-time tended to quickly erase any initial awkwardness in operating the vehicle.
[0007] When development of the air cooled cars was discontinued with the transition from the 993 to the water cooled 996, major engineering changes were accompanied by some major styling changes, especially to the interior. The familiar, classic 911 dashboard was abandoned. A new overlapping instrument cluster layout was implemented and the center console now penetrated up into the dashboard structure and was designed to accommodate new electronics. As the 911 continued to evolve, new electronic capability was offered such as a satellite navigation system, mobile phone controls, and digital music functionality. GPS capability, phone integration, and iPod/mp3 player (iPod® is a trademark of, a copyright of, and made by Apple, Inc.) connectivity made the new 911 interior seem luxurious and modern in comparison to the relatively spare, austere, and dated cabin of the classic air cooled 911s.
[0008] This new dashboard configuration incited controversy among some hardcore Porsche enthusiasts who felt purity of design and distinctiveness had been shamefully sacrificed and that the 911 interior now had a look and feel common to a luxury sedan rather than a high performance sports car. Nonetheless, its modern communication management conveniences had major appeal to “daily-driver” and “adventure-road-trip” owners and, for some, made the “raw” classic 911 seem like a weekend-only car.
SUMMARY OF THE INVENTION
[0009] The background outlined above helps explain the utility and demand-side rationale for the invention outlined in this disclosure. The value proposition for this product for an end-use customer (the owner and/or driver of a classic air cooled Porsche 911) is that the MED mounting and positioning bracket provides a simple, affordable, purpose-designed, attractive, non-invasive pathway to very significantly upgrade the electronic communications functionality and convenience of the classic Porsche 911. MED mounting using this invention provides for a modernized driver experience that can include GPS navigation and phone connectivity to the world as well as the ability to integrate one's full library of digital music with the classic 911's audio system. The classic Porsche 911 sports car can be transformed with enhanced communications management capability to deliver a modern, convenient travelling experience to its devoted ownership enthusiasts.
[0010] GPS navigation capability, in particular, has become an increasingly desired option for new vehicles. In many luxury models, navigation assistance has evolved to become an expected integrated feature, not an à la carte, add-on vehicle option. Nonetheless, if not factory installed as an OEM (original equipment manufacturer) integrated device, a number of companies have developed and marketed portable, after-market GPS navigation appliances that can be retrofit to vehicles (old and new) to deliver excellent navigation capability. As noted above, however, positioning these MEDs in a driver convenient location has led to a number of general purpose and occasionally, vehicle-specific hardware designs and attachment schemes for mounting these devices with limited levels of success. For the classic Porsche 911, the MED mounting and positioning challenge is exacerbated by the small size of the passenger cabin and the near absence of useable flat surfaces and workable attachment points. The novel invention described herein solves the problem of placing and securing an MED such as a portable GPS navigation appliance in a driver-convenient position in the classic Porsche 911. This invention creates a very stable and secure MED mounting surface platform in an ergonomically ideal location without conflicting with vehicle controls, driver visibility, or cabin ventilation.
[0011] A very important companion aspect driving the need for this invention resides in the coincident market acceleration underway with respect to the expanding prevalence of multi-function smartphones and their ever increasing “apps” functionality which enables people to stay fully connected to the world, wherever they may be. The ability to utilize this removable MED, hands-free, in a vehicle can largely replicate the convenience of very expensive, “at-your-fingertips,” in-dash installations of navigation, phone, and digital music systems. Smartphone “apps” have become increasingly powerful and sophisticated with feature offerings that can match and often exceed the usability of “high-end,” onboard music and communication management systems. “Apps” have been developed to transform a phone screen to a customizable, menu-accessed, digital dashboard with notification readouts for GPS-calculated-speed, vehicle location, elevation, compass direction, weather updates, traffic congestion, etc. and driver driven capabilities for destination navigation, phone connectivity, and digital music management.
[0012] Smartphone capability and functionality are creating a cyber-connectivity dependency in the public at large and represent an important indirect driver of demand for the customized MED mounting and positioning bracket described in this disclosure. Classic Porsche 911 owners (who most likely have smart phones) will place high value in having ready, convenient, safe access to certain features, especially navigation assistance, provided by this amazing MED. Vehicle driving convenience will be significantly upgraded.
[0013] In one embodiment, the invention is a non-invasive, secure, stable attachment device for mounting a mobile electronic device (MED) to a dashboard of a vehicle without requiring surface marring adhesives or drilling of holes, said device comprising:
a) a bracket assembly securing two-end, mechanical anchoring of a MED mounting platform to the dashboard, b) a first dashboard fastening mechanism for one end of the bracket assembly which uses pressure and friction achieved by sandwiching the bracket assembly between a flange of at least one cylindrical vehicle instrument and a face of an instrument housing panel of the vehicle, said flange being created by a bezel rim of the instrument and lip of a circumferential ribbed rubber boot used in press fitting and holding the instrument securely in a circular opening in the vehicle's instrument housing panel, preferably wherein the fastening mechanism is an annular ring of the bracket assembly and fit to a clock in a left-hand drive vehicle or to a fuel level, oil level gauge in a right hand drive vehicle, c) a second fastening mechanism for the end of the bracket assembly opposite to the end used in b), which mechanically attaches a bracket support arm or brace connecting the bracket assembly to the dashboard and/or dashboard frame using at least one pre-existing vehicle bolt, preferably wherein the bracket support arm or brace is mechanically attached to the vehicle dashboard or dashboard frame using a bolt, screw or rivet, and d) a MED mounting platform configured with a hole or pattern of holes to accept various adaptor plates and connector mechanisms to attach to MEDs and/or device holders/cradles.
[0018] The first dashboard fastening mechanism of the bracket assembly can be an annular ring and fit to a clock, or a fuel level gauge and/or oil level gauge of the vehicle. The MED mounting platform can be fitted with a spacer wedge increasing platform canting relative to a major horizontal axis of the dashboard. The bracket assembly can be removable from the vehicle without evidence of prior installation. The MED mounting mechanism can be coupled to and/or removable from a portable MED. The MED or the MED docking holder or cradle can be hardwired to an electronic system of the vehicle. The hardwiring preferably powers the MED and/or enables sound interaction using an integrated audio component of the vehicle, especially for navigation appliances, mobile phones and/or digital music players.
[0019] In a second embodiment, the invention is a bracket assembly for mounting, positioning, and supporting a mobile electronic device (MED) in a vehicle, the bracket assembly comprising:
a) an annular ring for securing the bracket assembly to an instrument of an instrument housing panel of the vehicle, b) a plate contiguous and/or connected to the annular ring that conforms to design contours and configuration of a dashboard of the vehicle, c) a cantilevered extension contiguous and/or connected to the plate for sideward positioning of MED placement, d) a MED mounting platform contiguous and/or connected to the cantilevered extension, and e) a support arm connecting the bracket assembly to the dashboard or dashboard frame of the vehicle to brace the MED mounting platform, reinforce bracket stability, constrain bracket movement, and dampen vibration of the mounted MED.
[0025] The instrument housing panel can comprise at least one circular opening to accommodate a cylindrical vehicle instrument.
[0026] The annular ring of the bracket assembly, preferably, is concentrically fit to the circumference of at least one cylindrical vehicle instrument and sits behind a protruding rim or flange feature of said instrument and is held securely to the face of the instrument housing panel by pressure and friction created when the cylindrical vehicle instrument with flange is pressed into a circular opening in the instrument housing panel. The annular ring sits behind the protruding rim or flange of the instrument in the sense that the ring is located between the instrument outer bezel, a collar-like gasket (usually an elastomeric material such as rubber, such as the lip of the ribbed rubber boot shown in the figures herein) and the instrument housing panel itself, when the instrument is reinstalled. Thus, the preferred order of the components when installed according to the invention herein, moving from the interior of the vehicle forward toward the windshield, is: instrument, instrument bezel, rubber boot lip, annular ring of the bracket assembly, and then the face of the instrument housing panel itself. The annular ring of the bracket assembly is located concentrically on top of the collar-like gasket (for example, the ribbed rubber boot) surrounding the instrument; that is, the annular ring is “sandwiched” between the gasket-creating flange and the instrument housing panel. If no such gasket-creating flange pre-exists on the instrument then a suitable flange should be installed in front of (and under if appropriate) the annular ring, such that the annular ring of the invention is tightly “squeezed” between the gasket-creating flange and the instrument housing panel when installed. If not originally present, the gasket-creating flange can be added in the form of an “o-ring” in a suitable size to fit tightly, at least partially, preferably concentrically, around the instrument. To further stabilize the bracket installation, an “o-ring” of suitable size can also be added behind the annular ring of the bracket, between it and the instrument housing panel. The instrument also need not be circular, but can be polygon in face shape, for example, elliptical or angular (such as rectangular or square) in shape. A flexible gasket, if not present, can be added in this instance as well. Such a gasket or flange can be an “o-ring,” stretched to fit, or can be an elastomeric material aligned in place in a similar fashion to that described above. In the case of a non-circular instrument, then the annular ring described in the invention would be modified to fit the instrument in question. That is, the “annular ring” may not be circular in face projection, but could be a polygon in face shape, for example, elliptical or a shape appropriate for the application.
[0027] In addition, the annular ring of the bracket can be installed between the instrument bezel and lip of the ribbed rubber boot (i.e. behind the bezel and in front of the collar-like gasket). It can also be installed without using a collar-like gasket or flange. That is, the annular ring can be “sandwiched” directly between the instrument bezel and the instrument housing panel face. In either case, with or without the gasket, with the annular ring contacting, directly, the instrument's outer surface circumference, the annular ring must be sized appropriately. The annular ring must be sized such that the inner diameter of the annular ring is within a tight tolerance of the outer diameter of the instrument, less than and usually no more than from about 0.5 to about 1.25 percent of the outer diameter of the instrument. For example, if the instrument is about 80 mm in outer diameter, then the inner diameter of the annular ring should be no more than about 81 mm, or within about 1.25 percent. Utilizing a tight tolerance between the outer diameter of the instrument and the inner diameter of the annular ring is important to avoid migration displacement (e.g. rotation) of the annular ring and bracket assembly after installation. Vehicle motion caused vibration, road condition jarring, and the like, can all contribute to potential unwanted movement of the MED mounting and bracket assembly, if not properly designed and installed. An improperly designed annular ring with excessive inner diameter can result in the bracket assembly actually dislodging from the installation by slipping off the instrument housing panel over the front of the instrument bezel. Obviously, the outer diameter of the annular ring can vary somewhat, but it would be desirable for it to be somewhat smaller to minimally larger than either the outer diameter of the instrument bezel or lip of the ribbed rubber boot (if present) for aesthetic purposes.
[0028] Finally, the annular ring need not be a complete uninterrupted piece of structure (such as a perfect uninterrupted “O.” The annular ring could be a partial ring, with a gap or two (or more) present, if convenient for installation and/or aesthetics. However, a completely concentric, uninterrupted annular ring is preferable, especially for secure mounting and installation.
[0029] The annular ring of the bracket assembly can be fit to a clock or fuel level gauge and/or an oil level gauge of the vehicle. Fitting the annular ring to the clock is preferable in left-hand drive vehicles, while fitting the annular ring to the fuel level and oil level gauge is preferable in right hand drive vehicles.
[0030] The cantilevered extension can position the MED mounting platform in an unobstructed, line-of-sight location for a driver of the vehicle. The MED mounting platform can be configured with a hole or pattern of holes to accept adaptor connectors for attaching various MEDs and/or MED docking holders/cradles. The MED mounting platform can be fitted with a spacer wedge to increase platform canting relative to a major horizontal axis of the dashboard.
[0031] The MED can be a variety of devices, mostly electronic, typically a mobile telephone, portable GPS navigation appliance, digital music player, satellite radio, or some combination thereof. The MED is preferably hardwired to the electronic systems of the vehicle, especially for mobile telephones or digital music players, for powering the MED and/or sound interaction using the vehicle's integrated audio components. The device can also be a mechanical device, such as a cup holder.
[0032] The device can have a MED mounting mechanism configured to allow, optionally, easy coupling and easy removal of a portable MED. The device can include a MED mounting platform to accept various adaptor plates and/or connector mechanisms attached to MEDs and/or device holders/cradles. The bracket support arm or brace can be mechanically attached to the vehicle dashboard or dashboard frame using a bolt, screw or rivet.
[0033] In a third embodiment, the invention is a non-invasive, secure, stable attachment system for mounting a mobile electronic device (MED) to a dashboard of a vehicle without requiring surface marring adhesives or drilling of new holes, said system comprising:
a) a bracket assembly securing two-end, mechanical anchoring of a MED mounting platform to the dashboard, b) a first dashboard fastening mechanism for one end of the bracket assembly which uses pressure and friction achieved by sandwiching the bracket between the flange of at least one cylindrical vehicle instrument and the face of an instrument housing panel of the vehicle, said flange being created by the bezel rim of the instrument and lip of a circumferential ribbed rubber boot used in press fitting and holding the instrument securely in a circular opening in the vehicle's instrument housing panel, c) a second fastening mechanism for the opposite end of the bracket assembly which mechanically attaches a bracing support arm connected to the bracket to the dashboard and/or dashboard frame using at least one pre-existing vehicle bolt, and d) optionally, a MED mounting platform configured with a hole or pattern of holes to accept various adaptor plates and connector mechanisms to attach to MEDs and/or device holders/cradles.
[0038] The first dashboard fastening mechanism can comprise an annular ring for the bracket assembly, and is preferably fit to a clock for left-hand drive vehicles and preferably fit to a fuel level gauge and/or oil level gauge for right-hand drive vehicles. Where the MED mounting platform is not optional, it can be fitted with a spacer wedge to increase platform canting relative to the major horizontal axis of the dashboard. The bracket assembly can be removable from the vehicle without evidence of prior installation. The bracket assembly can have a MED mounting mechanism or platform configured to allow, optionally, easy coupling and easy removal of a portable MED. The MED can be hardwired to at least one electronic system of the vehicle to power the MED and/or to provide sound interaction using integrated audio components of the vehicle. The bracket support arm or brace can be mechanically attached to the vehicle dashboard or dashboard frame using a bolt, screw or rivet.
[0039] In a fourth embodiment, the invention is a bracket assembly used to mount a mobile electronic device (MED) in a vehicle, the bracket assembly comprising:
a) an annular ring integral to and securing the bracket assembly to an instrument housing panel of the vehicle, b) a plate contiguous and/or connected to the annular ring that conforms to a dashboard design contour and/or configuration of the vehicle, c) a cantilevered extension contiguous and/or connected to the plate for generally sideward positioning or placement of the MED, d) a MED mounting platform contiguous and/or connected to the cantilevered extension, e) wherein the annular ring is an anchoring point for the bracket assembly, and f) optionally, a support arm connecting and anchoring the bracket assembly to the dashboard or a dashboard frame of the vehicle.
[0046] In a fifth embodiment of the invention, in a bracket assembly used to mount a mobile electronic device (MED) in a vehicle, the bracket assembly comprising an annular ring integral to and securing the bracket assembly to an instrument housing panel of the vehicle, the improvement comprises:
a) a plate contiguous and/or connected to the annular ring that conforms to a dashboard design contour and/or configuration of the vehicle, b) a cantilevered extension contiguous and/or connected to the plate for generally sideward positioning or placement of the MED, c) a MED mounting platform contiguous and/or connected to the cantilevered extension, d) wherein the annular ring is an anchoring point for the bracket assembly, and e) optionally, a support arm connecting and anchoring the bracket assembly to the dashboard or a dashboard frame of the vehicle.
[0052] In a yet another embodiment of the invention, in a bracket assembly used to mount a mobile electronic device (MED) in a vehicle, the bracket
[0000] assembly comprising an annular ring integral to and securing the bracket assembly to an instrument housing panel of the vehicle, the improvement comprises connecting or attaching a plate to the annular ring that conforms to a dashboard design contour and/or configuration of the vehicle, and optionally, the bracket assembly comprising a cantilevered extension contiguous and/or connected to the plate for generally sideward positioning or placement of the MED. Preferably, the cantilevered extension is not optional in this embodiment.
[0053] In another embodiment of the invention, in a bracket assembly used to mount a mobile electronic device (MED) in a vehicle, the bracket assembly comprising an annular ring integral to and securing the bracket assembly to an instrument and an instrument housing panel of the vehicle, the improvement comprising connecting or attaching a plate to the annular ring, wherein the annular ring and the plate conforms to a dashboard design contour and/or configuration of the vehicle, sizing the annular ring such that the annular ring has an inner diameter less than and within 0.5 to about 1.25 percent of an outer diameter of the instrument, and optionally, the bracket assembly comprising a cantilevered extension contiguous and/or connected to the plate for generally sideward positioning or placement of the MED. Preferably, the cantilevered extension is not optional in this embodiment.
[0054] Preferably, in either of the latter two embodiments, the plate also is attached to an MED mounting platform ( 3 in FIGS. 20 and 21 ). As in FIG. 20 , the MED mounting platform can be integral to (part of) the plate, or as shown in FIG. 21 , the MED mounting platform can be attached to the plate, either in-line with the plate, or at any angle to the plate (shown in FIG. 21 as a 90 degree angle).
BRIEF DESCRIPTION OF THE FIGURES
[0055] FIGS. 1 and 12 are schematic drawings of the MED mounting and positioning bracket assembly constructed in accordance with embodiments of the invention.
[0056] FIG. 2 is an illustration of the dashboard layout, instrument cluster configuration, and controls arrangement in a classic Porsche 911 (1995 model 993 in this case) showing the attachment points for securing the MED mounting & positioning bracket assembly to the dashboard of the vehicle. (This Figure is developed from a Porsche owner's manual entitled “Dashboard Assembly, Instruments” which makes the following copyright notation: © Dr. Ing. h.c. F. Porsche Aktiengesellschaft All rights reserved. Printed in Germany).
[0057] FIG. 3 shows a classic Porsche clock and ribbed rubber boot which provides one anchoring point for the MED mounting & positioning bracket.
[0058] FIGS. 4 and 13 illustrate how the bracket assembly is secured by the Porsche clock with the annular ring of the bracket inserted behind the lip of the ribbed rubber boot which, in turn, holds the clock in position in the instrument housing panel of the classic Porsche 911 dashboard. Each figure shows a different brace arm attached to the bracket.
[0059] FIGS. 5 and 14 are a rear view of the bracket assembly (using two different brace arms) secured by the clock.
[0060] FIG. 6 is an illustration of the slightly concave instrument housing panel for a classic Porsche 911 with its symmetrical five-hole legacy design layout for holding the cluster of instruments for the vehicle.
[0061] FIGS. 7 and 15 show the MED mounting and positioning bracket assembly sandwiched between the face of the instrument housing panel and the flange created by the clock bezel and lip of the ribbed rubber boot and installed on the instrument housing panel.
[0062] FIGS. 8 and 16 are a front view of the bracket assembly on the clock installed on the instrument housing panel.
[0063] FIGS. 9 and 17 are a rear view of the bracket assembly on the clock installed on the instrument housing panel.
[0064] FIGS. 10 and 18 show how the bracket assembly's MED mounting platform with AMPS hole pattern platform accepts (for example) a 17 mm swivel ball adaptor plate used in attaching various MEDs or their holding docks or cradles.
[0065] FIGS. 11 and 19 show the MED mounting and positioning bracket assembly equipped with a 15 deg. wedge to increase the cant of the bracket assembly's mounting and positioning platform.
[0066] FIG. 20 shows a modified version of the MED mounting and positioning bracket that can be installed on the fuel level and/or oil level gauge or the analog clock in either LHD or RHD vehicles.
[0067] FIG. 21 shows another modified version of the MED mounting and positioning bracket that can be installed on the fuel level and/or oil level gauge or the analog clock in either LHD or RHD vehicles.
DETAILED DESCRIPTION OF THE INVENTION
[0068] The invention is a bracket assembly designed to fit the shape contours and legacy features of the dashboard of a classic Porsche 911 vehicle to provide a stable mounting and positioning platform for a portable mobile electronic device (MED) such as a smart phone (smartphone), portable global positioning system (GPS) navigation appliance, iPod or other mp3 player, satellite radio, or combination thereof in a driver-convenient location in the vehicle. A novel attribute of this invention is a design that enables secure, two-end attachment of the bracket assembly to the dashboard of the vehicle in a fashion that does not require conspicuous surface marring adhesives or drilling of dashboard damaging holes. One support arm brace design (shown in FIGS. 12-19 ) is an L-shaped flat surface beam with two “S” bends to accommodate dashboard contours and a downward L-bend at the front that creates a face plate that attaches to the MED bracket via two machine screws.
[0069] In one embodiment shown in FIGS. 12-19 , the bracket support arm brace is an L-shaped flat surface beam with two S-bends that accommodate the design contours of the legacy dashboard of the classic Porsche 911 and an angled 90 deg. vertical bend on one arm end that creates a face plate that provides a surface to fasten the support arm brace to the canted MED mounting platform of the bracket. One arm of the brace runs parallel to the major axis of the vehicle's dashboard in a channel along the underside of the dashboard overhang. The other arm projects outward from the dashboard to connect to the MED mounting platform of the bracket. An S-bend at the intersection of the two arms of the brace allows for a vertical offset such that the arm running outward from the dashboard axis can clear the ridge of the dashboard overhang that creates the one edge of the channel. The bend angles of this S-bend can be 60-90 deg. The channel running arm of the brace is configured with a shallow 30-45 deg. S-bend at its far end to create a vertical offset connection tab that conforms to a recessed sheet metal contour in the dashboard frame where the pre-existing air-bag cover bolt is located in certain Classic Porsche 911 vehicles. A slotted hole in the connection tab lines up with the pre-existing bolt location.
[0070] For later classic 911 Porsche models (1989-1998), the support brace is preferably anchored to the dashboard frame using a pre-existing bolt (for the passenger-side airbag cover) per the shallow S-bend tab at the far end of the brace. For the earlier classics (<1989) this bolt may not be present. For these earlier cars, the support brace design provides a way to anchor the brace to the dashboard. The legacy dashboard design and its frame create a sheet metal channel ( 15 in FIG. 2 ) under the dashboard overhang that provides a mating surface for attaching the support arm brace. Fastening can be mechanical as in drilling an “invisible” hole for a sheet metal screw or using double sided tape to adhere the upper surface of the support arm brace to the sheet metal surface under the dashboard overhang (not visible to the driver or MED user). The following detailed description of the invention references the accompanying figures. These figures illustrate, by way of example, specific embodiments of the invention. It is to be understood that the drawings are for the purposes of illustration and description only and are not intended as a definition of the limits of the invention. Other embodiments can be utilized and alterations can be made without departing from the scope of the present invention.
[0071] The materials used to make the bracket assembly can be varied, but are typically sufficiently stiff enough to resist excessive distortion under stress. Such materials can be, for example, metals and metal alloys such as aluminum, titanium, copper, stainless steel, carbon steel. Materials can also be used alone, or in combination with other metals or other plastics. Such plastics include commodity thermoplastics such as polypropylene, polyethylene and copolymers thereof and engineering thermoplastics such as acrylonitrile butadiene styrene (ABS), polycarbonate, polyamides (e.g. Nylon), polysulphone, polybutylene terephthalate (PBT), polyethylene terephthalate (PET). Plastics include composite materials e.g. plastics containing inorganic or organic fillers and/or high aspect ratio reinforcements e.g. fiberglass, carbon fibers, graphite fibers. The plastics can also be cross-linked by conventional means to control stiffness of the final part. Thermosets can also be used such as epoxy resins, phenolic resins including composites of these resins with fillers and reinforcements.
[0072] Presented each in FIGS. 1 and 12 is a schematic illustration of the MED mounting and positioning bracket assembly. Its various embodiments include constituent components: an annular ring 1 for securing one end of the bracket assembly to the vehicle's instrument housing panel; a plate 1 A contiguous and/or connected to the annular ring; a cantilevered extension 2 contiguous and/or connected to the plate 1 A for sideward positioning of MED placement; a MED mounting platform 3 contiguous and/or connected to the cantilevered extension 2 for fitting various adaptor plates and connector mechanisms to attach to MEDs and/or device holders (together, the annular ring, the contiguous plate, the cantilevered extension, and the mounting platform form a sideways “P” shape); and a bracket support arm brace 40 with connector tab 50 which fastens the other end of the bracket assembly to the dashboard and/or dashboard frame of the vehicle. The MED mounting platform 3 illustrated in FIG. 12 is equipped with two, near-center-line, countersunk holes 60 and face located holes 60 A arranged in an industry standard AMPS pattern consisting of 4 holes configured in a rectangular array spaced at 1.188 in. by 1.813 in. (30 mm by 38 mm). In this exemplary embodiment, the AMPS array is shown in both a vertical and horizontal positioned pattern. The bracket support arm brace 40 can be affixed to the bracket by various means, welding, screw connection, bolting, riveting, adhesive, and the like. The exemplary embodiment of FIG. 12 shows two countersunk holes 60 in the MED mounting platform 3 to accept machine screws for connecting an L-shaped, flat surface, bent beam serving as a support arm brace 40 to the bracket mounting platform 3 . The bracket support arm brace 40 is sized and configured to extend from the cantilevered extension 2 or MED mounting platform 3 to reach to the underside of the dash overhang 15 (shown in FIG. 2 ). The support arm brace 4 or 40 can include a positioning hole 5 or 50 A to accommodate sheet metal screw attachment of the brace to the vehicle's dashboard frame metal channel that runs along the underside of the dashboard overhang 15 . Attachment can also employ double-sided tape ( 40 A in FIG. 12 ) to join the brace and metal channel surfaces.
[0073] FIG. 2 presents an illustration of the dashboard design layout for left hand drive (LHD) vehicles which shows the location of dash attachment points for the MED mounting and positioning bracket assembly. The dashboard instrument housing panel 7 holds the fuel level and oil level gauge 8 , the oil temperature and oil pressure gauge 9 , the tachometer 10 , the speedometer 11 , and the analog clock 12 . Right hand drive (RHD) vehicles use this same instrument configuration with the instrument housing panel 7 shifted to the right hand side of the vehicle. For LHD vehicles, the analog clock 12 is used to anchor one end of the bracket assembly. Alternatively, for RHD vehicles, the fuel level and oil level gauge 8 is used as one anchoring point for the bracket assembly. Symmetry of the dash instrument configuration is such that the radii of the fuel and oil level gauge 8 and the clock 12 are equal. Accordingly, in a preferred embodiment of the invention, the annular ring 1 of the MED mounting and positioning bracket assembly is sized such that either instrument 8 or 12 can serve as one anchoring point for the bracket assembly as described below. The other end of the bracket assembly, the support arm connector tab 5 (or 50 in FIG. 12 ) attaches to the dashboard at a location along the underside of the dashboard overhang 15 . In a preferred embodiment for certain (>1989 model year vehicles), the support arm connector tab 5 (or 50 in FIG. 12 ) is fastened via an existing dashboard frame bolt 13 located under the dashboard overhang 15 just below the center vent 14 for LHD vehicles and symmetrically located in RHD vehicles. In vehicles without this existing dashboard frame bolt 13 , the support arm connector tab 5 (or 50 in FIG. 12 ) can be eliminated and the support arm brace 4 or 40 can be fastened, mechanically, to the dashboard frame using, for example, a self-tapping sheet metal screw by drilling a hidden hole in the support arm brace 4 or 40 when fitted to the vehicle into the sheet metal channel surface of the dashboard frame under the dashboard overhang 15 . Alternatively, the support arm brace 4 (or 40 ) can be attached to the vehicle using double sided tape ( 40 A in FIG. 12 ) to secure the upper surface of the support arm brace 4 (or 40 in FIG. 12 ) to the sheet metal channel surface that runs along the underside of the dashboard overhang 15 .
[0074] FIGS. 3-9 (and FIGS. 13 , 14 , 15 - 17 ) illustrate how the annular ring 1 end of the bracket assembly is secured to the vehicle dashboard instrument housing panel 7 via pressure and friction. FIG. 3 shows the analog clock 12 fitted with the ribbed rubber boot 16 that surrounds its circumference and is positioned just behind the clock's bezel 18 . The fuel level and oil level gauge 8 is likewise surrounded by a ribbed rubber boot. Perspective FIGS. 4 , 13 and 5 , 14 show that the annular ring 1 of the bracket assembly is configured with a radius and thickness such that the ring fits tightly over the ribbed rubber boot 16 that surrounds either the analog clock 12 for LHD vehicles or the fuel level and oil level gauge 8 for RHD vehicles.
[0075] The shape of the instrument housing panel 7 as illustrated in FIG. 6 is slightly concave to the driver. Because of this panel curvature, the faces of the extremity instrument openings; 8 A for the fuel level and oil level gauge 8 and 12 A for the analog clock 12 , are somewhat canted to the major axis of the vehicle dash. Since these extremity instruments are used to hold the bracket assembly flush to the face of the instrument housing panel 7 , the MED mounting and positioning platform 3 , in turn, is also canted to the major axis of the vehicle dash. This desirable canted alignment of the bracket assembly provides for excellent driver-line-of-sight positioning for a mounted MED.
[0076] When installed in a left-hand drive vehicle, the annular ring of the bracket assembly 1 sits just behind the lip 17 of the ribbed rubber boot which together with the clock bezel 18 serves as a flange that holds the bracket assembly securely to the face of the instrument housing panel 7 by pressure and friction. The ribbed rubber boot holds the clock securely in position when inserted and pressed into the far right extremity opening 12 A in the instrument housing panel 7 as shown in FIG. 6 and similarly for right-hand drive vehicles which uses the fuel level and oil level gauge 8 and right hand opening 8 A of the instrument housing panel.
[0077] FIGS. 7 and 15 show the MED mounting and positioning bracket assembly secured to the instrument housing panel 7 for a left-hand drive vehicle with the annular ring 1 sandwiched between the flange created by the clock bezel 18 and lip of the ribbed rubber boot 16 on the clock 12 and the face of the instrument housing panel 7 . FIGS. 8 and 16 show a front view and FIGS. 9 and 17 a rear view of this bracket assembly installation.
[0078] FIGS. 10 and 18 illustrate how the bracket assembly's MED mounting platform 3 configured with an industry standard AMPS hole pattern consisting of 4 holes located in a rectangular array spaced at 1.188 in. by 1.813 in. (30 mm by 38 mm) accepts, for example, an MED adaptor plate 19 equipped with a 17 mm swivel ball 20 used in ball and socket attachments of various MEDs or their holding docks or cradles.
[0079] FIGS. 11 and 19 show that to further increase the canting of the bracket's MED support platform off the major axis of the dashboard, a wedge plate 21 can be inserted between the bracket assembly and the MED adaptor plate.
[0080] FIG. 20 illustrates a truncated version of the MED mounting and positioning bracket with: an annular ring 1 for securing the bracket assembly to the vehicle's instrument housing panel; a plate 1 A contiguous and/or connected to the annular ring; and a MED mounting platform 3 contiguous and/or connected to plate 1 A for fitting various adaptor plates and connector mechanisms to attach to MEDs and/or device holders. In this version of the bracket, the cantilevered extension 2 is absent which allows for installation in the constrained space to the left of the steering wheel on the fuel level and/or oil level gauge 8 in Left Hand Drive (LHD) vehicles and to the right of the steering wheel on the analog clock 12 in Right Hand Drive (RHD) vehicles. Because there is no under dashboard sheet metal channel in this location, this bracket installation does not incorporate a support arm brace. Of course, this truncated bracket could also be positioned on the clock for LHD vehicles and/or the fuel level and/or oil level gauge in RHD vehicles.
[0081] FIG. 21 illustrates another version of the MED mounting and positioning bracket with: an annular ring 1 for securing the bracket assembly to the vehicle's instrument housing panel; a plate 22 contiguous and/or connected to the annular ring; and a MED mounting platform 3 contiguous and/or connected to plate 22 for fitting various adaptor plates and connector mechanisms to attach to MEDs and/or device holders. In this version of the bracket, the cantilevered extension 2 is absent. In the embodiment shown in FIG. 21 , plate 22 is a cylindrical arc shaped plate projecting outward from the plane of the annular ring 1 to the MED mounting platform 3 . It can be placed on or attached to the annular ring along a portion of the annular ring circumference, usually within an arc span of about 10 to about 180 degrees of the total 360 degrees of the ring circumference, but preferably the arced plate 22 is placed on about 15 to about 60 degrees of the annular ring arc, more preferably from about 25 to about 35 degrees of the annular ring arc. In FIG. 21 , the plate 22 is shown extending outward from the plane of the annular ring at about a 90 degree (perpendicular) angle. In other embodiments, plate 22 can project outward from the plane of the annular ring at acute or oblique angles up to about 30 degrees from perpendicular. Generally, however, plate 22 is positioned as shown in FIG. 21 . In FIG. 21 , the MED mounting platform 3 is shown cantilevered from plate 22 at a 90 degree (perpendicular) angle to the outward projecting axis of plate 22 . In other embodiments, the MED mounting platform can be configured at acute or oblique angles to the outward projecting axis of plate 22 up to about 30 degrees from perpendicular. In another embodiment of this bracket design, the MED Mounting platform 3 can be shifted sideways in position away from the centerline of the annular ring 1 by incorporating a cantilevered extension between the cylindrical arc plate 22 and the MED mounting platform 3 . Plate 22 need not be uniform in its projected arc width or thickness; that is, the plate may be relatively wide or thick at the attachment point to the annular ring, and then narrow or thin as it meets the MED mounting platform 3 (or vice versa). Because there is also no under dashboard sheet metal channel in this location (as in FIG. 20 ), this bracket installation does not incorporate a support arm brace. This bracket can be positioned on the clock and/or the fuel level and/or oil level gauge for either LHD or RHD vehicles.
[0082] Ball and socket attachment of an MED holding dock or cradle allows for multi-axis tilt and/or cant adjustment of MED screen position for fine tuning its driver-line-of-site visibility.
[0083] As described in the background section, because of the continuity in dashboard shape, configuration, and instrument housing panel arrangement throughout the thirty three year production of classic 911s, the design of the MED mounting and positioning bracket systems described herein work with essentially all classic Porsche 911s. Tweaks in certain bracket dimensions may be required for the earliest vehicles but, in general, the design fits all classic air cooled Porsche 911s from about the 1970 models through to the last of the 1998 993 model vehicles.
[0084] In a preferred embodiment of the MED mounting and positioning bracket systems described herein, the annular ring 1 of these systems is designed to attach to either of the extremity instruments, the fuel level and oil level gauge 8 or the analog clock 12 in the instrument housing panel 7 of the classic Porsche 911. In another embodiment of the invention, the bracket assembly annular ring 1 can be sized with a larger radius such that it fits over the ribbed rubber boot that surrounds either the larger diameter oil temperature and oil pressure gauge 9 or the speedometer 11 . In this embodiment, the cantilevered extension 2 of the bracket assembly is lengthened to position the MED mounting platform 3 in a driver-convenient location. As described previously, the annular ring is held in place by pressure and friction as it sits sandwiched between the flange created by gauge bezel and lip of the ribbed rubber boot and the face of the instrument housing panel 7 when the gauges 9 or 10 are pressed into openings 9 A or 11 A shown in FIG. 6 .
[0085] In some embodiments of the invention, the horizontal centerline of the MED mounting platform 3 is configured to reside either above or below the horizontal centerline of the bracket assembly's cantilevered extension 2 thus raising or lowering the position of the mounted MED relative to the driver's line-of-sight.
[0086] In another embodiment of the invention, canting of the MED mounting support platform to the major axis of the vehicle dash is achieved by implementing a vertical bend of the cantilevered extension 2 constituent of the bracket assembly.
[0087] In a further embodiment of the invention, affixing just the annular ring 1 of the bracket to the instrument housing panel 7 may be sufficient to provide stability and rigidity for secure MED mounting without need for a support arm brace 4 . In another embodiment, a MED mounting platform may be positioned and secured using just the support arm 4 without the annular ring attachment.
[0000]
TABLE 1
Listing of Figure Label Items
Label
Description
1
Annular ring
1A
Plate
2
Cantilevered Extension
3
MED mounting platform
4/40
Bracket support arm brace
5/50
Connector tab
6/60
Countersunk holes
7
Dashboard instrument housing panel
8
Fuel level/oil level gauge
9
Oil temperature/oil pressure gauge
10
Tachometer
11
Speedometer
12
Analog clock
13
Dashboard frame bolt
14
Center vent
15
Dash overhang (Sheet metal channel underneath)
16
Ribbed rubber boot
17
Ribbed rubber boot lip
18
Clock bezel
8A
Left extremity opening on instrument panel (for fuel
level/oil level gauge)
9A/11A
Instrument openings (for, respectively, oil temperature/oil
pressure gauge 9 and speedometer 11)
12A
Right extremity opening (for analog clock)
19
MED adaptor plate
20
Swivel ball
21
Wedge plate
22
Cylindrical arc plate
40A
Double sided tape
50A
Positioning hole
60A
Face located holes arranged in AMPS pattern (in FIG. 12)
[0088] While the invention has been described and illustrated in accordance with particular embodiments, it is to be understood that there are many variations and modifications to the configuration of the MED mounting and positioning bracket assembly which may be made by those skilled in the art. Accordingly, the invention is not restricted to the details of the forgoing embodiments; it is limited only by the spirit and scope of the claims.
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A novel bracket assembly enables secure retrofit mounting and positioning of a mobile electronic device (MED) such as smart phone, portable GPS navigation appliance, iPod/MP3 player, or satellite radio to an ideal, driver-convenient locale. The vehicle-specific bracket system design provides for easy driver-line-of-sight device-interaction without causing interference with vehicle operation, windshield visibility, ventilation, or switch controls.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a divisional application of U.S. application Ser. No. 13/365,743 filed Feb. 3, 2012.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not Applicable.
REFERENCE TO SEQUENCE LISTING, A TABLE OR COMPUTER PROGRAM LISTING, COMPACT DISK APPENDIX
Not Applicable.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to pallet truck adapters and, more particularly, to a method for moving pallets from place to place on a pallet truck.
2. Background Art
Pallet truck adapters are typically mounted on the tines of a fork lift truck, walkie rider or pallet jack, in order to more specifically adapt the truck to particular uses. The term “pallet truck” as used herein refers to any mobile device designed to carry pallets on tines which can be inserted beneath the pallet and raised to lift the pallet for carrying and lowered to place the pallet at a desired location. Thus, “pallet truck” encompasses a fork lift truck, a so called walkie rider, a pallet jack, or like device. Such trucks typically have a pair of tines, though sometimes more, which are inserted under a pallet. However, the term “tine” is intended to include a single pallet lifting platform, or several tines, serving the same lifting, carrying and lowering function of the more typical pair of tines. Likewise, the tines of a walkie rider or pallet jack are often thicker than those of a fork lift truck, and often include floor engaging wheels located in the tines, which are associated with a lifting mechanism located in the tines, such that as the tines are elevated, the wheels continue to make contact with the floor.
SUMMARY OF THE INVENTION
In accordance with the invention, a method is provided for moving pallets from place to place on a pallet truck. The pallets are sufficiently small in width so that two can be moved on a set of pallet truck tines. The method includes providing a pallet truck adapter having at least a pair of shoes for fitting over pallet supporting tines. The shoes have bottoms, tops, and sides. The shoe bottoms are both in approximately the same plane, and the shoes are of differing heights. The method in accordance with the invention comprises manipulating the pallet truck so as to locate the taller shoe beneath a first pallet resting on the floor. The pallet adapter is then lifted slightly off of the supporting surface by raising the pallet truck tines. The first pallet is then moved, and the lower shoe of the adapter is located beneath a second pallet resting on the floor. The adapter is further raised to also lift the second pallet off the floor. Both the first and second pallets are thus moved about, and are deposited in the same location, or alternatively, in separate locations, by lowering the adapter such that the second pallet makes contact with the supporting floor first, and then the first pallet makes contact with the supporting surface.
These and other objects, advantages and features of the present invention will be more fully understood and appreciated by reference to the specification and appended drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a slightly elevated perspective view of the pallet truck adapter of the preferred embodiment;
FIG. 2 is a bottom plan view of the adapter;
FIG. 3 is a rear elevation of the adapter
FIG. 4 is a cross sectional view of the adapter taken along plane IV-IV of FIG. 1 , with the support legs in their elevated position;
FIG. 5 is the same cross sectional view with the legs in their lowered position;
FIG. 6 is an exploded view of the leg assembly, showing the leg in its elevated position;
FIG. 7 is an enlarged cross sectioned perspective view of a portion of the adapter, showing the manner in which the detent pin helps hold the leg in its elevated position.
FIG. 8 is the same view as FIG. 7 , showing the manner in which the detent pin helps hold the leg in its lowered position.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the preferred embodiment, pallet truck adapter 1 comprises a right shoe 10 a and a left shoe 10 b for fitting over the tines of a pallet truck, joined by a backstop plate 2 and a bottom brace 3 . ( FIGS. 1-3 ) Backstop plate includes spaced openings 2 a one of which is aligned with the interior of right shoe 10 a and the other of which is aligned with the interior of left shoe 10 b . This allows the tines of a fork lift truck to be inserted into shoes 10 a and 10 b , so that adapter 1 can be raised and lowered with the tines of the fork lift truck.
Each shoe 10 a - b includes a retractable leg assembly 20 . Legs 21 of each assembly can be retracted as shown in FIGS. 4 and 6 , or lowered as shown in FIGS. 1, 3 and 5 , by pulling or pushing, respectively, an actuator rod 30 . Legs 21 are sufficiently long that, when lowered, they leave a gap between the bottom of shoes 10 a and 10 b and the floor on which adapter 1 is resting. This gap is tall enough that the tines of a walkie rider, pallet jack or like device having tines with floor engaging wheels can slide underneath adapter 1 , to facilitate adapter 1 being raised and lowered with the walkie rider tines.
Once the tines of a fork lift or walkie rider are inserted fully into or beneath, respectively, shoes 10 a and 10 b , chain and quick-disconnect clip 4 can be used to secure adapter 1 to the fork lift truck or walkie rider. Preferably clip 4 is a carabiner clip. If the legs 21 had been in their lowered position, they can be raised.
Preferably, each shoe 10 a and 10 b is sufficiently wide to stably support a half size pallet, with legs depending downwardly on opposite sides of the shoe. The shoes are sufficiently short from top to bottom that the legs of the pallet extend below the bottom of the shoes. Thus, a forklift truck or walkie rider with adapter 1 attached can be driven into position with the one or both of the shoes of adapter 1 passing beneath a pallet or pair of side by side pallets, each shoe passing between the legs of a pallet. When the tines are raised, adapter 1 and pallets supported thereon are raised accordingly. When the tines are lowered, adapter 1 is lowered, and the pallet legs come to rest on the floor at the location desired for their placement. The walkie rider or forklift truck can then be operated in reverse, so that shoes 10 a and 10 b slide out from under the pallet or pallets.
The sidewalls of right shoe 10 a are taller than the sidewalls 12 of left shoe 10 b . Shoes 10 a and 10 b are arranged with their bottoms aligned. In this way, right shoe 10 a can be used to pick up or drop off a pallet in a different location than left shoe 10 b . Thus for pickup, right shoe 10 a can be slid into position below a first pallet, raised slightly to lift the first pallet off of the floor, and the truck or walkie rider moved to a different location for picking up another pallet using left shoe 10 b . Because it is shorter in height, left shoe 10 b can be slid under a second pallet while the first pallet is held slightly elevated off of the floor. The tines of the forklift truck or walkie rider can then be elevated still farther until both the first and second pallets are lifted off of the floor. The pallets can then be moved to a different location and the tines, and accordingly shoes 10 a and 10 b , lowered sufficiently that the pallet being carried by the shorter shoe 10 b engages the floor. Shoe 10 b can be slid out from beneath the pallet which is now supported by the floor, leaving it in place. The truck or walkie rider is then moved to a different location where its tines are lowered still farther so that the first pallet supported by the taller shoe 10 a engages the floor. Shoe 10 a can then be removed from beneath the pallet so lowered to the floor. If adapter 1 is no longer needed on the times, it can be driven to a storage location, legs 21 rotated downwardly into their erected position by pulling on actuator rod 30 , and adapter 1 lowered to the floor by lowering the tines. Once it is resting on the floor, the forklift or walkie rider can be operated in reverse to remove the tines from within or from beneath adapter 1 , respectively.
Adapter 1 is preferably made of steel or other rugged material. Each shoe 10 a and 10 b is box-like in configuration, having a top wall 11 , downwardly depending sidewalls 12 and a generally open bottom. Bottom braces 13 which are “L” shaped in cross section extend across the open bottom of each shoe 10 a and 10 b , between the opposite sidewalls 12 . Two cross braces 13 are located towards the front of each shoe. A third cross brace 13 is positioned generally midway between the front of the shoe and its junction with back plate 2 . The fourth brace 13 is positioned adjacent backstop plate 2 , and the vertical leg of the fourth brace is secured to backstop plate 2 .
Elongated load support strips 14 are located on shoe top plate, near each of the opposed side edges thereof. A pallet being supported by shoe 10 a or 10 b will rest on load support strips 14 . Each shoe 10 a - b has a side wall 12 facing inwardly towards the inwardly facing side wall 12 of the other shoe, and an outwardly facing sidewall 12 which faces away from the adjacent shoe. Located at the bottom of each shoe 10 a - b , and towards the outwardly facing sidewall 12 of each shoe 10 a - b is a bottom guide rail 15 , also referred to herein as a walkie tine guide rail 15 . Each guide rail 15 is generally “L” shaped in cross section so that it has a downwardly extending leg. The tines of a walkie rider can slide between guide rails 15 . Each guide rail 15 on each shoe 10 a and 10 b is bolted to the front, middle and back bottom braces 13 . As shown in FIG. 2 , guide rails 15 are spaced at their maximum distance apart. Alternative bolt holes 13 a are provided on the front, middle and back bottom braces 13 so that guide rails 15 can be moved closer towards one another, thereby providing for a reasonably close fit at the outside edges of walkie rider tines, no matter what the combined width of the walkie rider tines is.
Located in the interior of each shoe 10 a and 10 b are spaced inner and outer interior guide rails 16 and 17 ( FIGS. 1, 2 ), sometimes referred to herein as forklift tine guide rails 16 and 17 . These guide rails are “L” shaped in cross section. Each outside rail 17 is the taller of the two, and is adjustably secured to the underside of shoe top wall 11 . Guide rail 17 serves not only as a guide rail for the forklift tines which are inserted through openings 2 a in the backstop wall 2 , but also serves to protect the retractable leg assembly 20 from being hit by the forklift tines as they are inserted into the shoes 10 a and 10 b . The inner forklift tine guide rails 16 are mounted on mounting bars 16 a , which in turn are secured to the underside of shoe top wall 11 . Outer guide rail 17 can be adjusted to one of several different positions, in order to accommodate forklift tines of differing widths between outer interior guide rail 17 and inner interior guide rail 16 .
The retractable leg assembly 20 comprises legs 21 pivotably mounted between outer and inner mounting plates 22 and 23 , respectively, and joined at their tops by an elongated actuator rod 30 ( FIGS. 4-6 ). The outside mounting plate 22 is secured to the outwardly facing shoe wall 12 by fasteners 22 a , 22 b and 22 c ( FIGS. 1, 7 and 8 ). Each leg 21 and a leg stop block 24 are positioned between outer mounting plate 22 and inner mounting plate 23 . Leg stop block 24 includes a raised leg stop surface 24 a , and a lowered leg stop surface 24 b . These surfaces limit the position of the legs 21 in their raised and lowered positions respectively.
Locator pins 25 pass through mating holes in inner mounting plate 23 , leg stop block 24 and outer mounting plate 22 ( FIG. 6 ). Rear mounting bolts 26 pass through apertures at the rear of inner mounting plate 23 , the rear of leg stop block 24 and are threaded into receiving apertures in outer mounting plate 22 . Forward mounting bolt and pivot axle 27 passes through a forward aperture in inner mounting plate 23 , passes through a bushing 28 which itself is located in a pivot aperture 21 a located about two-thirds up the length of leg 21 . Bolt 27 then threads into a forwardly and centrally located threaded aperture in outer mounting plate 22 .
An elongated control rod 30 and a stabilizer bar 31 are connected to the upper ends of each pair of front and rear legs 21 . Control rod connector bolts 31 a pass through apertures in stabilizer bar 31 , and through bushings 31 b which are positioned in leg aperture 21 b near the upper ends of legs 21 . Bolts 31 a are then threaded into receiving apertures in control rod 30 . A control rod actuator knob 32 is threaded onto a threaded member 33 which in turn threads into a nut 34 which is welded or otherwise secured to the end of control rod 30 . Control knob 32 is located at or near the front opening in shoe 10 a - b , so as to be readily manipulated. By pulling on control knob 32 , one pulls on control rod 30 , causing legs 21 to rotate downwardly until they hit leg stop surface 24 b . Similarly, legs 21 can be raised (retracted) by pushing against knob 32 and rod 30 to rotate legs 21 upwardly until they engage leg stop surface 24 a.
A detent member 29 is provided to engage at least one of the legs 21 to hold it in its retracted or extended position. Detent 29 is a threaded member having an internal spring loaded plunger. It is threaded into a nut 29 a which is welded or otherwise secured to inner mounting plate 23 until the tip of detent 29 engages leg 21 with the desired force.
FIG. 7 is a partially cross sectioned view which shows the relative positions of the control rod 30 and leg 21 in the legs retracted position. FIG. 8 is the same cross sectional view, but showing the relationship between the components when leg 21 is in its lowered (extended) position.
In operation, pallet truck adapter 1 will be stored in some location, preferably with legs 21 extended. Legs 21 don't have to be extended if adapter 1 is going to be used with a forklift truck rather than a walkie rider. Indeed, leg assemblies 20 can be omitted entirely if the adapter is to be used solely with a fork lift truck. However with legs 21 in their extended, erect position, adapter 1 can be loaded onto the tines either of a forklift truck, which are inserted through openings 2 A in backstop plate 2 and on into the interior of shoes 10 A and 10 B, between forklift tine rails 16 and 17 ; or alternatively, the tines of a walkie rider can be slid underneath adapter 1 with its legs 21 extended, and with the walkie rider tines positioned between the walkie tine guide rails 15 . The position of guide rails 15 can be adjusted to accommodate wider or narrower walkie rider tines. Similarly, the adjustable outer forklift tine rails 17 can be adjusted to different positions to accommodate forklift tines of differing widths.
With the forklift or walkie rider tines in position, adapter 1 can be quickly secured to the truck or walkie rider using the quick disconnect clip 4 . The tines are then raised to lift adapter 1 off of the floor, control knob 32 is pushed to cause legs 21 to retract into their upper position, and adapter 1 is now ready for use in conjunction with the walkie rider or forklift truck.
The truck or walkie rider is conveyed to the location of a “half pallet,” and taller shoe 10 a is inserted between the legs and beneath the bottom surface of the pallet. The pallet can then be raised slightly by raising the tines and the adapter 1 , moved to another location and the shorter shoe 10 b can then be inserted between the legs and below another half pallet. By raising the tines still further, the second pallet is also lifted off of the floor. The process can then be reversed to deposit the two pallets in the same or different destination positions.
Upon completion of use, the adapter can be stored by pulling on control knob 32 and control rod 30 to again extend the legs. The tines are lowered until the adapter 1 is resting on the floor, and the tines can then be removed by reversing the walkie rider or forklift truck.
Of course it is understood that the foregoing is a preferred embodiment of the invention and that various changes and alterations can be made without departing from the spirit and broader aspects of the invention.
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A pallet truck adapter having side by side shoes for fitting over pallet supporting tines, in which the shoes are of different heights. This facilitates locating one pallet on the higher shoe, lifting it slightly off of the supporting surface, and then moving to and lifting another pallet on the lower shoe. The adjacent pallets can then be moved together and off loaded at different locations, unloading the pallet on the lower shoe first, and the pallet on the higher shoe thereafter.
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FIELD OF THE INVENTION
The present invention is directed to a moisturizing composition comprising an aminopeptide mixture. More particularly, the invention is directed to a moisturizing composition that replenishes the skin's natural moisturization factor while surprisingly delivering excellent sensory benefits. The composition of this invention is not sticky or draggy, has components suitable to penetrate various segments of the stratum corneum and does not become unpleasantly viscous during and after application.
BACKGROUND OF THE INVENTION
The Natural Moisturizing Factor (NMF) of skin contains the components “responsible” for keeping skin healthy and making sure the structure of the epidermis is intact of skin moisturization. NMF exists within the corneocytes in top layers of the stratum corneum, the outer most layer of the epidermis. NMF is a product of proteolysis of filaggrin, which aids self-assembly of keratin intermediate filaments that form the corneocytes. Depletion of NMF in upper layers of the stratum corneum (often associated with skin washing) can induce dry skin conditions, especially in the winter. In other cases, when the gene producing filaggrin protein is mutant, NMF levels in human skin are significantly reduced, leading to severe skin dryness and even dermatological disorders such as atopic dermatitis and Ichthyosis vulgaris.
Regardless of the cause associated with NMF reduction, topical application of compositions designed to mimic NMF is difficult since such compositions are thick upon application, and undesirable for consumer use. In fact, such known compositions result in an unpleasant sticky layer that offers little sensory benefits to consumers in need of skin moisturization.
In view of the above, there is an increasing interest to develop compositions that deliver components to moisturize skin in a manner that mimics the body's NMF. Moreover, it is desirable to develop such so that the same do not comprise high viscosity and unpleasant stickiness characteristics, especially during application and after applying. This invention, therefore, is directed to a moisturizing composition comprising an aminopeptide mixture. The composition mimics and replenishes the skin's NMF while surprisingly delivering excellent sensory benefits. The composition of this invention is not sticky and draggy, has components suitable to penetrate various segments of the stratum corneum and does not become unpleasantly viscous (i.e., sticky) during and after application.
ADDITIONAL INFORMATION
Efforts have been disclosed for making topical skin compositions. In DE 4127790A, skin-care cosmetics having oligopeptide and metal complexes are described.
Other efforts have been disclosed for making topical compositions. In U.S. Pat. No. 7,659,233, personal care compositions with silicones and dihydroxypropyl trialkyl ammonium salts are described.
None of the additional information above describes a composition with an aminopeptide mixture as described in this invention.
Even other efforts have been disclosed for making topical compositions. In U.S. Patent Application No. 2004/0247631, compositions for skin moisturizing are described.
SUMMARY OF THE INVENTION
In a first aspect, the present invention is directed to a composition for moisturizing skin, the composition comprising:
a) an aminopeptide mixture comprising:
i. water soluble amino acid or functionalized amino acid; ii. water soluble dipeptide having a molecular weight from about 150 to about 410; iii. water soluble tripeptide having a molecular weight from about 225 to about 600, water soluble vitamin or vitamin derivative comprising peptide bonds or both; and
b) cosmetically acceptable carrier
wherein amino acid and water soluble dipeptide together make up from 50 to 99% by weight of the total weight of the aminopeptide mixture.
In a second aspect, the present invention is directed to a method of moisturizing skin by applying components that mimic the skin's NMF, the method comprising the step of contacting skin with the composition of the first aspect of this invention.
Skin, as used herein, is meant to include skin on the face, neck, chest, back, arms (including underarms) hands, legs, buttocks and scalp. Water soluble, as used herein, means that at least 0.5 grams of material dissolves in 100 ml of water at 25° C. Comprising, as used herein, is meant to include consisting essentially of and consisting of. For the avoidance of doubt, the aminopeptide mixture of this invention may consist essentially of or consist of amino acid, dipeptide and tripeptide. All ranges identified herein are meant to include all ranges subsumed therein if, for example, reference to the same is not explicitly made.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The only limitation with respect to the amino acid or functionalized amino acid that may be used in this invention is that the same may be used in a topical composition and is water soluble. Typically, the amino acids have a partitioning coefficient defined as log kp from −4.5 to 0; and preferably, from −4.5 to −1; and most preferably, from −4.5 to −2 in n-octanol-water (as described in Journal of Chromatography, 216 (198 I) 79-92 Elsevier Scientific Publishing Company, Amsterdam—Printed in The Netherlands CHROM. 14,027).
Preferably, the same have a molecular weight from about 70 to about 225. Illustrative yet non-limiting examples of amino acid or functionalized amino acid suitable for use in this invention include glutamine, aspargine, glycine, glutamic acid, threonine, lysine, alanine, serine, hydroxyproline, N-acetyl-L-tyrosine, N-acetyl-L-hydroxyproline, N-acetyl-L-cysteine, L-ornitine monochloride or a mixture thereof.
With respect to the water soluble dipeptides suitable for use, preferred include glycyl-L-glutamate, glycyl-L-tyrosine, L-alanyl-L-glutamine, glycyl glycine, lysyl lysine, glycyl alanine, glycyl lysine, glycyl histidine, or a mixture thereof.
The tripeptides which are water soluble and suitable for use in this invention include L-glutathione, gamma-L-glutamyl-L-cysteinyl-glycine), S-methylglutathione, glycl-prolyl-glutamic acid, lysyl-tyrosyl-lysine, lysyl-tyrosyl-lysine, glycyl-glycyl-histidine, lysyl-lysyl-lysine or a mixture thereof. Water soluble vitamin comprising peptide bond which may be used in this invention includes, for example, D-L-panthenol. An example of a water soluble vitamin derivative suitable for use includes calcium pantetheine-S-sulfonate.
In a preferred embodiment, the total weight of amino acid and dipeptide in the aminopeptide mixture is from about 50 to about 80%, and most preferably, from about 60 to about 75% by weight amino acid and dipeptide based on total weight of amino acid, dipeptide and tripeptide in the aminopeptide mixture.
Optimally, amino acid makes up from about 5 to about 50% by weight of the total weight of amino acid, dipeptide and tripeptide in the aminopeptide mixture; and most optionally, 10 to about 30% by weight.
Typically, aminopeptide mixture makes up from about 0.5 to about 35%, and preferably, from about 2 to about 20%, and most preferably, from about 6 to about 12% by weight of the total weight of the composition.
In an especially preferred embodiment the aminopeptide mixture employed in this invention has a glass transition temperature from about −75 to about 15° C., and most preferably, from about −48 to about 12° C., and optionally, from about −40 to about 5° C., including all ranges subsumed therein. In a most optimal embodiment, the glass transition temperature of the aminopeptide mixture is from about −17 to about 2° C. when the water concentration of the aminopeptide mixture ranges from about 9 to about 16%.
Compositions of the present invention will typically include cosmetically acceptable carrier components. Water is the most preferred additional carrier. Amounts of water may range from about 1 to about 99%, and preferably, from about 5 to about 90%, and most preferably, from about 35 to about 80%, and optimally, from about 40 to about 75% by weight, based on total weight of the composition for coloring skin and including all ranges subsumed therein. Ordinarily the compositions of this invention will be water and oil emulsions, most preferably, of the oil-in-water variety. Water-in-oil emulsions, and especially, those generally classified as water-in-oil and high internal phase emulsions are, however, an option. Illustrative examples of the high internal phase emulsions suitable to carry the beads of this invention are described in commonly owned U.S. Patent Application Publication Nos. 2008/0311058 and 2009/0247445, the disclosures of which are incorporated herein by reference.
Other cosmetically acceptable carriers suitable for use in this invention may include mineral oils, silicone oils, synthetic or natural esters, and alcohols. Amounts of these materials may range from about 0.1 to about 50%, and preferably, from about 0.1 to about 30%, and most preferably, from about 1 to about 20% by weight of the composition, including all ranges subsumed therein.
Silicone oils may be divided into the volatile and non-volatile variety. The term “volatile” as used herein refers to those materials which have a measurable vapor pressure at ambient temperature. Volatile silicone oils are preferably chosen from cyclic or linear polydimethylsiloxanes containing from about 3 to about 9, and preferably, from about 4 to about 5 silicon atoms.
Linear volatile silicone materials generally have viscosities of less than about 5 centistokes at 25° C. while cyclic materials typically have viscosities of less than about 10 centistokes.
Nonvolatile silicone oils useful as carrier material include polyalkyl siloxanes, polyalkylaryl siloxanes and polyether siloxane copolymers. The essentially non-volatile polyalkyl siloxanes useful herein include, for example, polydimethylsiloxanes (like dimethicone) with viscosities of from about 5 to about 100,000 centistokes at 25° C.
An often preferred silicone source is a cyclopentasiloxane and dimethiconol solution.
Among suitable esters are:
(1) Alkenyl or alkyl esters of fatty adds having 10 to 20 carbon atoms like isopropyl palmitate, isopropyl isostearate, isononyl isonanonoate, oleyl myristate, isopropyl myristate, oleyl stearate, and oleyl oleate; (2) Ether-esters such as fatty acid esters of ethoxylated fatty alcohols; (3) Polyhydric alcohol esters such as ethylene glycol mono- and di-fatty acid esters, diethylene glycol mono- and di-fatty acid esters, polyethylene glycol (200-6000) mono- and di-fatty acid esters, propylene glycol mono- and di-fatty acid esters, polypropylene glycol 2000 monooleate, polypropylene glycol 2000 monostearate, ethoxylated propylene glycol monostearate, glyceryl mono- and di-fatty acid esters, polyglycerol poly-fatty esters, ethoxylated glyceryl monostearate, 1,3-butylene glycol monostearate, 1,3-butylene glycol distearate, polyoxyethylene polyol fatty acid ester, sorbitan fatty acid esters, and polyoxyethylene sorbitan fatty acid esters; (4) Wax esters such as beeswax, spermaceti, myristyl myristate, stearyl stearate; and (5) Sterol esters, of which soya sterol and cholesterol fatty acid esters are examples thereof.
Emulsifiers may be present in the composition for moisturizing skin of the present invention. Total concentration of the emulsifier may range from about 0.1 to about 40%, and preferably, from about 1 to about 20%, and most preferably, from about 1 to about 5% by weight of the composition, including all ranges subsumed therein. The emulsifier may be selected from the group consisting of anionic, nonionic, cationic and amphoteric actives. Particularly preferred nonionic actives are those with a C 10 -C 20 fatty alcohol or acid hydrophobe condensed with from about 2 to about 100 moles of ethylene oxide or propylene oxide per mole of hydrophobe; C 2 -C 10 alkyl phenols condensed with from 2 to 20 moles of alkylene oxide; mono- and di-fatty acid esters of ethylene glycol; fatty acid monoglyceride; sorbitan, mono- and di-C 3 -C 20 fatty acids; and polyoxyethylene sorbitan as well as combinations thereof. Alkyl polyglycosides and saccharide fatty amides (e.g. methyl gluconamides) are also suitable nonionic emulsifiers.
Preferred anionic emulsifiers include alkyl ether sulfate and sulfonates, alkyl sulfates and sulfonates, alkylbenzene sulfonates, alkyl and dialkyl sulfosuccinates, C 8 -C 20 acyl isethionates, C 8 -C 20 alkyl ether phosphates, alkylethercarboxylates and combinations thereof.
Cationic emulsifiers that may be used include, for example, palmitamidopropyltrimonium chloride, distearyldimonium chloride and mixtures thereof. Useful amphoteric emulsifiers include cocoamidopropyl betaine, C 12 -C 20 trialkyl betaines, sodium lauroamphoacetate, and sodium laurodiamphoacetate or a mixture thereof.
Additional emulsifiers that may be used in this invention include amino acid derived amphiphilic compounds such as sodium dilauramidoglytamide lysine (known also under the tradename Pellicer™ L-30), N-acyl arginine methylester hydrochloride with the acyl group containing from 8 to 14 carbon atoms, and N-alkyl amide and ester derivatives of arginine, histidine, lysine, aspartic acid or glutamic acid containing 8 to 14 carbon atoms.
Other generally preferred emulsifiers include glyceryl stearate, glycol stearate, stearamide AMP, PEG-100 stearate, cetyl alcohol as well as emulsifying/thickening additives like hydroxyethylacrylate/sodium acryloyldimethyl taurates copolymer/squalane and mixtures thereof.
Preservatives can desirably be incorporated into the compositions for moisturizing skin of this invention to protect against the growth of potentially harmful microorganisms. Suitable traditional preservatives for compositions of this invention are alkyl esters of para-hydroxybenzoic acid. Other preservatives which have more recently come into use include hydantoin derivatives, propionate salts, and a variety of quaternary ammonium compounds. Cosmetic chemists are familiar with appropriate preservatives and routinely choose them to satisfy the preservative challenge test and to provide product stability. Particularly preferred preservatives are iodopropynyl butyl carbamate, phenoxyethanol, methyl paraben, propyl paraben, imidazolidinyl urea, sodium dehydroacetate and benzyl alcohol. The preservatives should be selected having regard for the use of the composition and possible incompatibilities between the preservatives and other ingredients in the emulsion. Preservatives are preferably employed in amounts ranging from about 0.01% to about 2% by weight of the composition, including all ranges subsumed therein.
Thickening agents may optionally be included in compositions of the present invention. Particularly useful are the polysaccharides. Examples include starches, beta-glucan, natural/synthetic gums and cellulosics. Representative of the starches are chemically modified starches such as sodium hydroxypropyl starch phosphate and aluminum starch octenylsuccinate. Tapioca starch is often preferred. Suitable gums include xanthan, sclerotium, pectin, karaya, arabic, agar, guar, carrageenan, alginate and combinations thereof. Suitable cellulosics include hydroxypropyl cellulose, hydroxypropyl methylcellulose, ethylcellulose and sodium carboxy methylcellulose. Synthetic polymers are yet another class of effective thickening agent. This category includes crosslinked polyacrylates such as the Carbomers, polyacrylamides such as Sepigel® 305 and taurate copolymers such as Simulgel EG® and Aristoflex® AVC, the copolymers being identified by respective INCI nomenclature as Sodium Acrylate/Sodium Acryloyldimethyl Taurate and Acryloyl Dimethyltaurate/Vinyl Pyrrolidone Copolymer. Another preferred synthetic polymer suitable for thickening is an acrylate-based polymer made commercially available by Seppic and sold under the name Simulgel® INS100.
Amounts of the thickener, when used, may range from about 0.001 to about 5%, and preferably, from about 0.1 to about 2%, and most preferably, from about 0.2 to about 0.5% by weight of the composition including all ranges subsumed therein.
Conventional humectants may be employed in the present invention. These are generally polyhydric alcohol-type materials. Typical polyhydric alcohols include glycerol (i.e., glycerine or glycerin), propylene glycol, dipropylene glycol, polypropylene glycol, polyethylene glycol, sorbitol, hydroxypropyl sorbitol, hexylene glycol, 1,3-butylene glycol, isoprene glycol, 1,2,6-hexanetriol, ethoxylated glycerol, propoxylated glycerol and mixtures thereof. Most preferred is glycerin, propylene glycol or a mixture thereof. The amount of humectant employed may range anywhere from 0.5 to 20%, preferably between 1 and 15% by weight of the composition.
Fragrances, colorants, fixatives and abrasives may optionally be included in compositions of the present invention. Each of these substances may range from about 0.05 to about 5%, preferably between 0.1 and 3% by weight.
Turning to the other components including actives suitable for use herein, the same can include opacifiers like TiO 2 and ZnO and colorants like iron oxide red, yellow and black. Such opacifiers and colorants typically have a particle size from 50 to 1200 nm, and preferably, from 50 to 350 nm.
To even further enhance skin moisturization, actives classified as cationic ammonium compounds may optionally be used in the compositions of this invention. Such compounds include salts of hydroxypropyltri(C 1 -C 3 alkyl)ammonium mono-substituted-saccharide, salts of hydroxypropyltri(C 1 -C 3 alkyl)ammonium mono-substituted polyols, dihydroxypropyltri(C 1 -C 3 alkyl)ammonium salts, dihydroxypropyldi(C 1 -C 3 alkyl)mono(hydroxyethyl)ammonium salts, guar hydroxypropyl trimonium salts, 2,3-dihydroxypropyl tri(C 1 -C 3 alkyl or hydroxalkyl)ammonium salts or mixtures thereof. In a most preferred embodiment and when desired, the cationic ammonium compound employed in this invention is the quaternary ammonium compound 1,2-dihydroxypropyltrimonium chloride. If used, such compounds typically make up from about 0.01 to about 30%, and preferably, from about 0.1 to about 15% by weight of the composition.
When cationic ammonium compounds are used, preferred additional active for use with the same are moisturizing agents such as substituted ureas like hydroxymethyl urea, hydroxyethyl urea, hydroxypropyl urea; bis(hydroxymethyl)urea; bis(hydroxyethyl)urea; bis(hydroxypropyl)urea; N,N′-dihydroxymethyl urea; N,N′-di-hydroxyethyl urea; N,N′-di-hydroxypropyl urea; N,N,N′-tri-hydroxyethyl urea; tetra(hydroxymethyl)urea; tetra(hydroxyethyl)urea; tetra(hydroxypropyl)urea; N-methyl-N′-hydroxyethyl urea; N-ethyl-N,N-N′-hydroxyethyl urea; N-hydroxypropyl-N′-hydroxyethyl urea and N,N′-dimethyl-N-hydroxyethyl urea or mixtures thereof. Where the term hydroxypropyl appears, the meaning is generic for either 3-hydroxy-n-propyl, 2-hydroxy-n-propyl, 3-hydroxy-i-propyl or 2-hydroxy-i-propyl radicals. Most preferred is hydroxyethyl urea. The latter is available as a 50% aqueous liquid from the National Starch & Chemical Division of ICI under the trademark Hydrovance.
Amounts of substituted urea, when used, in the composition of this invention range from about 0.01 to about 20%, and preferably, from about 0.5 to about 15%, and most preferably, from about 2 to about 10% based on total weight of the composition and including all ranges subsumed therein.
When cationic ammonium compound and substituted urea are used, in a most especially preferred embodiment at least from about 1 to about 15% glycerin external to the particle is used, based on total weight of the composition and including all ranges subsumed therein.
Compositions of the present invention may include vitamins as the desired active. Illustrative vitamins are Vitamin A (retinol) as well as retinol esters like retinol palmitate and retinol propionate, Vitamin B 2 , Vitamin B 3 (niacinamide), Vitamin B 6 , Vitamin C, Vitamin E, Folic Acid and Biotin. Derivatives of the vitamins may also be employed. For instance, Vitamin C derivatives include ascorbyl tetraisopalmitate, magnesium ascorbyl phosphate and ascorbyl glycoside. Derivatives of Vitamin E include tocopheryl acetate, tocopheryl palmitate and tocopheryl linoleate. Total amount of vitamins when present in compositions according to the present invention may range from 0.001 to 10%, preferably from 0.01% to 1%, optimally from 0.1 to 0.5% by weight of the composition.
Octadecenedioic acid, azelaic acid, ubiquinone, dihydroxyacetone (DHA) and mixtures thereof may also be used as actives in the composition of this invention. Such compounds, when used, typically make up from about 0.2 to 4.5%, and preferably, from about 0.5 to 3% by weight of the composition, including all ranges subsumed therein.
Other optional actives suitable for use in this invention include resveratrol, resorcinols like 4-ethyl resorcinol, 4-hexyl resorcinol, 4-phenylethyl resorcinol, dimethoxytoluyl propyl resorcinol, 4-cyclopentyl resorcinol, 4-cyclohexylresorcinol, alpha- and/or beta-hydroxyacids, petroselinic acid, conjugated linoleic acid, octadecanoic acid, phenylethyl resorcinol (Symwhite 377 from Symrise), undecylenol phenylalanine (Seppi White from Seppic) mixtures thereof or the like. Such actives, when used, collectively make up from about 0.001 to about 12% by weight of the composition.
Desquamation promoters may be present. Illustrative are the alpha-hydroxycarboxylic acids, beta-hydroxycarboxylic acids. The term “acid” is meant to include not only the free acid but also salts and C 1 -C 30 alkyl or aryl esters thereof and lactones generated from removal of water to form cyclic or linear lactone structures. Representative acids are glycolic and its derivatives, lactic and malic acids. Salicylic acid is representative of the beta-hydroxycarboxylic acids. Amounts of these materials when present may range from about 0.01 to about 15% by weight of the composition.
A variety of herbal extracts may optionally be included in compositions of this invention. The extracts may either be water soluble or water-insoluble carried in a solvent which respectively is hydrophilic or hydrophobic. Water and ethanol are the preferred extract solvents. Illustrative extracts include those from green tea, yarrow, chamomile, licorice, aloe vera, grape seed, citrus unshui, willow bark, sage, thyme and rosemary. Soy extracts may be used and especially when it is desirable to include retinol.
Also optionally suitable for use include materials like chelators (e.g., EDTA), C 8-22 fatty acid substituted saccharides, lipoic acid, retinoxytrimethylsilane (available from Clariant Corp. under the Silcare 1M-75 trademark), dehydroepiandrosterone (DHEA) and combinations thereof. Ceramides (including Ceramide 1, Ceramide 3, Ceramide 3B and Ceramide 6) as well as pseudoceramides may also be useful. Occlusives like Oilwax LC are often desired. Amounts of these materials may range from about 0.000001 to about 10%, preferably from about 0.0001 to about 1% by weight of the composition.
Sunscreen actives may also be included in compositions of the present invention and carried by the particle comprising hydrophobic material as described herein. Particularly preferred are such materials as phenylbenzimidazole sulfonic acid (Ensulizole), ethylhexyl p-methoxycinnamate, available as Parsol MCX®, Avobenzene, available as Parsol 1789® and benzophenone-3, also known as Oxybenzone. Inorganic sunscreen actives may be employed such as microfine titanium dioxide, zinc oxide, polyethylene and various other polymers. Also suitable for use is octocrylene. Amounts of the sunscreen agents when present may generally range from 0.1 to 30%, preferably from 0.5 to 20%, optimally from 0.75 to 10% by weight.
Conventional buffers/pH modifiers may be used. These include commonly employed additives like sodium hydroxide, potassium hydroxide, hydrochloric acid, citric acid and citrate/citric acid buffers. In an especially preferred embodiment, the pH of the composition of this invention is from about 4 to about 8, and preferably, from about 4.25 to about 7.75, and most preferably, from about 6 to about 7.5, including all ranges subsumed therein. The composition of this invention may be a solid stick or bar. Viscosity of the composition of this invention is, however, preferably from about 1,000 to about 120,000 cps, and most preferably, from about 5,000 to 80,000 cps, taken at ambient temperature and a shear rate of 1 s −1 with a strain controlled parallel plate rheometer made commercially available from suppliers like T.A. Instruments under the ARES name.
A wide variety of packaging can be employed to store and deliver the composition of this invention. Packaging is often dependent upon the type of personal care end-use. For instance, leave-on skin lotions and creams, shampoos, conditioners and shower gels generally employ plastic containers with an opening at a dispensing end covered by a closure. Typical closures are screw-caps, non-aerosol pumps and flip-top hinged lids. Packaging for antiperspirants, deodorants and depilatories may involve a container with a roll-on ball on a dispensing end. Alternatively these types of personal care products may be delivered in a stick composition formulation in a container with propel-repel mechanism where the stick moves on a platform towards a dispensing orifice. Metallic cans pressurized by a propellant and having a spray nozzle serve as packaging for antiperspirants, shave creams and other personal care products. Toilette bars may have packaging constituted by a cellulosic or plastic wrapper or within a cardboard box or even encompassed by a shrink wrap plastic film.
When applying composition of this invention topically, typically from about 0.5 to about 5 mg of composition is applied per cm 2 of skin.
The following examples are provided to facilitate an understanding of the present invention. The examples are not intended to limit the scope of the claims.
Example 1
The compositions in the following examples were made by combining the ingredients indentified below. The compositions were made by mixing the ingredients with moderate shear under conditions of atmospheric pressure and ambient temperature.
Sample 1
Sample 2
Ingredient
Weight percent
Weight percent
Glutamine
1.39
—
Aspargine
1.11
—
Glycine
1.39
5.73
Glutamic acid
0.56
—
Threonine
1.94
—
Lysine
1.11
—
Alanine
1.67
4.11
Serine
0.83
12.13
Pyrrolidone
—
8.03
carboxylic acid
Arginine
—
2.75
Citrulline
—
2.75
Histidine
—
6.31
Water
Balance
Balance
Sample 3
Sample 4
Sample 5
Sample 6
Weight
Weight
Weight
Weight
Ingredient
percent
percent
percent
percent
N-acetyl-L-
2.22
2.5
2.5
2.5
hydroxyproline
L-alanyl-L-Glutamate
2.22
2.5
3.75
2.5
Glycyl Glycine
2.22
2.5
2.5
3.75
L-Glutathione
3.33
2.5
1.25
1.25
Water
Balance
Balance
Balance
Balance
Other Examples
Ingredient
Weight percent
Sample 7
Glutamine
1.39
Aspargine
1.11
Glycine
1.39
Glutamic acid
0.56
Threonine
1.94
Lysine
1.11
Alanine
1.67
Serine
0.83
Sunflower oil
3
Tinocare gel
10
Pellicer
0.3
Water
Balance
Sample 8
N-acetyl-L-
2.22
hydroxyproline
L-alanyl-L-Glutamate
2.22
Glycyl Glycine
2.22
L-Glutathione
3.33
(Reduced)
Sunflower oil
3
Tinocare gel
10
Pellicer
0.3
Water
Balance
Sample 9
Glutamine
1.39
Aspargine
1.11
Glycine
1.39
Glutamic acid
0.56
Threonine
1.94
Lysine
1.11
Alanine
1.67
Serine
0.83
Trehalose
1
Sunflower oil
3
Xanthan
1
Water
Balance
Sample 10
Sample 11
Ingredient
Weight percent
Weight percent
N-acetyl-L-hydroxyproline
2.22
2.22
L-alanyl-L-Glutamate
2.22
2.22
Glycyl Glycine
2.22
2.22
L-Glutathione Reduced
2.33
—
Calcium pantetheine-S-sulfonate
—
2.33
L-Glutathione (Oxidized)
1.0
1.0
Trehalose
1
1
Sunflower oil
3
3
Xanthan
1
1
Water
Balance
Balance
Example 2
Skin Moisturization
Skin moisturization was assessed in terms of hydration, measured using a Corneometer (Courage+Khazaka, Germany, model CM 825, consistent with the Sorption Desorption Test described in Bioengineering of the Skin:Water and the Stratum Corneum , by G. Borroni et al., Ed by P. Elsner et al., CBC Press, Chapter 18, 1995). Instrument readings typically vary from 5 to 120 units, with small numbers (˜6) typical for nails, higher numbers typical for dry skin (˜10-20), medium numbers typical for hydrated skin (˜40) and large numbers typical for skin immediately after application of water-based humectants (above 100).
Ex-vivo porcine skin (area 1.5 cm×1.5 cm) was treated with 0.1 ml of the compositions identified in Table 1 as well as a 10% glycerol solution and deionized water as the control. Readings were taken before treatments as a baseline and at least 5 measurements were made at the same position at the time intervals shown in the table.
The relative hydration numbers were calculated as 100%*(C t -C 0 )/C 0 , where C 0 is the reading before the treatment, and C t is the reading taken at the time t after treatment.
The change in hydration with respect to the initial hydration number for a given area of skin after 10, 30, and 60 minutes of composition application to model skin was found to be maximal for the aminopeptide containing composition of Sample 3 which is made consistent with this invention. When only a combination of water soluble amino acids was used (Sample 1), skin hydration was lower as was skin hydration observed for glycerol.
TABLE 1
Deionized
Composition
(Sample 3)
(Sample 1)
Glycerol (10%)
Water
Time (minutes)
Relative Hydration (percent)
10
55
13.1
23
21
30
42
15.5
11
4.6
60
40
16
10
4
The results in this table unexpectedly demonstrate that when compositions made consistent with this invention are applied, excellent moisturization results are obtained.
Example 3
Glass Transition Temperature
Glass transition temperatures were measured using differential scanning calorimetry (DSC Q1000, TA Instruments) at a heating rate of 10 K/min from −80 to +40° C. Glass transition temperatures were determined using TA instrument software (TA Advantage) from the middle of the heat capacity curve. The compositions comprising aminopeptide mixtures consistent with this invention were assessed against glycerol and other compositions with amino acids. Table 2 below depicts the glass transition temperatures of the compositions assessed. Water concentration means the water concentration of the composition at the time the glass transition temperature was obtained. Water was evaporated from contained compositions by storing the same at room temperature at a relative humidity of about 33%.
TABLE 2
Water
concentration
(% in
composition
Sample
at reading)
3
Sample 2
Sample 4
Samples 5
Glycerol
40
—
—
—
—
−108
23
−50
−67
−68.26
—
—
19
−33
−50
−56.42
—
—
15
−16
−37
−44.58
—
—
10.3
—
—
—
−36.4
—
10
3
−21
−29.77
—
—
9.6
—
—
—
−11.5
—
8.7
14
−9
−25.92
2.4
—
0
—
—
—
—
−83
The data in Table 2 shows, unexpectedly, that compositions made according to this invention will yield a consumer desirable glassy film that results in excellent water retention. For Sample 6, glass transition temperatures observed were similar to those of Sample 5. In the samples not consistent with this invention, rapid water evaporation (i.e., poor moisturization) is observed.
Example 3
Hydration of Stratum Corneum
The hydration of the stratum corneum was estimated from hysteresis observed during the sorption-desorption cycle. Disks of stratum corneum (6 mm in diameter) were treated with 0.06 mL aminopeptide mixture, glycerol or water at both sides and dried. The samples were then placed in a Dynamic Water Sorption Analyzer and with controlled humidity. When the humidity was increased in small steps (Delta RH=10%) water uptake was measured after 3 hours equilibration for each step. Water uptake is defined as a mass of water per the dry mass of stratum corneum.
Table 3 depicts the values of water uptake for sorption and desorption for stratum corneum treated with aminopeptide mixture consistent with this invention (Sample 3), glycerol and stratum corneum treated with deionized water. The difference between the water uptake at sorption and desorption shows the degree of moisturization at given experimental conditions.
TABLE 3
(results for Sample 3)
Relative
Water uptake,
Water uptake,
Water uptake
humidity, %
mg/g-sorption
mg/g-desorption
difference in mg/g
20
26.97
39.63
12.66
30.8
48.98
57.79
8.81
40.8
73.75
105.12
31.37
50.7
103.47
146.84
43.37
61
144.74
208.42
63.68
71
206.93
264
57.07
The data in Table 3 unexpectedly shows high water uptake at high relative humidity, meaning excellent water retention and moisturization results.
TABLE 4
(results for glycerol (10%) and water treatment, 0.12 mL applied)
water uptake
Relative
difference in mg/g
humidity
Water uptake
Water uptake
(desorption-
%
mg/g-sorption
mg/g-desorption
sorption)
10% Glycerol treatment
20.8
122.22
87.3
34.92
31
161.38
135.34
−26.04
41
209.84
192.06
−17.78
51
275.13
261.90
−13.23
60.2
366.67
366.67
0
70.35
524.34
524.34
0
Water treatment
20
23
25
2
27
30
35.8
5.8
34
37.4
43
5.6
41
45.7
51
5.3
47
53.9
59
5.04
54
63.8
69.9
6.1
61
78
82.6
4.6
The results in Table 4 demonstrate, surprisingly, that water retention and moisturization is significantly better for the compositions made consistent with this invention.
Example 4
Viscosity Measurements
Viscosity of aminopeptide mixtures consistent with this invention and amino acid mixtures were measured at different temperatures and concentrations of water using standard plate-plate geometry (25 mm) in an oscillatory deformation regime at frequency 1 Rad/s with amplitudes ranging from 0.1 to 10% depending on the sample viscosity. The dynamic viscosity under these conditions is defined as the loss modulus G″ divided by the frequency of oscillatory deformation. The increase in viscosity at low water concentrations indicates the stickiness and unattractiveness of the formula on skin. When composition dries and the water concentration drops lower than 20%, composition not consistent with this invention (Sample 2) leads to the formation of viscous films on skin whereas the viscosity of the composition having aminopeptide mixture consistent with this invention in (Sample 3) yields a lower and desirable viscosity. This behavior unexpectedly results in a composition that is less sticky or draggy.
TABLE 5
Dynamic Viscosity, Pa * s
Water weight
NMF
fraction (%)
(Sample 2)
(Sample 3)
7.35
8184.5
1456
9
1878.1
255
11.6
317.3
33
12.44
68.03
15
15.8
9.73
3.7
17.5
4.39
2.29
20
1.28
1.5
27
0.23
0.8
15.8
9.73
3.7
The results in Table 5 unexpectedly reveal that composition comprising aminopeptide mixtures consistent with this invention do not become thick and sticky subsequent to water loss.
Compositions made consistent with this invention (including those described in Samples 7-11) were topically applied to skilled panelist and all concluded that the compositions were easy to apply and not sticky during and after application. All panelists further concluded that such compositions yielded sensory results consistent with excellent moisturization.
|
The invention is directed to skin moisturizing compositions comprising an aminopeptide mixture. The composition replenishes the skins natural moisturization factor and delivers excellent sensory benefits. The composition is not unpleasantly viscous during and after application.
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FIELD OF THE INVENTION
[0001] This invention relates to the field of packet networks, and in particular to a method of managing the flow of time-sensitive data, such as voice or audio.
BACKGROUND OF THE INVENTION
[0002] It is becoming increasingly common to establish video conferencing sessions over IP networks rather than circuit-switched networks, such as ISDN. Such networks can, for example, be LANs, WANs, or virtual networks established over the Internet. In a typical session, a TCP/IP virtual connection is established between a pair of video endpoints, which can then communicate with each other to provide a telecollaboration session. The endpoints stream video and audio data to each other over other virtual connections (e.g. using RTP).
[0003] Video data is streamed over a network in compressed form and comprises two kinds of frames: P-frames and I-frames. P-frames are smaller in size than I-frames because the P-frames only contain information about the changes relative to a previous frame. For example, if an object moves over a static background, the P-frames only carry information pertaining to the movement of the object. On the other hand, when there is a change of scene, it is necessary to transmit the entire frame, and this is achieved with an I-frame. Because small data errors in P-frames can result in disproportionate degradation of received video, I-frames are also transmitted periodically to limit perpetuation of these data errors. Although the I-frame may be compressed internally, it is still much larger than a P-frame.
[0004] When multiple Video sources are streamed onto an IP network, I-frames occurring simultaneously create bandwidth or traffic peaks. As a result of the network internal congestion controls, which discard packets when congestion exceeds a certain threshold, the important I-frames may be discarded en route. This problem can occur when multiple video conference calls are in process and particularly in the case of multi-party conferences when the same video source is connected to two or more remote endpoints.
[0005] Existing stream buffers attempt overcome this problem by indiscriminately delaying arbitrary packets. This technique can result in undesirable latency in the video conference case. Another solution can be achieved at the endpoints if the users accept lower quality video, e.g. lower resolution and/or lower frame rate will be exchanged for more consistent, reliable performance.
SUMMARY OF THE INVENTION
[0006] According to the present invention there is provided a method of managing multiple data streams transported over a common communications resource in a packet network, wherein data flowing through said resource travels in both directions, and wherein each stream is subject to data peaks, comprising determining a round trip delay for each data stream; and delaying transmission of data peaks in one or more of said data streams to at least reduce the degree of coincidence in the data peaks of different streams without increasing the maximum round trip delay for the data streams.
[0007] By measuring the Round Trip Delay (RTD) for each video connection, data associated with connection(s) having the least RTD are delayed to smooth net traffic. This will result in zero delay to the connection having greatest RTD. The effect of this, other factors being equal, is to ensure that no party in a multiparty conference will experience RTD greater than would be experienced by parties communicating via the path of greatest point to point delay when all other connections are disconnected.
[0008] As the number of connections is increased traffic peaks from each source will preferably be distributed as evenly as possible to minimize the probability of traffic loss due to bandwidth caps in each transmission paths. Such caps are considered to have essentially unknown clipping characteristics that will significantly deteriorate video rendered at the endpoint equipment.
[0009] According to another aspect of the invention there is provided a de-synchronizer for reducing packet loss in a packet network wherein multiple data streams are transported over a common communications resource, wherein data flowing through said resource travels in both directions, and wherein each stream is subject to data peaks, comprising an interface for communicating with transmitters and receivers for said data streams; and a processor configured to issue signals, in response to reported round trip delays for the data streams, delaying transmission of data peaks in one or more of said data streams so as to at least reduce the degree of coincidence in the data peaks of different streams without increasing the maximum round trip delay for the data streams.
[0010] In a still further aspect of the invention there is provided a video conference apparatus, comprising at least one video source; at least one transmitter for transmitting a transmitted video signal from said at least one source as a data stream; at least one receiver for receiving a data stream and outputting a received video signal; at least one display unit for displaying received a received video signal; and a processor responsive to round trip delays for the data streams reported by said receivers to delay transmission of data peaks in one or more of said data streams so as to at least reduce the degree of coincidence in the data peaks of different streams without increasing the maximum round trip delay for the data streams.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The invention will now be described in more detail, by way of example only, with reference to the accompanying drawings, in which:—
[0012] FIG. 1 is a schematic diagram of a typical video conferencing system;
[0013] FIG. 2 is a functional block diagram of a video conferencing system;
[0014] FIG. 3 is illustrates a typical video signal in the prior art;
[0015] FIG. 4 illustrates a video signal with de-synchronization applied in accordance with one embodiment of the invention;
[0016] FIG. 5 illustrates the case for three video three signals;
[0017] FIG. 6 is a flow chart showing the operation of the desynchronizer;
[0018] FIG. 7 is a high-level block diagram of a desynchronizer.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0019] FIG. 1 illustrates a part of a typical video conference system. Endpoints 1 a at location 1 are connected to endpoints locations 2 , 3 and 4 at different locations. The endpoints 1 a and 1 b are connected via LAN 6 to router 5 , which connects to IP network 8 , to which the endpoints 2 , 3 , 4 are also connected. An important point to realize is that there is a point-to-point IP connection set up between each source and each destination endpoint. In the example shown, there are three IP connections to the router 5 shown at the edge of the IP Network 8 . The router 5 is typical of many in each IP connection. The IP Network shown could be, for example, a corporate private network, the public Internet, or a combination of such networks.
[0020] A typical stylized IP Video Signal 44 is illustrated in FIG. 3 . Larger peaks 44 a represent periods of high data traffic associated with video I-frames transmitting the entire picture. Smaller traffic peaks 44 b represent P-frames, transmitting small fragments of the picture, which have changed with respect to the previous I and P-frames, and other data. The signal shown in FIG. 3 reflects a typical one to two second period.
[0021] Each video connection in FIG. 1 carries a signal similar to that shown in FIG. 3 . In the case where the signal from one common video source is transmitted to two destinations, the signal traffic to each destination will be similar; for example, signal 44 and signal 48 . These are signals transmitted on a virtual IP connection.
[0022] FIG. 3 shows aggregate traffic on the real, physical, LAN 6 . In general, the video data from different sources are not synchronized, which means that there is no particular temporal relationship between traffic peaks resulting from the various I-frames coming from different sources. These peaks from different sources will drift with respect to one another when viewed over time but they will always coincide if the same source streams to multiple destinations. From time to time drifting I-frame peaks will coincide again resulting in a signal similar to that shown at 49 in FIG. 3 . When the traffic peaks on each of the connections to multiple destinations roughly coincide it is possible that the instantaneous traffic level may exceed the traffic capacity of one of more devices (e.g. router 5 in FIG. 1 ) in the system. This capacity limit is shown as a cap 49 a in FIG. 3 . The router 5 typically discards any data, which would otherwise have exceeded the cap. The consequence of this loss of data is a degradation of the transmitted picture when it is rendered at the display for a period of time that is noticeable and significant to the system users.
[0023] In a one-way video application, for example, a YouTube video, if the video signal is delayed a few hundred ms or even several seconds, users likely will either not notice or not be too concerned. Such delay typically occurs once at the point the user starts watching the video and has no perceivable effect to the viewer on the remainder of that video.
[0024] Unlike streaming one-way video applications, round trip delay (RTD) is a very important parameter in a videoconference system. A video conference is a two-way communication, like a telephone call. Human communication evolved in an environment in which the delay in sound traveling from a speaker's mouth to a listener's ear is typically a few ms. to human perception this is instantaneous. Visual cues are received even faster. It has been found that communication can continue naturally when the RTD is kept under approximately 150 ms. Between this figure and 500 or 600 ms users will find conversation increasingly difficult, especially, for example, if discussion is heated or users are in negotiation.
[0025] As it relates to video, RTD is the time taken from the moment an individual at the source moves or makes a gesture until that movement occurs on the distant display plus the time taken for a similar movement at the distant location to occur on the local display. Each way this includes typically time taken to scan the scene, encode it, packetize it, traverse the IP network and carry out the inverse functions at the display end, where further delay is incurred in a jitter buffer. It is extremely difficult if not impossible with current technology and user desired picture quality to meet the ideal RTD requirements. It will be clear that arbitrarily adding further delay to smooth traffic using a video buffer will further deteriorate the user experience.
[0026] FIG. 2 is a functional block diagram of a system in accordance with one embodiment of the invention. With the exception of the DeSync Control block 32 and delay blocks 52 , whose function will be described in more detail below, the function of the remaining blocks is known in the art. The video displays 12 and 13 could be a dedicated device, such as may be found in a typical conference room or a window on a display more typically found at an individuals desk.
[0027] Network Receiver 16 terminates the IP connection 42 from a remote source at endpoint 2 and delivers the digital video signal 14 to the display 12 . Video Source 22 could be a video camera, a group of switched cameras, or any other source of video including a Video Player, Multiparty Conference Unit (MCU), or a Gateway connection to legacy video equipment. Network Transmitter 26 converts the digital video signal 24 from the source and sends it as an IP signal 44 to the remote endpoint 2 .
[0028] Desynch block 32 , shown in FIG. 7 , comprises a processor 70 , memory 72 , and interface 74 for interfacing with transmitters 26 and receivers 16 .
[0029] The blocks shown illustrate functions that may be physically integrated with each other and/or other equipment (not illustrated). For example displays 12 and 13 may be simply two windows on a single display or they may be separate standalone displays. At remote locations details, similar to 1 with or without blocks 32 and 52 , of video encoding and decoding and IP transmission and reception are omitted for clarity.
[0030] The endpoints 1 and 2 , 3 , 4 are interconnected via the IP network 8 , which is understood to include all equipment necessary for IP connectivity between the locations. In particular, the network will include many routers, similar to 5 shown and other equipment. This other equipment may be at the respective location and/or part of a private network, a public network, especially the Internet. It will be understood that signals traversing the network are subject to significant arbitrary and variable delay ranging from tens of milliseconds to seconds.
[0031] Connections 42 and 44 form one logical two-way connection (IP virtual connections are illustrated as dashed lines to differentiate from other signals). It will be understood that these connections comprise more than one signal. These signals include both the video signal (e.g. carried in Real Time Protocol—RTP) and round trip delay (RTD) information on the RTP flow (e.g. derived from RTP Control Protocol RTCP)
[0032] Referring again to FIG. 3 , it will be seen that the peaks associated with I-frames are aligned and when aggregated onto the LAN they result in a 2× traffic peak. It should be noted that in the example peaks necessarily line up because a single encoder is used. However had there been two independent video sources with two encoders the same situation would arise periodically as the two signals drift in and out of phase. Each time they come into phase a large traffic peak is created resulting potentially in data loss around the peak as described earlier.
[0033] The deSync control 32 , shown in FIG. 2 , receives signals 34 from each Receiver (Rx) block 16 (two or more) indicative of Round Trip Delay (RTD), which information is derived from a network protocol (e.g. RTCP) in the IP Transport layer.
[0034] Signals 36 from each controlled video source 22 are indicative of the time the last I-Frame was transmitted in video signal 24 .
[0035] The purpose of the desync function is to delay the transmission of the signal transmitted on certain connections in order to minimize aggregate traffic peaks whilst at the same not increasing RTD of any connection beyond the greatest undelayed RTD for all connections. This is achieved by signal 38 .
[0036] The network transmitter 26 is preceded by the addition of a delay block 52 at the video input. Block 52 delays signal 24 by a time specified in signal 38 . The result is that the IP signal 48 is delayed by block 52 by the value specified in signal 38 when compared to conventional endpoints. It will be understood that this modification may or may not be embedded within the existing transmitter code.
[0037] The deSync control 32 determines the delay of each stream so as to separate peaks that would otherwise coincide. It does so by delaying streams with the least RTD more than those with higher RTD such that the stream with the highest RTD is not delayed at all. The amount of delay per stream also has a maximum value so as to cap the total delay.
[0038] FIG. 4 illustrates the result of the implementing a controlled delay as described and should be compared with FIG. 3 . In this example it is assumed that connection 44 has the greatest RTD and no further delay has been added to this signal. A delay is, according to the invention, applied only to the signal driving connection 48 so that its I-frame peaks do not align with signal 44 . The peaks in the resultant aggregate LAN traffic therefore do not exceed the arbitrary traffic cap as they do in FIG. 3 .
[0039] It will be understood that this method may be used for any number of connections. FIG. 5 illustrates the operation of the invention more generally. In this case three video signals 44 , 48 , and 50 are being transmitted simultaneously. The deSync function will attempt to distribute I-frame peaks in signals 48 and 50 between successive peaks of Signal 44 which is the un-delayed Signal on the connection with the greatest RTD.
[0040] However, in practice I-frame transmission is not strictly periodic and the round trip delay experienced by each connection may change over time. This change may result in the rank order of connections by RTD changing. The connection with the greatest delay at one moment may be replaced by a different connection at a later moment.
[0041] FIG. 6 shows a simplified flow chart of embodiment of the desynchronizing control unit 32 . However, it will be appreciated that there a numerous alternative ways of implementing the described function, which will be apparent to a person skilled in the art. In this exemplary embodiment, the process described in the flow chart shown in FIG. 6 is executed on a schedule once every 9-10 seconds.
[0042] The first step in the process 60 is to create an empty SignalTable in computer memory. The table contains a row for each destination endpoint currently active. It contains the two columns:
[0043] 1. Last I-frame time (I) for the destination
[0044] 2. Current Round Trip Delay (RTD) for the destination
[0000] In step 62 the SignalTable is populated with data from the Network Receivers 16 and the video sources 22 as described earlier.
[0045] It will be understood that the round trip delay reported by receivers 16 reflects only the delay in the network, the total for outbound path plus return path, and does not include any additional delay introduced in the endpoint as a result of this invention, either at the subject endpoint or the remote endpoint, if the invention is implemented in any or all the remote endpoints 2 , 3 and 4 .
[0046] It will be understood that the time stamp signal 36 indicating the last I-frame from a given video source 22 will be relative to a common arbitrary real time clock.
[0047] In the next step 64 , the SignalTable is sorted on the basis of the RTD column in descending order. In step 66 the time reference (Ref) for the purposes of the rest of the process steps is established. It is taken to be the time of the last I-frame for the video source feeding the connection with the longest RTD, i.e. the first entry in the SignalTable column I.
[0048] Further each I value in the SignalTable, except the first, is adjusted. It will be understood that I values are roughly periodic. The I values are adjusted by adding or subtracting the I-frame period to I such that I now has a value greater than Ref but not exceeding I+Ref.
[0049] Next in 68 a table of time slots is created, bSlotsTable. Initially each entry is FALSE. The period into which I-frames could be potentially delayed is divided into “slots”, at least as many slots as there are endpoints. Each entry in the bSlotsTable corresponds to one slot, each having a different associated SlotTime. In the preferred embodiment slots are evenly spaced in time so that the SlotTime is proportional to the slot number.
[0050] The remaining loop determines a delay value for each destination (row) which will result in moving all but one of any coincident I-frames to an empty slot, so that no slot has more than one I-frame in it.
[0051] Because the destination with greatest RTD is taken as reference, it will be evident that it will not be further delayed by this process.
[0052] Steps 70 and 80 control a typical software loop processing one row of the table, i.e. one destination, in each loop.
[0053] In the first step of the loop 72 , the next empty slot that is no more than the maximum allowable delay ahead in time is found, i.e. slot having a SlotTime value greater than or equal to the I value but no more than the maximum allowable delay ahead in time. Under certain circumstances it is possible that such a slot may not be found.
[0054] A test 74 selects the subsequent step on the basis of whether an empty slot was found in 72 .
[0055] Typically a slot is found and step 76 sets the delay 38 (the specific signal connected to the transmitter 26 of the current loop destination). It is set to a value equal to the SlotTime-I. Following this 78 the slot value in bSlotsTable is set TRUE so that this slot will not again be chosen in step 72 when finding a slot for the remaining destinations in SignalTable.
[0056] In the event that no slot is found for this endpoint the delay 38 for that endpoint transmitter is set to zero in step 82 , i.e. no delay.
[0057] Step 80 is the end of the loop. The flowchart either loops back to 70 or ends when all destination have been processed.
[0058] It should be appreciated by those skilled in the art that any block diagrams herein represent conceptual views of illustrative circuitry embodying the principles of the invention. For example, a processor may be provided through the use of dedicated hardware as well as hardware capable of executing software in association with appropriate software. When provided by a processor, the functions may be provided by a single dedicated processor, by a single shared processor, or by a plurality of individual processors, some of which may be shared. Moreover, explicit use of the term “processor” should not be construed to refer exclusively to hardware capable of executing software, and may implicitly include, without limitation, digital signal processor (DSP) hardware, network processor, application specific integrated circuit (ASIC), field programmable gate array (FPGA), read only memory (ROM) for storing software, random access memory (RAM), and non volatile storage. Other hardware, conventional and/or custom, may also be included.
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A method is disclosed for managing multiple data streams transported over a common communications resource in a packet network, wherein data flowing through the resource travels in both directions, and wherein each stream is subject to data peaks. The round trip delay is determined for each data stream, and the transmission of data peaks in one or more of the data streams is delayed to at least reduce the degree of coincidence in the data peaks of different streams without increasing the maximum round trip delay for the data streams.
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RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Patent Application Ser. No. 61/764,724 filed Feb. 14, 2013, the disclosure of which is hereby incorporated in its entirety herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to substituted dihydropyrazoles, processes for preparing them, pharmaceutical compositions containing them and their use as pharmaceuticals as modulators of sphingosine-1-phosphate receptors. The invention also relates 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 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 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:
[0007] R 1 is H, halogen or optionally substituted C 1-6 alkyl, CN, NO 2 , C(O)R 7 , NR 12 R 13 or OR 14 ;
[0008] R 2 is H, halogen or optionally substituted C 1-6 alkyl, CN, NO 2 , C(O)R 7 , NR 12 R 13 or OR 14 ,
[0009] R 3 is H, halogen or optionally substituted C 1-6 alkyl, CN, NO 2 , C(O)R 7 , NR 12 R 13 or OR 14 ,
[0010] R 4 is H, halogen or optionally substituted C 1-6 alkyl, CN, NO 2 , C(O)R 7 , NR 12 R 13 or OR 14 ,
[0011] R 5 is H, halogen or optionally substituted C 1-6 alkyl, CN, NO 2 , C(O)R 7 , NR 12 R 13 or OR 14 ,
[0012] R 6 is H, optionally substituted C 6-10 aryl, optionally substituted heterocycle or optionally substituted C 1-6 alkyl;
[0013] R 7 is H, OH, OC 1-6 alkyl or optionally substituted C 1-6 alkyl;
[0014] R 8 is H, halogen or optionally substituted C 1-6 alkyl, CN, NO 2 , C(O)R 7 , NR 12 R 13 or OR 14 ,
[0000] R 9 is H, halogen or optionally substituted C 1-6 alkyl, CN, NO 2 , C(O)R 7 , NR 12 R 13 or OR 14 ;
R 10 is H, halogen or optionally substituted C 1-6 alkyl, CN, NO 2 , C(O)R 7 , NR 12 R 13 or OR 14 ;
R 11 is H, halogen or optionally substituted C 1-6 alkyl, CN, NO 2 , C(O)R 7 , NR 12 R 13 or OR 14 ;
R 12 is H or optionally substituted C 1-6 alkyl;
R 13 is H or optionally substituted C 1-6 alkyl;
R 14 is H or optionally substituted C 1-6 alkyl;
X is O, CH 2 , NR 12 or S;
[0015] a is 0, 1, 2 or 3;
b is 0, 1, 2 or 3;
Z is OPO 3 H 2 , carboxylic acid, PO 3 H 2 , —P(O)MeOH, —P(O)(H)OH or OR 15 ; and
R 15 is H, C(O)R 7 or optionally substituted C 1-6 alkyl.
In another embodiment, the invention provides a compound having Formula I wherein
[0016] R 1 is H, halogen or optionally substituted C 1-6 alkyl;
[0017] R 2 is H, halogen or optionally substituted C 1-6 alkyl;
[0018] R 3 is H, halogen or optionally substituted C 1-6 alkyl;
[0019] R 4 is H, halogen or optionally substituted C 1-6 alkyl;
[0020] R 5 is H, halogen or optionally substituted C 1-6 alkyl;
[0021] R 6 is optionally substituted C 1-6 alkyl,
[0022] R 8 is H, halogen or optionally substituted C 1-6 alkyl;
[0023] R 9 is H, halogen or optionally substituted C 1-6 alkyl;
[0024] R 10 is H, halogen or optionally substituted C 1-6 alkyl;
[0025] R 11 is H, halogen or optionally substituted C 1-6 alkyl;
[0026] X is O, CH 2 or S;
[0027] a is 0, 1, 2 or 3;
[0028] b is 1, 2 or 3; and
[0029] Z is carboxylic acid or PO 3 H 2 .
[0000] In another embodiment, the invention provides a compound having Formula I wherein
[0030] R 1 is H, halogen or optionally substituted C 1-6 alkyl;
[0031] R 2 is H, halogen or optionally substituted C 1-6 alkyl;
[0032] R 3 is H, halogen or optionally substituted C 1-6 alkyl;
[0033] R 4 is H, halogen or optionally substituted C 1-6 alkyl;
[0034] R 5 is H, halogen or optionally substituted C 1-6 alkyl;
[0035] R 6 is optionally substituted C 1-6 alkyl,
[0036] R 8 is H, halogen or optionally substituted C 1-6 alkyl;
[0037] R 9 is H, halogen or optionally substituted C 1-6 alkyl;
[0038] R 10 is H, halogen or optionally substituted C 1-6 alkyl;
[0039] R 11 is H, halogen or optionally substituted C 1-6 alkyl;
[0040] X is O;
[0041] a is 0, 1, 2 or 3;
[0042] b is 1, 2 or 3; and
[0043] Z is carboxylic acid or PO 3 H 2 .
[0000] In another embodiment, the invention provides a compound having Formula I wherein
[0044] R 1 is H, halogen or optionally substituted C 1-6 alkyl;
[0045] R 2 is H, halogen or optionally substituted C 1-6 alkyl;
[0046] R 3 is H, halogen or optionally substituted C 1-6 alkyl;
[0047] R 4 is H, halogen or optionally substituted C 1-6 alkyl;
[0048] R 5 is H, halogen or optionally substituted C 1-6 alkyl;
[0049] R 6 is methyl, ethyl or n-propyl;
[0050] R 8 is H, halogen or optionally substituted C 1-6 alkyl;
[0051] R 9 is H, halogen or optionally substituted C 1-6 alkyl;
[0052] R 10 is H, halogen or optionally substituted C 1-6 alkyl;
[0053] R 11 is H, halogen or optionally substituted C 1-6 alkyl;
[0054] X is O;
[0055] a is 0, 1, 2 or 3;
[0056] b is 1, 2 or 3; and
[0057] Z is carboxylic acid or PO 3 H 2 .
[0000] In another embodiment, the invention provides a compound having Formula I wherein
[0058] R 1 is H;
[0059] R 2 is H;
[0060] R 3 is H;
[0061] R 4 is H;
[0062] R 5 is H;
[0063] R 6 is methyl, ethyl or n-propyl;
[0064] R 8 is H;
[0065] R 9 is H;
[0066] R 10 is H or optionally substituted C 1-6 alkyl;
[0067] R 11 is H;
[0068] X is O;
[0069] a is 0 or 1;
[0070] b is 1 or 2; and
[0071] Z is carboxylic acid or PO 3 H 2 .
[0000] In another embodiment, the invention provides a compound having Formula I wherein
[0072] R 1 is H;
[0073] R 2 is H;
[0074] R 3 is H;
[0075] R 4 is H;
[0076] R 5 is H;
[0077] R 6 is methyl, ethyl or n-propyl;
[0078] R 8 is H;
[0079] R 9 is H;
[0080] R 19 is H or optionally substituted C 1-6 alkyl;
[0081] R 11 is H;
[0082] X is O;
[0083] a is 0 or 1;
[0084] b is 1 or 2; and
[0085] Z is PO 3 H 2 .
[0086] 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, carboxylic acid, phosphonic acid groups, sulphonic acid groups, phosphoric acid.
[0087] The term “heterocycle” as used herein, refers to a 3 to 10 membered ring, which can be aromatic or non-aromatic, saturated or non-saturated, containing at least one heteroatom selected form O or N or S or combinations of at least two thereof, interrupting the carbocyclic ring structure. Heterocycle can be monocyclic or polycyclic. The heterocyclic ring can be interrupted by a C═O; the S heteroatom can be oxidized. Heterocyclic ring moieties can be substituted by halogen, —SC 1-6 alkyl, —S(O) 2 C 1-6 alkyl, —S(O)C 1-6 alkyl, sulfonamide, amide, nitro, cyano, —OC 1-6 alkyl, —C 1-6 alkyl, —C 2-6 alkenyl, —C 2-6 alkynyl, ketone, amine, C 3-8 cycloalkyl, aldehydes, esters, carboxylic acid, phosphonic acid, sulfonic acid or hydroxyl groups.
[0088] 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 can be monocyclic or polycyclic. Aryl can be substituted by halogen, —SC 1-6 alkyl, —S(O) 2 C 1-6 alkyl, —S(O)C 1-6 alkyl, sulfonamide, amide, nitro, cyano, —OC 1-6 alkyl, —C 1-6 alkyl, —C 2-6 alkenyl, —C 2-6 alkynyl, ketone, amine, C 3-8 cycloalkyl, aldehyde, ester, carboxylic acid, phosphonic acid, sulfonic acid or hydroxyl groups. Usually aryl is phenyl. Preferred substitution site on aryl are meta and para positions.
[0089] 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.
[0090] The term “halogen”, as used herein, refers to an atom of chlorine, bromine, fluorine, iodine.
[0000] The term “hydroxyl” as used herein, represents a group of formula “—OH”.
The term “carbonyl” as used herein, represents a group of formula “—C═O”.
The term “carboxyl” as used herein, represents a group of formula “—C(O)O—”.
The term “sulfonyl” as used herein, represents a group of formula “—SO 2 ”.
The term “sulfate” as used herein, represents a group of formula “—O—S(O) 2 —O—”.
The term “carboxylic acid” as used herein, represents a group of formula “—C(O)OH”.
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 ”.
The term “phosphoric acid” as used herein, represents a group of formula “—(O)P(O)(OH) 2 ”.
The term “sulphonic acid” as used herein, represents a group of formula “—S(O) 2 OH”.
The term “amino” as used herein, represents a group of formula “—NH 2 ”.
The formula “H”, as used herein, represents a hydrogen atom.
The formula “O”, as used herein, represents an oxygen atom.
The formula “N”, as used herein, represents a nitrogen atom.
[0091] The formula “S”, as used herein, represents a sulfur atom.
[3-({3-Methyl-4-[(5-phenyl-1-propyl-4,5-dihydro-1H-pyrazol-3-yl)methoxy]benzyl}amino)propyl]phosphonic acid is a compound of the invention.
[0093] 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.
[0094] 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.
[0095] 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, an inorganic 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 Stahl & Camille G. Wermuth (Eds), Verlag Helvetica Chimica Acta-Zürich, 2002, 329-345).
[0096] 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.
[0097] 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.
[0098] 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.
[0099] 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.
[0100] In another embodiment, there are provided pharmaceutical compositions including at least one compound of the invention in a pharmaceutically acceptable carrier.
[0101] 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.
[0102] 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.
[0103] 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, autoimmune uveitis, renal ischemia/perfusion injury, contact hypersensitivity, atopic dermatitis, 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.
[0104] 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 diastereisomers thereof.
[0105] 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, autoimmune uveitis, renal ischemia/perfusion injury, contact hypersensitivity, atopic dermatitis, 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.
[0106] 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.
[0107] 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.
[0108] 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.
[0109] 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.
[0110] 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.
[0111] 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.
[0112] 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.
[0113] Pharmaceutical compositions containing invention compounds may be in a form suitable for topical use, for example, as oily suspensions, as solutions or suspensions in aqueous liquids or nonaqueous liquids, or as oil-in-water or water-in-oil liquid emulsions. Pharmaceutical compositions may be prepared by combining a therapeutically effective amount of at least one compound according to the present invention, or a pharmaceutically acceptable salt thereof, as an active ingredient with conventional ophthalmically acceptable pharmaceutical excipients and by preparation of unit dosage suitable for topical ocular use. The therapeutically efficient amount typically is between about 0.001 and about 5% (w/v), preferably about 0.001 to about 2.0% (w/v) in liquid formulations.
[0114] For ophthalmic application, preferably solutions are prepared using a physiological saline solution as a major vehicle. The pH of such ophthalmic solutions should preferably be maintained between 4.5 and 8.0 with an appropriate buffer system, a neutral pH being preferred but not essential. The formulations may also contain conventional pharmaceutically acceptable preservatives, stabilizers and surfactants. Preferred preservatives that may be used in the pharmaceutical compositions of the present invention include, but are not limited to, benzalkonium chloride, chlorobutanol, thimerosal, phenylmercuric acetate and phenylmercuric nitrate. A preferred surfactant is, for example, Tween 80. Likewise, various preferred vehicles may be used in the ophthalmic preparations of the present invention. These vehicles include, but are not limited to, polyvinyl alcohol, povidone, hydroxypropyl methyl cellulose, poloxamers, carboxymethyl cellulose, hydroxyethyl cellulose cyclodextrin and purified water.
[0115] Tonicity adjustors may be added as needed or convenient. They include, but are not limited to, salts, particularly sodium chloride, potassium chloride, mannitol and glycerin, or any other suitable ophthalmically acceptable tonicity adjustor.
[0116] Various buffers and means for adjusting pH may be used so long as the resulting preparation is ophthalmically acceptable. Accordingly, buffers include acetate buffers, citrate buffers, phosphate buffers and borate buffers. Acids or bases may be used to adjust the pH of these formulations as needed.
[0117] In a similar manner an ophthalmically acceptable antioxidant for use in the present invention includes, but is not limited to, sodium metabisulfite, sodium thiosulfate, acetylcysteine, butylated hydroxyanisole and butylated hydroxytoluene. Other excipient components which may be included in the ophthalmic preparations are chelating agents. The preferred chelating agent is edentate disodium, although other chelating agents may also be used in place of or in conjunction with it.
[0118] The ingredients are usually used in the following amounts:
[0000]
Ingredient
Amount (% w/v)
active ingredient
about 0.001 to about 5
preservative
0-0.10
vehicle
0-40
tonicity adjustor
0-10
buffer
0.01-10
pH adjustor
q.s. pH 4.5-7.8
antioxidant
as needed
surfactant
as needed
purified water
to make 100%
[0119] The actual dose of the active compounds of the present invention depends on the specific compound, and on the condition to be treated; the selection of the appropriate dose is well within the knowledge of the skilled artisan.
[0120] The ophthalmic formulations of the present invention are conveniently packaged in forms suitable for metered application, such as in containers equipped with a dropper, to facilitate application to the eye. Containers suitable for drop wise application are usually made of suitable inert, non-toxic plastic material, and generally contain between about 0.5 and about 15 ml solution. One package may contain one or more unit doses. Especially preservative-free solutions are often formulated in non-resalable containers containing up to about ten, preferably up to about five units doses, where a typical unit dose is from one to about 8 drops, preferably one to about 3 drops. The volume of one drop usually is about 20-35 μl.
[0121] 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.
[0122] 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.
[0123] 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.
[0124] 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.
[0000]
[0125] The following abbreviations are used in Scheme 1 and in the examples:
[0000] RT room temperature
CD 3 OD deuterated methanol
CDCl 3 deuterated chloroform
HOAc acetic acid
THF tetrahydrofuran
DIAD diisopropyldiazocarboxylate
PPh 3 triphenylphosphine
LiBH 4 lithium borohydride
EtOH ethanol
KOH potassium hydroxide
MeOH methanol
HCl hydrochloric acid
R 6 NHNH 2 .HCl hydrazine
H + acid
H 2 SO 4 sulfuric acid
[0126] Those skilled in the art will be able to routinely modify and/or adapt the following scheme to synthesize any compounds of the invention covered by Formula I.
DETAILED DESCRIPTION OF THE INVENTION
[0127] 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.
[0128] 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 diastereisomeric forms. Unless it is specifically noted otherwise, the scope of the present invention includes all enantiomers, diastereisomers 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.
[0129] 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.
[0130] 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. 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. Compound names were generated with ACDLabs version 8.00 or 12.5 and in some cases Chem Bio Draw Ultra version 12.0; and Intermediates and reagent names used in the examples were generated with software such as ACD version 12.05, Chem Bio Draw Ultra version 12.0 or Auto Nom 2000 from MDL ISIS Draw 2.5 SP1. In general, characterization of the compounds is performed according to the following methods: NMR spectra are recorded on 300 and/or 600 MHz Varian and acquired at room temperature; or at 60 MHz on a Varian T-60 spectrometer or at 300 MHz on a Varian Inova system. Chemical shifts are given in ppm referenced either to internal TMS or to the solvent signal. 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, AscentScientific LLC., 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. Compounds of the invention were purified according to either of the following methods below: added amino modified silica gel to organic solution (MeOH/CHCl 3 ) and concentrated, auto column on a silica gel-amine column with 70% MeOH, 0.5% acetic acid in dichloromethane gave product after removal of solvents, and drying under vacuum, product tituration with methanol, filtered, and washed with methanol to give product after removal of solvents, and drying under vacuum, column chromatography (Auto-column) on a Teledyne-ISCO CombiFlash with a silica column, unless noted otherwise.
Example 1
Intermediate 1
(E)-2-oxo-4-phenylbut-3-enoic acid
[0131]
[0132] In a 2 L 3-necked flask equipped with a mechanical stirrer, dropping funnel and thermometer was placed benzaldehyde (119.8 g, 1.13 mol) and pyruvic acid (99.44 g, 1.13 mol) in methanol (100 mL) under argon. The reaction mixture was cooled to 10° C. A freshly prepared solution of potassium hydroxide (95.2 g, 1.7 mol) in methanol (350 mL) was added over 30 min. During the addition, the solution turned yellow and eventually a precipitate was formed. The reaction was allowed to warm to room temperature and was placed in a refrigerator overnight. The granular solid in the flask was collected, and was suspended over a cold mixture of methanol (500 mL) and ether (500 mL). After stirring for 1 hr, the solid was collected and dried in a desiccator under high vacuum to give 185 g of a solid. This solid was dissolved in water (1500 mL) and extracted with ethyl acetate (2×200 mL). The aqueous layer was acidified with 3M HCl to pH 2 and extracted with dichloromethane (5×250 mL). The combined organic layers were washed with brine (2×250 mL), dried over magnesium sulfate (30 g) and concentrated under reduced pressure to give 84 g of intermediate 1 as an oil which solidified (32%).
[0133] 1 H NMR (60 MHz, CDCl 3 ): δ 9.5 (s, 1H), 8.2-7.2 (m, 7H) ppm.
Example 2
Intermediate 2
(E)-Ethyl 2-oxo-4-phenylbut-3-enoate
[0134]
[0135] A solution of intermediate 1 (63.4 g, 0.36 mol) in 20% sulfuric acid in ethanol (500 mL, w/w) was stirred at room temperature overnight and then was concentrated under reduced pressure. To the residue was added water (750 mL) and extracted with ethyl acetate (3×250 mL). The combined organic layers were washed with saturated sodium bicarbonate (2×100 mL), brine (100 mL), dried over magnesium sulfate (15 g), and concentrated under reduced pressure to give 60 g of intermediate 2 as yellow oil (82%).
[0136] 1 H NMR (60 MHz, CDCl 3 ): δ 7.9-7.1 (m, 7H), 4.4 (q, 2H), 1.4 (t, 3H) ppm.
Example 3
Intermediate 3
Ethyl 5-phenyl-1-propyl-4,5-dihydro-1H-pyrazole-3-carboxylate
[0137]
[0138] To a solution of intermediate 2 (8.16 g, 0.04 mol) in ethanol (100 mL) was added n-propylhydrazine hydrochloride (5.88 g, 0.04 mol) and stirred at room temperature for 2 hr under argon. To the reaction mixture was added acetic acid (30 mL) and refluxed for 2 hr. The reaction mixture was concentrated under reduced pressure and diluted with ethyl acetate (200 mL). It was washed with water (2×100 mL), saturated sodium bicarbonate (2×100 mL), brine (100 mL), filtered and concentrated under reduced pressure to give oil. The oil was flash chromatographed over silica gel (175 g) with anhydrous sodium sulfate (25 g) on top packed with hexanes. The compound was eluted with 10% ethyl acetate in hexane to give intermediate 3 3.8 g (36%) as an orange oil.
[0139] 1 H NMR (60 MHz, CDCl 3 ): δ 7.2 (s, 5H), 4.8-4.2 (m, 3H), 3.7-2.8 (m, 4H), 2.0-1.2 (m, 5H), 0.9 (t, 3H) ppm.
Example 4
Intermediate 4
(5-Phenyl-1-propyl-4,5-dihydro-1H-pyrazol-3-yl)methanol
[0140]
[0141] To a solution of intermediate 3 (3.4 g, 0.013 mol) in tetrahydrofuran (25 mL) and methanol (2 mL) was added a solution of lithium borohydride (16.35 mL of 2M in THF, 0.0327 mol) over 45 min at 0° C. under argon. The reaction mixture was warmed to room temperature and after 90 min quenched with acetone (15 mL) at 0° C. To the reaction mixture was added water (25 mL) and 1M HCl (30 mL) and extracted with ethyl acetate (2×50 mL). The combined organic layers were washed with brine (50 mL), filtered and concentrated under reduced pressure to give 3.0 g of crude product as oil. The oil was flash chromatographed over silica gel (60 g) with anhydrous sodium sulfate (10 g) on top packed with hexanes. The compound was eluted with 20% ethyl acetate in hexane to give intermediate 4 2.8 g (78%) as an oil.
[0142] 1 H NMR (60 MHz, CDCl 3 ): δ 7.2 (s, 5H), 4.3 (s, 2H), 4.6-3.8 (m, 1H), 3.2-2.6 (m, 4H), 1.6-1.2 (m, 3H), 0.8 (t, 3H) ppm.
Example 5
Intermediate 5
3-Methyl-4-((5-phenyl-1-propyl-4,5-dihydro-1H-pyrazol-3-yl)methoxy)benzaldehyde
[0143]
[0144] To a solution of intermediate 4 (2.18 g, 0.01 mol), 4-hydroxy-3-methylbenzaldehyde (1.8 g, 0.013 mol), and triphenylphosphine (3.1 g, 0.012 mol) in tetrahydrofuran (25 mL) at 0° C. was added diisopropyldiazocarboxylate (2.4 g, 0.012 mol) over 30 min under argon. The reaction mixture was warmed to room temperature and stirred overnight. The reaction mixture was diluted with ethyl acetate (75 mL), washed with 50 mL water:brine (4:1), brine (50 mL), filtered and concentrated to give to give crude material as an oil. The oil was flash chromatographed over silica gel (75 g) with anhydrous sodium sulfate (7 g) on top packed with hexanes. The compound was eluted with 10% ethyl acetate in hexane to give intermediate 5 1.14 g (34%) as a light orange oil.
[0145] 1 H NMR (300 MHz, CDCl 3 ): δ 9.9 (s, 1H), 7.7 (d, 2H), 7.4 (m, 5H), 7.1 (d, 1H), 4.8 (dd, 2H), 4.4 (dd, 1H), 3.2 (dd, 1H), 2.8 (m, 3H), 2.3 (s, 3H), 1.7 (m, 2H), 0.85 (t, 3H) ppm.
Example 6
Compound 1
[3-({3-Methyl-4-[(5-phenyl-1-propyl-4,5-dihydro-1H-pyrazol-3-yl)m]benzyl}amino)propyl]phosphonic acid
[0146]
[0147] To a solution of Intermediate 5 (102 mg, 0.30 mmol) and (3-aminopropyl) phosphonic acid (42 mg, 0.30 mmol) in methanol (10 mL) was added tetrabutylammonium hydroxide (1M in MeOH, 0.3 mL). The reaction mixture was heated to 50° C. for 1 h with stirring, cooled to RT, and then sodium borohydride (17 mg, 0.45 mmol) was added. After the reaction mixture was stirred at RT for 3 h, the mixture was concentrated and purified by MPLC (100% methanol in ethyl acetate) to give 64 mg of Compound I as a colorless solid.
[0148] 1 H NMR (600 MHz, CD 3 OD): δ 7.43 (m, 2H), 7.35-7.41 (m, 2H), 7.29 (s, 3H), 7.06-7.09 (m, 1H), 4.93 (m, 2H), 4.39-4.46 (m, 1H), 4.11 (s, 2H), 3.07-3.16 (m, 3H), 2.86-2.97 (m, 3H), 2.26 (s, 3H), 1.96-2.03 (m, 2H), 1.76-1.85 (m, 2H), 1.59-1.71 (m, 2H), 0.84-0.92 (m, 3H).
Biological Examples
In Vitro Assay
[0149] Compounds of the invention were tested for S1P1 activity using the GTP y 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.
[0150] GTP γ 35 5 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 y 35 5, and 5 pg 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 5 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.
[0000]
TABLE
Activity potency: S1P1 receptor from GTP γ 35 S: nM, (EC 50 )
S1P1
IUPAC name
EC 50
Structure
(nM)
[3-({3-Methyl-4-[(5-phenyl-1-propyl-4,5-dihydro-1H-pyrazol-3-
57
yl)methoxy]benzyl}amino)propyl]phosphonic acid
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The present invention relates to substituted dihydropyrazoles, processes for preparing them, pharmaceutical compositions containing them and their use as pharmaceuticals as modulators of sphingosine-1-phosphate receptors.
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BACKGROUND OF THE INVENTION
This invention relates to an acid drain opening system, in general, and, more particularly, to a system for administering acid to a clogged drain and the method of use of the system.
During normal use, drains tend to become clogged with various materials that are rinsed down the drain, such as oils, hair, toilet paper, talcum powder and petroleum jelly. The materials that clog the drain settle in the trap, and until they are removed or broken up, water will not pass through the drain.
Various devices and chemical compositions have been developed for clearing the drain. Some of these are mechanical in nature, such as a plunger, which consists of a rigid suction cup on a stick, or a plumber's snake or drain auger, which is a mechanical device rotated in the trap, in an attempt to break up the clog.
In recent years, pressurized cans have been developed, which break up the clogs through the use of released gas pressure. Devices of this type are shown in U.S. Pat. Nos. 3,823,427 (Pittet) and 4,034,427 (Breznock et al.).
Various alkali chemical cleaners are also used for clearing clogged drains. These chemical cleaners are available in both liquid and granular form. The liquid chemical cleaners can be poured through standing water in a sink, whereas the standing water should be drained before using the granular cleaners. The chemical cleaners cause a chemical reaction at the clog and many of them create substantial heat. The net result is that the clog is loosened sufficiently to permit it to be removed by cold running water, after the reaction has been completed.
If none of the foregoing devices and compositions work to remove the clog, a homeowner will normally call a plumber. One of the most common methods used by a plumber, and possibly by homeowners, to remove a clog, when all else has failed, is to pour concentrated sulfuric acid into the drain. If water remains in the drain, the acid, which has a higher specific gravity than water, will settle through the water, until it reaches the clog. At that point, the acid will react with the clog, and eat away at the clog, until the clog is destroyed. The drain can then be flushed with cold water.
One of the problems with using the acid is that it is extremely dangerous. A substantial amount of heat is created by the reaction of the acid with the material forming the clog, and on many occasions, this will cause the acid to blow back out of the drain and onto the person who administered the acid. Needless to say, serious injury to the skin or eyes can result from the use of sulfuric acid to clear a clog, even though sulfuric acid has been found to be extremely effective in breaking up the clog.
The device and method of this invention provide a safe and effective means of injecting sulfuric acid into a clog, while minimizing the danger to the person administering the acid.
The device of this invention includes a sealed bottle of sulfuric acid, with a means for piercing the seal, without the user of the acid having his skin come in contact with the acid. After the seal is pierced, the acid flows through a tube, which has an open end within the clog. Devices for removing liquid from a sealed container, and administering the liquid through a tube, are well known to the art. Generally, devices of this type have been used for removing oil from a sealed can, and pouring the oil, through a tube, into an engine. An example of such an oil-pouring device can be found in U.S. Pat. No. 4,600,125 (Maynard, Jr.).
The device of this invention is specifically different from that shown in Maynard. The device is secured to the acid bottle, and this prevents the inadvertent removal of the bottle from the pouring device. In Maynard, there is merely a piercing spout which pierces the top of a metal can. Additionally, the tube on this device is relatively rigid, so that it can be inserted down the drain and into the clog. In the Maynard device, the tube is flexible, and has a bellows construction. Although that construction is effective for pouring oil into a crankcase, it would not be effective for insertion into and through a clog. To the contrary, when the clog is contacted, the bellows would merely collapse.
Another advantage of the device of this invention over that of Maynard is that the acid leaving the bottle can only pass through the tube, and cannot come in contact with the person administering the acid. By way of contrast, in Maynard, after the oil can is pierced, the oil enters a funnel, and passes through a screen, before entering the spout. If the Maynard device were used for acid, if there were any blowback through the tube, it could blow the can away from the funnel, thereby blowing acid on the person administering the acid.
Since the device of this invention requires the draining of acid from a bottle that is closed, except for the top opening, in order to prevent creating a vacuum within the bottle as the acid is withdrawn, air holes are provided in the device to periodically admit air into the acid bottle. This prevents the creation of a vacuum, which could prevent or severely hinder the pouring of the acid. Vent holes of this type are known in the prior art, as shown in U.S. Pat. Nos. 2,435,033 (Campbell) and 2,714,977 (Davis). However, neither of the devices shown in these prior patents is used for pouring acid into a clog. In the former patent, the vent holes are used in connection with transferring various non-corrosive liquids, and in the latter patent, they are used in connection with dispensing oil into a crankcase.
OBJECTS OF THE INVENTION
Accordingly, it is a general object of this invention to provide a novel system for injecting acid into a drain clog.
It is another object of this invention to provide a safe and effective means for removing liquids from a container and injecting them into a remote location.
It is a further object of this invention to provide a novel bottle.
It is yet a further object of this invention to provide a novel method of injecting acid into a drain clog.
SUMMARY OF THE INVENTION
These and other objects of the invention are accomplished by providing a coupling having an open top and closed bottom. An opening is formed within the bottom, and a hollow piercing means is secured in and projects upwardly from the opening. A rigid, but slightly deformable, hollow tube is connected to and is in fluid communication with the piercing means, and projects downwardly from the bottom of the coupling. The coupling contains securing means for securing a container of liquid thereto. When the container of liquid is secured to the coupling, a portion of the container projects into the coupling, and a seal on that portion is pierced by the piercing means, to enable the liquid within the container to flow through the piercing means, through the tube and into a remote area in which the tube has been inserted.
The invention further encompasses a method of injecting acid into a drain clog comprising providing a coupling, said coupling having a piercing member mounted in an opening at the bottom thereof, said piercing member comprising a hollow tube, providing a rigid tube in fluid communication with said piercing tube, inserting the hollow tube into a drain until it is embedded in the clog, placing a portion of a sealed container of acid into said coupling in such a manner as to permit the piercing tube to pierce the container, whereby the acid from the container enters the piercing tube, passes through the hollow tube and into the clog, thereby reacting with and breaking up the clog.
DESCRIPTION OF THE DRAWINGS
Other objects and many of the attendant advantages of this invention will become readily appreciated as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, wherein:
FIG. 1 is a perspective view, partially broken away and partially exploded, showing the device of this invention placed in a sink and having its tube inserted in a clogged drain, with a bottle of acid positioned above the device;
FIG. 2 is an enlarged sectional view taken along the line 2--2 of FIG. 1;
FIG. 3 is a sectional view, similar to FIG. 2, but showing the bottle of acid secured within the device of this invention;
FIG. 4 is a sectional view taken along the line 4--4 of FIG. 3;
FIG. 5 is a perspective view of the piercing tube of the device of this invention; and,
FIG. 6 is a sectional view taken along the line 6--6 of FIG. 3.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now in greater detail to the various figures of the drawing, wherein like reference characters refer to like parts, an acid drain opening system embodying the present invention is generally shown at 20 in FIG. 1. Device 20 comprises a coupling 22 and a tube 24 in fluid communication with the coupling 22 and projecting downwardly therefrom. A rubber mat 26 is positioned between the coupling 22 and the tube 24. A bottle 28 containing concentrated sulfuric acid is used in conjunction with the device 20.
Referring to FIGS. 2 and 3, it is seen that the coupling 22 comprises a cylindrical sleeve 30, having one end closed by cylindrical insert 32. Sleeve 30 is open at its top, as viewed in FIG. 1, and its upper end is internally threaded, as shown at 34 in FIGS. 2 and 3. Vertically extending ribs 36 are equally spaced around the outer surface of sleeve 30. An octagonal rim 38, having eight equally-sized flattened faces, projects around sleeve 30, perpendicularly to the ribs 36 (see FIG. 1).
Insert 32 is maintained within sleeve 30 by a frictional fit. In order to enable the assembly of the insert 32 in the sleeve 30, insert 32 is also provided with an octagonal rim 40, similar to rim 38 on sleeve 30 (FIG. 1). In assembling the coupling 30, the top of insert 32 is inserted in the bottom of sleeve 30, and can be moved upward within the sleeve by rotating the insert. In order to facilitate the movement of the insert within the sleeve, open-end wrenches can be applied to the flattened faces of rims 38 and 40, and the insert can then be rotated relative to the sleeve. Sleeve 30 and insert 32 can be molded from any durable, sulfuric acid-resistant plastic, such as polyethylene, polyvinyl chloride, etc.
Insert 32 includes a base 42. A central opening is formed in base 42, and is in fluid communication with an internally threaded bore 44. A nipple 46 (FIG. 5) is threadedly secured in the upper portion of bore 44, through the use of external threads 48.
As seen in FIGS. 3 and 5, nipple 46 is formed from a hollow tube, and has two diametrically opposed piercing points 50 at the top thereof. The top of the wall forming the tube is formed with a concave cut, projecting downwardly from the points 50, and the wall is beveled, to leave upper and lower cutting edges 52 and 54, respectively. A pair of diametrically opposed holes 56 are formed through the threaded portion 48 of the nipple 46. The nipple can be formed from polypropylene.
Positioned beneath nipple 46 is a connector 58 (FIGS. 2 and 3). Connector 58 has a hollow interior, and external threads 60, which are threadedly secured in bore 44. As seen in FIG. 6, connector 58 has a hexagonal cross section. The connector 58 can be secured in bore 44 by grasping two of the flattened faces of the connector with an open end wrench, and by grasping one of the octagonal rim 40 with an open end wrench, and threadedly advancing the connector within the bore. Two openings 62 are formed in the base of connector 58. These openings place the interior of the connector in fluid communication with the surrounding atmosphere.
The bottom of connector 58 includes a barbed extension 64. Tube 24 is slid over the barbs, and is retained in place by the upper edges of the barbs. As seen in FIGS. 2 and 3, extension 64 is hollow, and is in fluid communication with the interior of connector 58. The lower end of tube 24 has an angled face 66, which terminates in a pointed end 68. A plurality of openings 70 are formed in the lower portion of tube 24.
Tube 24 is basically rigid, but is slightly bendable into an arcuate shape. The rigidity is sufficient to prevent the tube's being collapsed or deformed by applying pressure to the sides of the tube. The tube is non-collapsible longitudinally, and has only a limited amount of arcuate bend available. Various plastic materials can be used for forming the tube, such as polyethylene. A polyethylene tube having an outer diameter of 1/2 inch (1.27 cm) and an internal diameter of 3/8 inch (0.95 cm) has been found to have sufficient rigidity, and sufficient arcuate deformability, to function in carrying out this invention. The connector 58 can be formed from any of the plastics usable in the other parts of the coupling 22. The connector can also be formed from polypropylene.
Positioned between the bottom of insert 32 and ledge 72 (FIGS. 2 and 3) of connector 58 is mat 26. Mat 26 is formed from a flexible material, such as natural or synthetic rubber, and includes longitudinally extending ribs 74 along its lower surface. The ribs are equally spaced, and between the ribs are channels 76.
The rubber mat has a central opening, and the connector 58 passes therethrough. Positioned on ledge 72 of the connector is a washer 78. Washer 78 is formed from a material that will not be corroded by sulfuric acid, such as stainless steel. The purpose of the washer is to maintain the rubber mat 26 in a horizontal position in the area of the coupling 22.
The bottle 28 is molded from polyethylene or other plastic which will not react with sulfuric acid. The bottle has a large, threaded neck portion 80 and a smaller threaded neck portion 82. After the bottle is filled with sulfuric acid, schematically shown at 84 in FIG. 2, a plastic seal 86 (FIG. 2) is placed over the mouth of the bottle. The plastic seal can be formed from any acid-resistant material. A preferred material is polyethylene, which can be heat-sealed in place. After the heat seal is placed on the acid, a rigid plastic cap is secured on threaded neck portion 84. The cap protects the seal and prevents inadvertent removal of the acid from the bottle. When it is intended to remove the acid from the bottle, the cap is removed.
The system of this invention is adapted to remove a clog from all types of drains, such as drains in sinks, showers and toilets. By way of example, the system is shown as being used on a sink, in FIG. 1. As seen in FIG. 1, the sink includes a bowl 88, a countertop 90 and a faucet 92. As seen in FIG. 2, bowl 88 includes a central opening with a drain collar 94 mounted therein. A drainpipe 96 (FIGS. 1 and 2) is threadedly secured on collar 94. A trap 98 (FIG. 1) is mounted on the bottom of drainpipe 96, and a pipe 100 is shown for carrying away the waste water after it passes through the trap.
The system of this invention can be used on virtually any type of clog that would normally develop in a drain. If there is any standing water remaining in the fixture requiring draining, the standing water should first be removed to a point below the surface of the fixture, for instance, below the top surface of the collar 94 in FIG. 2. This can easily be accomplished by using a cup and a bucket to hold the removed water. A sponge can be used to lower the water level below the top surface of the collar.
After the surface water has been removed, the tube 24 is inserted through the collar 94 and down drainpipe 96. When the tube encounters the clog, normally, by rotation of the coupling 22 and applying downward pressure, the tube will pass through the clog to a point on the unclogged side of trap 98. However, if the clog is too dense for the tube to pass totally through it, the system of this invention will still operate, with the tip 68 of the tube embedded in the clog. The insertion of the tube into, and possibly through, the clog is facilitated by the fact that the tube is rigid, from a cross-sectional and longitudinal standpoint. Thus, it cannot be collapsed in either dimension. The tube is sufficiently bendable to form an arc in passing through the clog, as shown in FIG. 1. The pointed end 68 and angled face 66 facilitate the insertion of the tube into and through the clog.
With the tube 24 fully inserted into and through the clog, as shown in FIG. 1, the mat 26 will contact the surface of the bowl 88, with the ribs 74 and channels 76 being lowermost. Depending on the size of the drain opening, the washer 78 will either totally cover the opening in collar 94 or will be positioned in the center of the collar. The washer 78 will not go into the drain opening, since this would be prevented by the contact of the mat 26 with the bowl.
At this point, acid can be administered to the clog. In order to do this, the cap is first removed from bottle 28, thereby exposing the seal 86 at the top of the bottle. The bottle is then inverted, as shown in FIG. 1, and threaded neck portion 80 is aligned with the threads 34 in sleeve 30, as shown in FIG. 2. At this point, the seal 86 is spaced above the points 50 of nipple 46. The bottle 28 is then rotated in a clockwise direction, thereby moving it downwardly relative to the points 50. Eventually, the points 50 will contact the seal 86, and pierce the seal. Continued rotation of the bottle in a clockwise direction will cause the seal to rupture, and the beveled edges 52 and 54 (FIG. 5) of the nipple will partially sever the seal from the mouth of the bottle. It should be noted, however, that there is not total severance, and part of the seal will remain in place, heat-sealed to the lip of the bottle. This condition is shown in FIGS. 3 and 4. The net effect of the rotational movement of the bottle relative to the nipple is that the seal is broken, partially severed and pushed out of the way. The seal is not totally removed from the bottle, and accordingly, will not clog the tube 24.
After the seal is punctured and partially severed, to the position shown in FIGS. 3 and 4, acid will leave bottle 28, and pass through nipple 46. The shredded seal 86 should act as a gasket, to prevent any of the acid from leaking from the bottle to the exterior of nipple 46. However, if it does, the acid will hit the base 42 of insert 32, and pass into the interior of nipple 46 through openings 56. The acid proceeds downwardly from nipple 46 through connector 58, and into tube 24. The acid then exits from the tube through the angled face 66 at the end of the tube and through opening 70 in the tube.
Assuming the tube has been pushed through the clog, the acid exiting from the angled face will drain back into the clog, reacting with the clog at the far end, that is, the end away from the drain. Additionally, acid will leave the tube through openings 70, and react with the clog along the entire length of the clog. Within about five to ten minutes, the reaction between the acid and the clog will be complete. At this point, the bottle 28 is unthreaded from the coupling 22, and water can then be poured into coupling 22, to flush the remaining acid from the trap. The fresh water can be poured directly into the nipple 46, or if any is poured onto the base 42 of insert 32, it will pass through openings 56, and downwardly through tube 24. After all of the acid has been flushed from the trap, the tube 24 is removed from the drain. However, so long as the tube is in place when the initial flushing water is added, if there is any blowback up the drainpipe, it will be contained by washer 78 and mat 26.
One of the features of this invention is the fact that any blowback caused by the reaction of the acid with the clog can be contained, without its reaching the skin or eyes of the plumber. Thus, when the acid is added to the clog, there is a chemical reaction between the acid and clog, and this generates a substantial amount of heat. There is still water remaining in the drainpipe at the time the acid is added. If the reaction is too violent, as has occurred when plumbers pour the acid directly through the standing water in the drainpipe, the water-acid mixture is literally blown back through the drain. If it contacts the skin or eyes of the plumber or homeowner administering the acid, serious injury can result.
Utilizing the device of this invention, if the reaction does cause a blowback, the material coming back through the drain will first contact washer 78. The material would then spread laterally, but would be confined by the rubber mat 26, which has sufficient weight, even though it is flexible, to remain in contact with the surface of the bowl. The liquid emanating from the drain then passes along the undersurface of the mat, in channels 76 between ribs 74. By the time the blown-back liquid reaches the edge of the mat, it will have lost its explosive force, and will simply remain on the surface of the bowl. The mat gives the person administering the acid sufficient protection to avoid any danger from blown-back acid. Although the exact size of the mat is a matter of choice, it is believed that a mat that is a 1 foot (30.5 cm) square should be adequate to withstand virtually any blowback.
One of the features of this invention is the provision of openings 62 in connector 58. Without these openings, as the acid is drained from the bottle 28, a vacuum will form in the space between the top of the acid level and the bottom of the bottle, which would be uppermost when the bottle is in its operational position shown in FIGS. 2 and 3. The existence of the vacuum can eventually prevent the acid from leaving the bottle, and can, in fact, create a vacuum in the bottle that can draw water into the bottle, causing a violent reaction, and possible rupture of the bottle.
The openings 62 are sufficiently small to prevent the acid from passing therethrough, while at the same time, are sufficiently large to permit the passage of air to neutralize the vacuum created above the acid as it is drained. Thus, the surface tension of the acid will prevent leakage through the openings. However, as the acid is drained, and the amount of vacuum becomes greater, air, under atmospheric pressure, will find its way through the openings to provide neutralization of the vacuum above the acid. Once the vacuum has been neutralized, acid will continue to flow, until the vacuum is sufficiently great to permit more air to pass through openings 62. The air for openings 62 is provided by withdrawing sufficient standing water from the bowl so that it is below the level of the bottom of connector 58. If more air is needed within that space, the coupling 22 can be rocked slightly, to provide more air.
The size of the openings 62 is somewhat critical. Thus, if the openings are too small in diameter, the vacuum within the acid bottle can actually draw water back into the bottle, causing the reaction and dangerous situations previously described. If the openings are too large in diameter, the acid will leave the bottle too quickly. This in turn will cause the clog to react with the acid too quickly, and generate too much heat, which could lead to a dangerous blowback. Although the optimum diameters of the openings 62 can be determined through experimentation, in the embodiment shown, utilizing a bottle containing 1 pint (47.3 cl) of acid, it has been found that having two openings which are 3/32 inch (0.24 cm) in diameter provides optimum results. Using openings of this diameter will permit the acid to drain in one to one and one-half minutes, and this will result in effective dissolution of the clog within five to ten minutes, without a dangerous blowback.
The theory of utilizing openings such as openings 62 to control liquid flow where a vacuum is being formed is described in greater detail in aforementioned U.S. Pat. No. 2,435,033 (Campbell). Campbell discloses the use of such openings for dispensing or transferring liquids in various environments, none of which is the same as the environment in which the instant invention is used. However, the theory on which the patented invention is based is the same theory that applies to this aspect of the instant invention.
Having the threaded connection between bottle 28 and coupling 22 provides many advantages. The removal of the seal 86 from the bottle opening is controlled by the rotation of the bottle in the threads. If the bottle were merely pushed downwardly, the seal might be severed totally, and could partially clog the tube 24. Additionally, by having the threaded connection between the bottle and the coupling, leakage is prevented. In the prior art devices where a can containing oil or other liquid is punctured by a piercing spout, leakage could occur. Having the threaded connection prevents leakage, which leakage could be dangerous when using acid.
Another safety feature of having the bottle threadedly connected to the coupling is that in the event of a sudden blowback, if the blowback should be partially through the tube 24, the bottle 28 will not be blown off. If there were nothing securing the bottle in place, such as the threads, the bottle could be easily dislodged, as could occur when the only connection is by puncturing the bottle with a spout.
Although this invention has been developed specifically for use with acid to remove a drain clog, the invention can be used with other chemical solutions that are normally used for opening drain clogs, and which may cause a violent reaction with or at the clog. Thus, the invention can be used with potassium hydroxide solutions, sodium hydroxide solutions or solvent-based solutions, for removing the clogs.
Without further elaboration, the foregoing will so fully illustrate this invention that others may, by applying current or future knowledge, readily adapt the same for use under various conditions of service.
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A system for administering acid to a clogged drain, and the method of using the system. The system includes a coupling to which a container of the acid can be threadedly secured. The coupling includes a piercing nipple, which penetrates a seal on the acid bottle. The nipple is hollow, and the acid passes from the bottle through the nipple and into a rigid, but arcuately deformable, tube that is connected to the coupling and is in fluid communication with the nipple. The tube is inserted into the clogged drain, until it is embedded in the clog. The acid is delivered directly to the clog, where it reacts with and dissolves the same.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to an antibody or a monoclonal antibody for quantitative determination of hepatocyte growth factor activator inhibitor-1 (hereinafter, sometimes abbreviated as “HAI-1”), to a method of using the same and to a kit for measuring the same. Also, the present invention relates to a method of detecting and measuring the state of a patient suffering from a disease, In particular inflammation of an organ, nephritis, cancers, liver diseases, blood diseases, myocardial infarction, angina pectoris, cerebral infarction, or thrombosis.
[0003] 2. Description of the Related Art
[0004] The hepatocyte growth factor activator inhibitor-1 (HAI-1) is known as a control agent for a hepatocyte growth factor inhibitor and as a kind of Kuniz type serine protease inhibitor (Shimomura et al., J. Biol. Chem., 272: 6370-6376 (1997)). HAI-1 is considered to be a protein that has a portion that penetrates through a cytoplasmic membrane (hereinafter, referred to as “cytoplasmic membrane-penetrating portion”) and is reported to have a molecular weight of about 66,000 (electrophoresis) (Shimomura et al., J. Biol. Chem., 126: 821-828 (1999)). Also, HAI-1 is known to exist in the supernatant of a culture of HAI-1-producing culture cells, such as MKN45, in a state where it has no cytoplasmic membrane-penetrating portion. It has been reported through the measurement by using an SDS-PAGE method under the reduction condition that these soluble HAI-1 molecules include a molecule having a molecular weight of about 58.000, a molecule having a molecular weight of about 48,000, a molecule having a molecular weight of about 40,000, and a molecule having a molecular weight of about 39,000, which are called “soluble forms of HAI” (Shimomura et al., J. Biol. Chem., 126: 821-828 (1999)); herein these are referred to as “soluble HAI-I.”
[0005] It has been known that HAI-1 has the effect of a protease inhibitor such as the effect of inhibiting a hepatocyte growth factor-activating factor [which is a factor that acts on a hepatocyte growth factor (hereinafter, abbreviated as “HGF” (Naka et al., J. Biochem., 267: 20114-20119 (1992)) and subjecting it to specific restricted decomposition to activate it (Shimomura et al., Cytotechnology, 8:219-229 (1992))]. The known antibody to HAI-1 includes murine monoclonal antibodies C76-18 and 1N7 (Shimomura et al., JP 11-295309 A: C76-18, Kataoka et al., J. Histochem. Cytochem., 47: 673-682 (1999): 1N7). Tissue staining using this antibody has revealed that HAI-1 is expressed in pancreas, liver, small intestine and uterus of normal persons. Tissue staining using the above-mentioned antibody has been performed for patients suffering from liver cancer and expression of HAI-1 has been examined (Kataoka et al., Cancer Research, 60, 6148-6159, 2000). However, the role and function of HAI-1 in human pathology have not been clarified yet. Further, the relationship between the concentration of soluble HAI-1 in the biological components such as blood and the pathology has not been known.
[0006] To analyze the relationship between the concentration of soluble HAI-1 in the biological components, such as blood level, and the pathology, it is necessary to quantitatively determine soluble HAI-1 that exists in the biological components such as human tissue, body fluid, urine or blood. Then, to quantitatively determine soluble HAI-1, it is indispensable to obtain a high-affinity antibody that recognizes soluble HAS-1, particularly desirably a high-affinity monoclonal antibody.
[0007] The known antibody to HAI-1 includes murine monoclonal antibodies C76-18 and 1N7 (Shimomura et al., JP 11-295309 A: C76-18, Kataoka et al., J. Histochem. Cytochem., 47: 673-682 (1999): 1N7). However, there has been no anti-soluble HAI-1 antibody having suitable properties for quantitatively determining soluble HAI-1 or no method or kit therefor for detecting or quantitatively determining soluble HAI-1 existing in the biological components such as human blood.
SUMMARY OF THE INVENTION
[0008] An object of the present invention is to provide a method of detecting soluble HAI-1 by using a high-affinity antibody that recognizes the soluble HAI-1, a method of quantitatively determining the same and a method of detecting a disease associated with soluble HAI-1, a method of quantitatively determining the same and a kit therefor.
[0009] The above-mentioned murine monoclonal antibodies to HAI-1, i.e., C76-18 and 1N7 (Shimomura et al., JP 11-295309 A: C76-18, Kataoka et al., J. Histochem. Cytochem., 47: 673-682 (1999) 1N7) are not suitable for quantitatively determining soluble HAI-1 in the biological components. In fact, attempts to construct a measurement system for measuring soluble HAI-1 by using obtained such existing antibodies have failed to realize construction of a system that allows determination of the concentration of soluble HAI-1 in blood. The reason for this would be as follows. That is, it is because although the existing antibodies could recognize HAI-1 on the surface of cells but could not recognize soluble HAI-1 such as one that exists in biological components such as blood or urine. Alternatively, it is because the existing antibodies might have low affinity for HAI-1 and could not sufficiently bind to soluble HAI-1 in the biological components. In fact the dissociation constants of the existing antibodies to HAI-1 measured are C76-18: Kd 1.48×10 −9 M, and 1N7: Kd 1.68×10 −8 M, which correspond to insufficient affinity for the measurement of concentrations of soluble HAI-1 in the biological components in human.
[0010] On the other hand, as a result of extensive studies, the inventors of the present invention were successful in obtaining a high-affinity murine monoclonal antibody to the soluble HAI-1. The high-affinity murine monoclonal antibody to the soluble HAI-1: HAI-1A-1-1-3-4, which the inventors have obtained has a dissociation constant of antigen-antibody reaction of Kd=2.67×10 −10 M, which is considerably higher in affinity than that of conventional antibodies, and also has sufficient affinity for determining the concentration of soluble HAI-1 in the biological components in human. Thus, the inventors successfully constructed a quantitative determination system by using such an antibody. Further, it revealed that the antibody of the present invention has enough affinity to analyze the relationship between the concentration of soluble HAI-1 and various human diseases in human pathology.
[0011] Accordingly, to analyze the relationship between the concentration of soluble HAI-1 in blood in human pathology and various human diseases, the inventors contemplated to construct a highly sensitive quantitative determination system for determining HAI-1 in human blood by using a high-affinity antibody HAI-1A-1-1-3-4. That is, an enzyme-linked immunosorbent assay (hereinafter, abbreviated as “ELISA assay system” using a double antibody sandwich method utilizing a murine monoclonal antibody HAI-1A-1-1-3-4 against soluble HAI-1 and a rabbit polyclonal antibody was constructed and the concentration of soluble HAI-1 was measured for bloods (blood plasmas or sera) of healthy persons and patients suffering from various diseases such as a disease of an organ.
[0012] As a result, by using the soluble HAI-1-specific highly sensitive measurement method and a kit therefor according to the present invention, the inventors have clarified the blood level range of soluble HAI-1 in a healthy person for the first time and found a considerable increase in the amount of soluble HAI-1 existing in the blood of patients suffering from organopathy such as glomerulonephritis or the like, cancers or thrombosis.
[0013] The present invention has been accomplished based on these findings and provides the followings.
[0014] (1) An antibody that recognizes and quantitatively binds to soluble hepatocyte growth factor activator inhibitor-1 (soluble HAI-1).
[0015] (2) The antibody according to (1), wherein the soluble HAI-1 has a molecular weight of about 39,000 to 58,000 daltons as measured by SDS-PAGE under reduced conditions.
[0016] (3) The antibody according to (1) or (2), wherein the antibody has a dissociation constant with respect to the soluble HAI-1 of 2×10 −6 M or less.
[0017] (4) The antibody according to any one of (1) to (3), wherein the antibody is a monoclonal antibody.
[0018] (5) A monoclonal antibody according to (4), wherein the antibody is produced by the hybridoma of which accession number is FERM BP-8022.
[0019] (6) A hybridoma cell line that produces a monoclonal antibody according to (4).
[0020] (7) The hybridoma cell line according to (6), wherein the cell line is the hybridoma of which accession number is FERM BP-8022.
[0021] (8) A method of quantitatively determining soluble HAI-1, comprising immunologically measuring the soluble HAI-1 by using one or a plurality of antibodies according to any one of (1) to (5).
[0022] (9) The method according to (8), wherein a sample in which soluble HAI-1 is to be measured is a biological component collected from a subject or animal suspected of a disease.
[0023] (10) The method according to (9), wherein the disease is selected from the group consisting of organ inflammation, nephritis, cancers, liver diseases, blood diseases, myocardial infarction, angina pectoris, cerebral infarction and thrombosis.
[0024] (11) The method according to (9), wherein the disease is hepatocellular carcinoma or pancreas cancer.
[0025] (12) The method of detecting a disease comprising detecting or measuring soluble HAI-1 in a biological component collected from a subject suspected of the disease.
[0026] (13) The method according to (12), wherein the disease selected from the group consisting of organ inflammation, nephritis, cancers, liver diseases, blood diseases, myocardial infarction, angina pectoris, cerebral infarction and thrombosis.
[0027] (14) The method according to (12), wherein the disease is selected from the group consisting of hepatocellular carcinoma and pancreas cancer.
[0028] (15) The method according to (9) or (12), wherein the biological component is blood or its fractionation product or a treated product.
[0029] (16) The method according to claim (9) or (12), wherein the biological component is plasma or blood serum.
[0030] (17) The method according to claim (9) or (12), wherein the biological component is urine.
[0031] (18) A kit for detecting or quantitatively determining soluble HAI-1, comprising one or a plurality of antibodies according to (1).
[0032] (19) The kit according to (18), wherein the kit is used for the diagnosis of at least one disease selected from the group consisting of organ inflammation, nephritis, cancers, liver diseases, blood diseases, myocardial infarction, angina pectoris, cerebral infarction and thrombosis.
[0033] (20) The kit according to (18), wherein soluble HAT-1 in a biological component collected from a patient suspected of a disease is measured with the kit.
[0034] (21) The kit according to (18), wherein the detection or measurement of the soluble HAI-1 is performed by immunological staining.
[0035] In this specification, the monoclonal antibody that recognizes soluble HAI-1 is sometimes referred to as “soluble HAI-1-specific high-affinity monoclonal antibody” and the polyclonal antibody that recognizes soluble HAI-1 is sometimes referred to as “soluble HAI-1-specific polyclonal antibody.” Further, these antibodies may be collectively referred to as “soluble HAI-1-specific high-affinity” antibody. Furthermore, the phraseology “recognizes soluble HAI-1” means that an antibody “binds to soluble HAI-1 by an antigen-antibody reaction.” In this case, the soluble HAI-1-specific high-affinity antibody of the present invention may bind to either full-length HAI-1 or a part thereof.
[0036] The phraseology “quantitatively binds” as used herein means that the antibody binds to such an extent that it is possible to detect the binding between the soluble HAI-1-specific high-affinity antibody of the present invention and soluble HAI-1 in correlation with the concentration of soluble HAI-1. Specifically, it means that the antibody binds to such an extent that it is possible to quantitatively determine soluble HAI-1 by an immunological method such as enzyme immunoassay, radioimmunoassay, fluorescence immunoassay, chemiluminescence immunoassay, immunoblotting, immunochromatography, or latex agglutination. For example, antibodies that enable quantitative determination of soluble HAT-1 in an amount of 10 ng/ml or more, preferably 1 ng/ml or more, and more preferably 0.5 ng/ml or more may be used as the soluble HAI-1-specfic high-affinity antibody of the present invention.
[0037] According to the present invention monoclonal antibodies and polyclonal antibodies that specifically bind to soluble HAI-1 can be provided. The antibodies of the present invention can be used for specific and highly sensitive measurement and detection of soluble HAT-1.
[0038] The method of measuring soluble HAI-1 according to the present invention can be utilized for the diagnosis of various diseases reflected by the blood level of soluble HAI-1.
BRIEF EXPLANATION OF THE DRAWINGS
[0039] [0039]FIG. 1A is a diagram illustrating the reactivity between standard HAI-1 and each monoclonal antibody in an HAI-1 measuring system in a concentration of HAI-1 in a range of from 0 to 40 ng/ml;
[0040] [0040]FIG. 1B is a diagram illustrating the reactivity between standard HAI-1 and each monoclonal antibody in an HAI-1 measuring system in a concentration of HAI-1 in a range of from 0 to 2.5 ng/ml out of the range shown in FIG. 1A in an enlarged view in which a closed rhombus indicates HAI-1A-1-1-3-4; an open square ( ) indicates C76-18; and a triangle indicates IN7; and
[0041] [0041]FIG. 2 is a diagram showing the amount of HAI-1 in blood serum of a healthy person in a histogram.
DETAILED DESCRIPTION OF THE INVENTION
[0042] Hereinafter, the present invention will be described in detail.
[0043] <1>Immunogen and Screening Antibody for Preparing Soluble HAI-1-Specific High-Affinity Antibody
[0044] HAI-1 for use as an immunogen may be a full-length HAI-1 or a soluble HAI-1, i.e., an extracellular domain of HAI-1 or its partial peptide. To efficiently obtain a soluble HAI-1-specific high-affinity antibody, it is preferred to use soluble HAI-1 or its partial peptide. At least one of the immunogen and HAT-1 used for screening monoclonal antibody is preferably soluble HAI-1 or a partial peptide thereof.
[0045] As the soluble HAI-1, for example, purified supernatant of a culture of HAI-1-producing cell line, for example, MKN45, obtained according to the method of Shimomura et al. (J. Biol. Chem., 272: 7370-6370 (1997)) can be used. Also, HAI-1 which is recombinant protein produced by microorganism such as Escherichia coli, insect cells, yeast, animal cells and animals utilizing HAI-1 cDNA described in JP 9-95497 A (U.S. Pat. No. 6,225,081) can be utilized. Furthermore, peptides having a partial sequence of HAI-1 prepared by chemical synthesis can be utilized.
[0046] In particular, to obtain HAI-1-specific high-affinity antibody, it is preferred to prepare high-purity HAI-1. For this purpose, the HAT-1 as used herein, recombinant protein prepared by using HAI-1 cDNA is desirable. For example, recombinant HAI-1 can be obtained by inserting HAI-1 cDNA encoding HAI-1 as described in JP 9-95497 A (U.S. Pat. No. 6,225,081) in its entire length or a part thereof into a suitable expression vector, introducing the expression vector into a microorganism such as Escherichia coli, an insect cell, yeast, an animal cell or an animal, and subjecting the supernatant of a culture of such a transgenic cell or intracellular fraction, tissue or body fluid that expresses HAI-1 to purification operation. In a case where animal cells suitable as a host for expressing the above-mentioned cDNA, for example, CHO cells are used, soluble HAI-1 is liberated in a culture supernatant, on the other hand, in a case where microbial cells are used as a host, a region that encodes an extracellular domain out of the HAI-1 cDNA may be expressed. Furthermore, a suitable secretion signal may be used if necessary.
[0047] It is also possible to prepare the target HAT-1 by using in vitro transcription/translation system using Rapid Translation System RTS500 (Roche Diagnostics Co.) without using any cell system.
[0048] As a specific example thereof, it is possible to obtain soluble HAT-1, which is a recombinant protein, by introducing an expression vector having inserted the HAI-1 cDNA described in JP 9-95497 A (U.S. Pat. No. 6,225,081) downstream of the promoter of an animal cell expression vector, into an animal cell, selecting a cell that expresses HAI-1 cDNA, and purifying soluble HAI-1 from a supernatant of the culture. The purification of soluble HAT-1 can be performed by ordinary purification methods for proteins, such as gel filtration by using HPLC or affinity chromatography.
[0049] Soluble HAI-1 having high purity is not only important as an immunogen but also very important as a material for separating a soluble HAI-1-specific polyclonal antibody by affinity purification and for screening a soluble HAI-1-specific high-affinity monoclonal antibody. Also, it is important as a standard preparation of soluble HAI-1 at the time of quantitative determination.
[0050] <2> Preparation of Soluble HAI-1-Specific High-Affinity Monoclonal Antibody
[0051] To obtain a soluble HAI-1-specific high-affinity monoclonal antibody, an immunological method usually used may be practiced by using the above-mentioned HAI-1, preferably soluble HAI-1, as an antigen for immunization.
[0052] The animals to be used for immunization are not particularly limited and any one of rabbit, goat, sheep, mouse, rat, guinea pig, and chicken may be used. Inoculation of the antigen for immunization to an animal is performed subcutaneously, intramuscularly, or intraperitoneally after well mixing the antigen for immunization with Complete Freund's adjuvant or Incomplete Freund's adjuvant. The inoculation is practiced every 2 weeks to 5 weeks and continued until the antibody titer of the immunized animal to the inoculated antigen sufficiently increases (i.e., to have a titer of preferably 1,000,000 folds dilution or more by an ELISA method in the case of high-affinity antibody) and for at least a predetermined period (i.e., for at least 2 months in the case of high-affinity antibody). Thereafter, intravenous injection of only antigen to the immunized animal that showed a sufficient increase in titer of the antibody is carried out and after 3 days from the injection, spleen or lymph node that is considered to contain antibody-producing cells is collected, and spleen cells or lymphocytes are subjected to cell fusion with tumor cells. Thereafter. antibody-producing cells (hybridomas) immortalized by cell fusion are isolated. Generally, it is desirable that the tumor cells used here are obtained from the animal of the same species as that of the animal that has been subjected to immunization and from which the spleen, cells or lymphocytes have been prepared. However, tumor cells from animals of different species may also be used.
[0053] Examples of tumor cells that can be used include myeloma cells such as p3 (p3/x63-Ag8), P3U1, NS-1, MPC-11, SP2/0, FO, x63.6.5.3, S194, and R210. The cell fusion may be performed according to the generally employed method, for example, the method described in “Monoclonal Antibody Experimentation Manual” (Kodansha Scientific, 1987). The cell fusion may be performed by adding a cell fusion accelerator to a fusion medium in which the cells to be fused are suspended. The cell fusion accelerator includes sendai virus, polyethylene glycol having an average molecular weight of 1,000 to 6,000 and the like. In this case, an adjuvant such as dimethyl sulfoxtde or cytokine such as IL-6 may be added to the fusion medium in order to further increase the efficiency of the fusion. For example, the mixing ratio of the tumor cells to the immunized spleen cells or lymphocytes may be such that the spleen cells or lymphocytes are about 1 fold to about 10 folds the tumor cells.
[0054] The fusion medium that can be used includes various commonly used media such as ERDF medium, RPMI-1640 medium, and MEM medium. At the time of fusion, it is generally recommended that fetal bovine serum (FBS) or other serum etc. be eliminated from the medium. Fusion is performed by well mixing predetermined amounts of the immunized spleen cells or lymphocytes and tumor cells with each other in the above-mentioned medium, adding from about 20% to about 50% of a polyethylene glycol solution, previously heated to about 37° C. and allowing the mixture to react preferably at from 30 to 37° C. for from about 1 to about 10 minutes. Subsequently, a suitable medium is added in succession, the mixture is centrifuged and the supernatant is removed. This procedure is repeated.
[0055] The target hybridoma is cultured in an ordinary selection medium, for example, HAT medium (a medium containing hypoxanthine, aminopterine, and thymidine). The culture in the HAT medium may be performed usually for from several days to several weeks, which is enough time for cells other than the target hybridoma (unfused cell etc.) to be killed. A technically important issue upon obtaining a soluble HAI-1-specific high-affinity monoclonal antibody is its screening. The screening of the hybridoma that produces soluble HAI-1-specific high-affinity monoclonal antibody can be achieved by analyzing the soluble HAI-1 or the like material obtained by the above-mentioned method by various immunochemical methods. For example, the binding of soluble HAI-1 used as an antigen for screening, to a monoclonal antibody secreted in the supernatant of hybridoma culture may be analyzed by an enzyme immunoassay such as an ELISA method or a Western blotting method to select the target hybridoma Specifically, the culture supernatant of the above-mentioned hybridoma is added to soluble HAT-1 adhered to, for example, a screening plate and blocked with BSA or the like to select a hybridoma that secretes an antibody capable of recognizing soluble HAI-1. For example, the culture supernatant of the selected hybridoma is added to a plate for the ELISA method to which soluble HAI-1 adheres and allowed to react and after sufficient washing operation, a labeled anti-murine IgG polyclonal antibody is added thereto, followed by further reaction. After one washing operation, the label is detected and the hybridoma whose culture supernatant is reactive with the soluble HAI-1-adhered plate is selected. The label that can be used includes various enzymes, fluorescent substances, chemiluminescant substances, radioisotopes, biotin, avidin and the like as will be described later.
[0056] The above-mentioned screening can give rise to a hybridoma that produces a monoclonal antibody that recognizes soluble HAI-1. On the other hand, upon screening such a hybridoma, reactivity with the above-mentioned partial sequence peptide may also be used as an index. The antibody produced by the hybridoma selected by such a method may be preferably further checked if it reacts with soluble HAI-1.
[0057] Although it has been reported that soluble HAI-1 includes molecular species having molecular weights of about 58,000, about 48,000, about 40,000 and about 39,000, respectively, the HAI-1-specific high-affinity monoclonal antibody of the present invention is not limited particularly as far as it has high affinity for soluble HAI-1 that has no cytoplasmic membrane-penetrating portion regardless of the molecular weight. However, it is preferred that the monoclonal antibody of the present invention binds to any of the above-mentioned soluble HAI-1's having respective molecular weights.
[0058] The soluble HAI-1-specific high-affinity monoclonal antibody of the present invention desirably has a dissociation constant with respect to soluble HAI-1 of 2×10 −9 M or less, preferably, 1×10 −9 M or less, and more preferably 5×10 −10 M or less.
[0059] The hybridoma clone that produces the above-mentioned soluble HAI-1 -specific high-affinity monoclonal antibody specifically includes HAI-1A-1-1-3-4 described in Examples hereinbelow. In addition to HAI-1A-1-1-3-4, hybridomas that produce the soluble HAI-1-specific high-affinity monoclonal antibody of the present invention can be obtained with ease by referring to the description herein and using the methods well known to one skilled in the art.
[0060] By cloning the obtained hybridoma by a limiting dilution method, a single hybridoma clone that produces a monoclonal antibody can be obtained. This hybridoma clone is cultured in a medium containing from about 1% to about 5% of FBS from which bovine antibody (IgG) has been removed in advance or in a serum-free medium and the obtained culture supernatant is provided as a raw material for purifying the target monoclonal antibody. On the other hand, the obtained hybridoma clone may be transferred into the abdominal cavity of a Balb/C mouse or Balb/c(nu/nu) mouse previously administered with pristane and after from 10 to 14 days ascites containing the monoclonal antibody in a high concentration may be collected to provide a raw material for purifying the target monoclonal antibody. The monoclonal antibody may be purified by using an ordinary method for purifying immunoglobulins. For example, the purification may be performed by an ammonium sulfate fractionation method, a polyethylene fractionation method, an ethanol fractionation method, anion exchange chromatography, affinity chromatography bound to protein A or protein G, or the like.
[0061] <3> Preparation of Soluble HAI-1-Specific Polyclonal Antibody
[0062] The soluble HAI-1-specific high-affinity polyclonal antibody can be obtained by performing the procedure of subjecting the obtained polyclonal antibody derived from the immunized animal to operation for purifying an antibody that recognizes soluble HAI-1 by using HAI-1, preferably soluble HAI-1 or a partial peptide thereof as an antigen for immunization. As the antigen for immunization to obtain the polyclonal antibody, a fused form consisting of the above-mentioned HAI-1 partial sequence peptide and a carrier may also be used.
[0063] The animals to be used for immunization are not particularly limited and any one of rabbit, goat, sheep, mouse, rat, guinea pig, chicken, and the like may be used. Inoculation of the antigen for immunization to an animal is performed subcutaneously, intramuscularly, or intraperitoneally after well mixing the antigen for immunization with Complete Freund's adjuvant or Incomplete Freund's adjuvant. The inoculation is practiced every 2 weeks to 5 weeks and continued until the antibody titer of the immunized animal to the inoculated antigen sufficiently increases. Thereafter, intravenous injection of only antigen is performed to the immunized animal and after 3 to 5 days from the injection, antisera is obtained.
[0064] The polyclonal antibody may be purified from the obtained antisera by using an ordinary immunoglobulin purification method, for example, an ammonium sulfate fractionation method, a polyethylene fractionation method, an ethanol fractionation method, anion exchange chromatography, affinity chromatography bound to protein A or protein G, or the like.
[0065] The purification procedure for obtaining a soluble HAI-1-specific polyclonal antibody may be any method that can fractionate or purify a polyclonal antibody that recognizes soluble HAI-1 and examples of which include ion exchange chromatography, hydrophobic chromatography, molecular sieve chromatography, reverse phase chromatography, hydroxyapatite chromatography, affinity chromatography, gel electrophoresis, immunoelectrophoresis, etc. One specific example thereof is affinity column chromatography using a resin having immobilized thereon soluble HAI-1. For example, the polyclonal antibody obtained by the above-mentioned method used as a material may be subjected to affinity chromatography using the soluble HAI-1-immobilized resin. By this method, the polyclonal antibody that exists in the adsorption fraction bound to soluble HAI-1 is recovered.
[0066] By these methods, soluble HAI-1-specific polyclonal antibody can be obtained. In the method of affinity chromatography, a partial sequence peptide of soluble HAI-1 may be utilized. The peptide-immobilized resin may be used as a carrier for immobilization for affinity chromatography for use in purifying soluble HAI-1-specific polyclonal antibody.
[0067] Polyclonal antibodies have no dissociation constant in a strict sense. However, a value similar to the dissociation constant of soluble HAI-1 may be obtained by the procedure similar to that used for monoclonal antibody, that is, the method described in Example 4 hereinbelow. It is desirable that the soluble HAI-1-specific polyclonal antibody of the present invention has a value measured in such a manner of 2×10 −9 M or less, preferably. 1×10 −9 M or less, and more preferably 5×10 −10 M or less.
[0068] <4> Method of Specifically and Quantitatively Determining Soluble HAI-1
[0069] This method is a method of quantitatively determining soluble HAI-1 by using soluble HAI-1-specific high-affinity antibody of the present invention. The method of the present invention can be used in various diagnostic methods, measurement methods, assay methods for quantitatively determining HAI-1 in biological samples. The method is not particularly limited as far as quantitative determination of soluble HAI-1 is intended. The method includes, for example, a tissue staining method or an immune precipitation method for specifically detecting soluble HAI-1 a competitive binding assay for specifically measuring soluble HAI-1; or a direct or an indirect sandwich assay; two-antibody sandwich assay, and the like. The detection method includes enzyme immunoassay, radioimmunoassay, fluorescent immunoassay, chemiluminescent immunoassay, immunoblotting, immunochromatography, a latex agglutination method and the like.
[0070] Application examples of immunoblotting include use of microarray or chip having added or immobilized thereto a soluble HAI-1-specific high-affinity antibody. It is also possible to use soluble HAI-1-specific high-affinity antibody with a fluorescence label in a fluorescence deflection solution method or a fluorescence correlation variance method to detect the interaction with soluble HAI-1. Furthermore, it is possible to measure the interaction between the soluble HAI-i-specific high-affinity antibody and soluble HAI-i by using a surface plasmon resonance apparatus. For example, soluble HAI-1 in a biological component can be quantitatively determined by allowing a biological sample containing soluble HAI-1 to flow through a surface plasmon resonance apparatus equipped with a sensor chip having bound thereto the soluble HAI-1-specific high-affinity antibody and tracking a change in time for a response signal.
[0071] The antibody used in the method of specifically measuring soluble HAI-1, for example, HAI-1-specific high-affinity antibody, may be used as it is, or it is possible to employ antibody in the form of Fab as obtained by papain treatment or in the form of F(ab′) 2 or F(ab′) as obtained by pepsin treatment, both treatments being established methods. The fragments of the soluble HAI-1-specific high-affinity antibody are also embraced by the present invention. Such fragments include, for example, fragments containing a complementarity determining region (CDR) in both variable domains of H chain and L chain or hypervariable region of soluble HAI-1-specific high-affinity antibody.
[0072] The two-antibody sandwich assay that quantitatively determines soluble HAI-1 in a biological component includes a method of specifically measuring soluble HAI-1, comprising the steps of (1) reacting a reagent comprising one or a plurality of soluble HAI-1-specific high-affinity antibodies with soluble HAT-1 in a sample to generate an immune reaction product, (2) after separating the immune reaction product, reacting the immune reaction product with a labeled antibody that recognizes the soluble HAI-1 in the immune reaction product, and (3) measuring the labeled antibody bound to the immune reaction product; or a method of specifically measuring soluble HAI-1, comprising the steps of (1) reacting a reagent comprising soluble HAI-1 and a primary antibody consisting of one or a plurality of soluble HAI-1-specific high-affinity antibodies with soluble HAI-1 in a sample to generate an immune reaction product, (2) after separating the immune reaction product, reacting the immune reaction product with a secondary antibody that recognizes the soluble HAI-1 in the immune reaction product to generate an immune reaction product, (3) after separating the immune reaction product, reacting a labeled antibody that recognizes the secondary antibody in the immune reaction. product, and (4) measuring the labeled antibody bound to the immune reaction product.
[0073] Specifically, soluble HAI-1-specific polyclonal antibody or soluble HAI-1-specific high-affinity monoclonal antibody as a primary antibody is immobilized to a solid phase such as micro-titer wells or micro-magnetic beads by a conventional procedure. Then, excessive protein binding site on the surface of the solid phase is blocked with bovine serum albumin, skimmed milk, gelatin or the like. Thereafter, the biological component containing soluble HAI-1 is added onto the surface of the solid phase to form an immune reaction product on the solid phase, followed by washing. Then, a labeled polyclonal antibody or a labeled monoclonal antibody that recognizes soluble HAI-1 as a secondary antibody was added and allowed to react. On this occasion, in the case where a monoclonal antibody was used as the primary antibody, a labeled soluble HAI-1-specific high-affinity monoclonal antibody having a different epitope than that of the primary antibody may be used as the secondary antibody. Further, after washing, the amount of the labeled antibody is measured to give a measured amount of the soluble HAI-1 in the biological component.
[0074] The label of the polyclonal antibody or monoclonal antibody as used herein may include enzymes such as alkaline phosphatase, horseradish peroxidase, galactosidase, urease, and glucose oxidase, and fluorescent substances such as fluorescein derivatives and rhodamine derivatives. In addition, the label may be rare earth elements or rare earth element complexes that enable time-resolved fluorometry, such as europium or europium complexes. Further, the label may be chemiluminescent substances such as acridinium esters or radioisotopes such as 125 I, 3 H, 14 C, and 32 P. That is, the present invention embraces quantitative determination of soluble HAI-1 in a biological component by using a method of determining color development, fluorescence, time-resolved fluorescence, chemiluminescence, electrochemical luminescence, or radioactivity. Also the present invention embraces labeling the secondary antibody with biotin and detecting alkaline phosphatase, horseradish peroxidase, β-galactosidase, urease, or glucose oxidase, fluorescein derivatives, rhodamine derivatives, rare earth element complexes, chemiluminescent substances such as acridinium ester, radioisotopes such as 125 I, 3 H, 14 C, and 32 P, forming a complex with avidin.
[0075] <5> Kit for Specifically and Quantitatively Determining or Staining Soluble HAT-1
[0076] A kit for specifically measuring soluble HAI-1 or a kit for specifically staining soluble HAI-1 is a kit for the diagnosis of diseases characterized by measuring or detecting soluble HAI-1. It has been revealed by the present invention for the first time that measuring soluble HAI-1 enables the diagnosis of patients in a state of diseases, for example, patients suffering from organopathy including glomerulonephritis, nephritis, hepatitis, pancreatitis, pneumonia, enteronitis, and gastritis, patients suffering from cancers, patients suffering from liver diseases, patients suffering from blood diseases, patients suffering from thrombosis including angina pectoris, myocardial infarction, and cerebral infraction. Therefore, measurement or detection of soluble HAI-1 enables to detect various diseases as described above. In the present invention, the kit for specifically measuring soluble HAI-1 is not particularly limited with regards to the material and method of constituting it as far as it is designed for specifically measuring the target soluble HAI-1.
[0077] Specifically, the kit of the present invention includes those kits that diagnose diseases by measuring or detecting soluble HAI-1 by using electrophoresis, HPLC method, various column chromatographic methods, various arrays, chips, or surface plasmon resonance apparatus, or the like. More specifically, the kit of the present invention includes a kit that measures or detects soluble HAI-1 by an immunological method using an antibody. The antibody that can be used includes at least one of the above-mentioned antibodies that recognize soluble HAI-1.
[0078] For example, in the case where the kit of the present invention is based on a two-antibody sandwich method, it includes a kit for specifically measuring soluble HAI-1 comprising the steps of (1) reacting a reagent comprising soluble HA1 and one or a plurality of soluble HAI-1-specific high-affinity antibodies with soluble HAI-1 in a sample to generate an immune reaction product, (2) after separating the immune reaction product, reacting the immune reaction product with a labeled antibody that recognizes the soluble HAI-1 in the immune reaction product, and (3) measuring the labeled antibody bound to the immune reaction product; or a kit of specifically measuring soluble HAI-1, comprising the steps of (1) reacting a reagent comprising soluble HAI-1 and a primary antibody consisting of one or a plurality of soluble HAI-1-specific high-affinity antibodies with soluble HAI-1 in a sample to generate an immune reaction product, (2) after separating the immune reaction product, reacting the immune reaction product with a secondary antibody that recognizes the soluble HAI-1 in the immune reaction product to generate an immune reaction product, (3) after separating the immune reaction product, reacting a labeled antibody that recognizes the secondary antibody in the immune reaction product, and (4) measuring the labeled antibody bound to the immune reaction product.
[0079] The kit comprises at least soluble HAI-1-specific high-affinity monoclonal antibody or soluble HAI-1-specific polyclonal antibody and may further comprise constituent elements necessary for the operation of detecting or measuring soluble HAI-1. Examples of the constituent elements include soluble HAI-1 as standard protein, enzyme, substrate and the like. The kit may contain the monoclonal antibody or polyclonal antibody in a state where it is bound to a label substance such as an enzyme or may contain a labeled antibody that recognizes the antibody. Furthermore, the kit may contain various kinds of suitable buffers, antigen dilutions, reaction dilutions, substrate solutions, reaction stop solution and the like. The kit of the present invention may include a vessel having a label and having encapsulated materials necessary for the detection and quantitative determination of soluble HAI-1. Examples of suitable vessel include vessels made of glass or various plastic materials such as polypropylene, polystyrene, polycarbonate, nylon, Teflon and the like. The kit preferably contains a manual that describes the method of detecting or measuring soluble HAI-1 in addition to the above-mentioned materials and vessel necessary for the detection or measurement of soluble HAI-1.
[0080] < 6 > Soluble HAI-1-Specific High-Affinity Antibody Associated with Human Diseases and Method of using the Same
[0081] By using the method of using soluble HAI-1-specific high-affinity antibody and the kit therefor according to the present invention, soluble HAI-1 in the biological component collected from a patient in a state of a disease can be detected or quantitatively determined. The biological material from which soluble HAI-1 is detected is not particularly limited and any biological material such as tissue, blood serum, blood plasma, urine, serum, cerebrospinal fluid, tissue extract and the like may be applied after performing a suitable pretreatment. Detection or quantitative determination of soluble HAI-1 present in a biological material of a patient in a state of a disease enables diagnosis, prediction, or evaluate the progress of the disease. Examples of the disease include organopathy including glomerulonephritis, nephritis, hepatitis, pancreatitis, pneumonia, enteronitis, and gastritis, cancers, liver diseases, blood diseases, thrombosis including angina pectoris, myocardial infarction and cerebral infraction and the like.
[0082] In particular, examples of nephritis include mesangium proliferative nephritis, IgA nephritis, membraneous proliferative nephritis, membraneous nephritis, focal sclerosing glomerulopathy, acute renal failure, streptococcal acute glomerulonephritis, chronic/acute interstitial nephritis, nephrotic syndrome and the like. Examples of angina pectorts and myocardial infarction include stable angina of effort, unstable angina, acute myocardial infarction, inveterate myocardial infarction, and stable angina. It is possible to know the state of disease and prognosis of patients who received coronary artery intervention operation, transesophageal echocardiography, lower limb artery bypass operation, or aorta balloon pumping operation or patients suffering from acute aorta dissociation. Examples of cancers include hepatocellular carcinoma and pancreas cancer.
[0083] Since it is expected to exhibit the effect of specifically inhibiting the activity of soluble HAI-1, there is a reasonable expectation that the soluble HAI-1-specific high-affinity antibody can be used as a remedy for treating diseases caused by the soluble HAI-1.
[0084] For example, the soluble HAI-1 has the property of acting on inactive type HGFA to inhibit its activation. Therefore, the antibody that inhibits the inhibitory activity of soluble HAI-1 will increase the amount of active-type HGFA emerging in the living organism and further cause an increase in active type HGF. Since the active-type HGF is one of vascularization factors (Molecular Medicine of HGF, Medical Review Co. (1998)), such an antibody can be used as a remedy or preventive for angiopathy such as arteriosclerosis. The antibody used for this purpose is preferably humanized by using genetic engineering techniques. The humanization of antibody may be performed by the method well known to one skilled in the art as described in JF 11-506327 A.
[0085] By measuring the soluble HAI-1 in a biological component of patients, it is possible to make a judgment of effectiveness of medication and make a decision on the policy of therapy. It is often the case that a medicine effective to a disease is not always effective to all the patients or gives side effects since there are individual differences. Therefore, measurements of soluble HAT-1 before and after administration of a medicine enables practitioners to confirm the effectiveness and side effects of a medicine to individual patients to give them a guideline as to whether or not the therapy is continued by administering the medicine concerned.
EXAMPLES
[0086] Hereinafter, the present invention will be described in detail by way of examples. However, the present invention should not be construed as being limited thereto.
Example 1
Preparation of Soluble HAI-1-Specific High-Affinity Monoclonal Antibody
[0087] The soluble HAT-1 used as an immunogen, antigen for screening and a standard soluble HAI-1 in the soluble HAT-1 measurement system was obtained by having expressed and secreted by recombinant CHO cells created by utilizing HAI-1 cDNA, and purifying it by column chromatography.
[0088] A solution containing 100 μg of soluble HAT-1 together with the same volume of Freund's complete adjuvant or Freund's incomplete adjuvant was administered to the endothelium and hypodermis of Balb/c mice 3 times at intervals of 4 weeks. After confirming production of soluble HAI-1-specific high-affinity antibody in the blood serum of the mouse, a solution containing 30 μg of soluble HAI-1 was administered through caudal vein. After 3 days, the spleen was extracted and spleen cells were subjected to cell fusion with myeloma cells P3U1 by using polyethylene glycol 1500 according to the method described in “Monoclonal Antibody Experimentation Manual” (Kodansha Scientific (1987)) and the fused cells were dispensed into the wells of a 96-well plate, followed by adding HAT medium and incubating the cells for 14 days.
[0089] Thereafter, screening of hybridomas that produce monoclonal antibodies specific to the soluble HAI-1 in the medium was performed. That is, to an ELISA plate for screening soluble HAI-1-specific high-affinity antibody having immobilized thereon the soluble HAI-1 and blocked with BSA was added the culture supernatant of hybridomas to be selected and the reactivity of monoclonal antibodies present in the culture supernatant was analyzed. After the culture supernatant of hybridomas to be selected was added to the ELISA plate for screening in an amount of 100 μl/well, the reaction is continued for 1 hour or more.
[0090] Thereafter, the wells of the plate were thoroughly washed with PBS(−) solution containing 0.05% Tween 20 (hereinafter abbreviated as “PBST solution”), and then 100 μl/well of PBS(−) containing 1 μg/ml of HRP (horse radish peroxidase)-labeled goat anti-murine IgG c polyclonal antibody (available from ICN Co.) and 1% BSA was added to the wells and allowed to react at room temperature for 1 hour. After thoroughly washing with PBST solution, citrate-phosphate buffer (pH 5.0) containing 0.4 mg/ml o-phenylenediamine (OPD, P-9029, trade name, manufactured by Sigma AB) and 0.015 to 0.03% hydrogen peroxide solution was added and allowed to react at room temperature to effect color development. Thereafter, 1N H 2 SO 4 solution was added to stop the reaction and measurement of the reaction mixture was performed at a measurement wavelength of 490 nm and a reference wavelength of 650 nm.
[0091] Then, each of the obtained hybridoma reactive with the soluble HAI-1 was cloned 3 times by limiting dilution and thereafter the culture supernatant was recovered and subjected to purification of monoclonal antibodies by affinity chromatography using immobilized protein A column (manufactured by Amersham Pharmacia Biotech AB).
[0092] A strain of the hybridoma clone thus cloned was named HAI-1A-1-1-3-4. HAI-1A-1-1-3-4 was deposited at International Patent Organism Depositary (IFOD), National Institute of Advanced Industrial Science and Technology (Chuo 6, 1-1, Higashi 1-chome, Tsukuba-shi, Ibaraki-ken, Postal Code: 305-8566, Japan) on Oct. 19, 2001 under the accession number FERM P-18565 and transferred from the original deposit to an international deposit on Apr. 17, 2002 under Budapest Treaty and assigned the accession number FERM BP-8022.
Example 2
Preparation of Polyclonal Antibody to Soluble HAI-1 and of its Labeled form
[0093] Polyclonal antibody to soluble HAI-1 was prepared as follows. That is, a mixture consisting of a solution containing 100 μg of soluble HAI-1 and the same volume of Freund's complete adjuvant or Freund's incomplete adjuvant as antigen was subcutaneously administered to a rabbit 7 times at intervals of 2 weeks. After confirming production of an antibody in the blood serum, additional 10 μg of the antigen was intravenously administered and after 5 days, antiserum was obtained. Further, after precipitation treatment with ammonium sulfate, the antiserum was purified by using a protein A column to obtain anti-soluble HAI-1 polyclonal antibody. Thereafter, the obtained anti-soluble HAI-1 polyclonal antibody was labeled with biotin to obtain biotin-labeled anti-soluble HAI-1 polyclonal antibody.
Example 3
Construction of Soluble HAI-1 Quantitative Determination System
[0094] The monoclonal antibody produced by the hybridoma clone HAI-1A-1-1-3-4 prepared in Example 1 and conventional monoclonal antibodies C76-18 and 1N7 were used as primary antibodies. Each monoclonal antibody was dissolved in 0.05 M carbonate-hydrogen carbonate buffer (pH 9.6) to a concentration of 20 Kg/ml and added to the wells of a 96-well plate in an amount of 50 μl/well and the plate was left to stand at 4° C. overnight (about 12 hours or more) or at 37° C. for 2 hours or more. After removing the primary antibody solution from the primary antibody-attached plate, 250 to 300 μl/well of 1% BSA-containing PBS(−) was added to the wells and the plate was left to stand at 4° C. overnight (about 12 hours or more) or at 37° C. for 2 hours or more to effect blocking operation. After removing the blocking solution from the plate, 50 μl/well of soluble HAI-i of varying concentration (0, 0.625, 1.25, 2.50, 5.00, 10.0, 20.0, or 40.0 ng/ml) dissolved in 20 mM sodium phosphate buffer (pH 7.5) containing 0.15 M NaCl, 0.05% Tween 20, and 1% BSA was added to the wells per time and allowed to react at room temperature for 1 hour.
[0095] Thereafter, the wells were thoroughly washed with a washing solution having a composition consisting of 500 mM NaCl, 0.05% Tween 20 and 20 mM Tris-HCl (pH 7.5) and then 100 μl/well of PBS(−)containing 10 μg/ml of the biotin-labeled anti-soluble HAI-1 polyclonal antibody prepared in Example 3 and 1% BSA was added to the wells and allowed to react at room temperature for 1 hour.
[0096] After thoroughly washing the wells with the above-mentioned washing solution, 100 μl/well of PBS(−) containing 1% BSA with 2,000-fold dilution of HRP-labeled streptoavidin (manufactured by Amersham Pharmacia Biotech AB, Code RPN1231) was added to the wells and allowed to react at room temperature for 1 hour. After thoroughly washing the wells with the above-mentioned washing solution, 100 μl/well of citrate-phosphate buffer (pH 5.0) containing 0.4 mg/ml of o-phenylenediamine (OPD, P-9029, manufactured by Sigma AB) and 0.015 to 0.03% hydrogen peroxide solution was added to the wells and allowed to react at room temperature to effect color development.
[0097] Thereafter, 100 μl/well of 1N H 2 SO 4 solution was added to the wells to stop the reaction and the measurement was performed at a measurement wavelength of 490 nm and a reference wavelength of 650 nm. The results are shown in FIGS. 1A and 1B. FIG. 1A illustrates the reactivity of each monoclonal antibody with soluble HAI-1 in a concentration of soluble HAI in a range of from 0 to 40 ng/ml. FIG. 1B is an illustration in an enlarged view of the reactivity in a range of from 0 to 2.5 ng/ml out of the range shown in FIG. 1A. For only the hybridoma clone HAI-1A-1-1-3-4, a concentration-dependent reaction curve could be obtained but the conventional antibodies C76-18 and 1N6 showed no reactivity.
Example 44
Measurement of Dissociation Constant of HAI-1-Specific High-Affinity Monoclonal Antibodies
[0098] The monoclonal antibody derived from hybridoma clone HAI-1A-1-1-3-4 out of the soluble HAI-1-specific high-affinity monoclonal antibodies prepared and purified in Example 1, and the conventional antibodies C76-18 and 1N7 were measured for dissociation constant. To a soluble HAI-1-immobilized plate obtained by immobilizing soluble HAI-1 to a plate and blocking it with BSA was added each antibody in a differing concentration, which was allowed to react until an equilibrium was reached (for 2 hours or more).
[0099] Thereafter, the wells of the plate was thoroughly washed with PBS(−) solution containing 0.05% Tween 20 (hereinafter abbreviated as “PBST solution”), 100 μl/well of PBS(−) containing 1 μg/ml of HRP (horse radish peroxidase)-labeled goat anti-murine IgG Fc polyclonal antibody (available from ICN Co.) and 1% BSA was added to the wells and allowed to react at room temperature for 1 hour. After thoroughly washing with PEST solution, citrate-phosphate buffer (pH 5.0) containing 0.4 mg/ml o-phenylenediamine (OPD, P-9029, manufactured by Sigma AB) and 0.015 to 0.03% hydrogen peroxide solution was added and allowed to react at room temperature to effect color development.
[0100] Thereafter, 1 N H 2 SO 4 solution was added to stop the reaction and measurement of the reaction mixture was performed at a measurement wavelength of 490 nm and a reference wavelength of 650 nm. From the measurement results, scattered plotting was performed to obtain dissociation constants. The results are shown in Table 1. The monoclonal antibody obtained by the present invention showed the smallest dissociation constant, that is, the highest affinity.
TABLE 1 Antibody Dissociation constant HAI-1A-1-1-3-4 2.67 × 10 −10 C76-18 1.48 × 10 −9 IN7 1.68 × 10 −8
Example 5
Measurement of HAI-1 in Blood of Healthy Person
[0101] By using the HAI-1-specific highly sensitive measurement system prepared in Example 3, soluble RAI-1 in blood sera from 56 healthy persons were measured. The blood sera from healthy persons were stored under freezing after the extraction and used by thawing just before the experiments. First, 50 μl/well of 20 mM sodium phosphate buffer (pH 7.5) containing 015 M NaCl, 0.05s Tween 20, and 1% BSA was added to the wells of the 96-well plate to which the primary antibody adhered and which was blocked prepared in Example 3 and then 50 μl/well of blood serum from a healthy person or standard soluble HAT-i of varying concentration (0, 0.625, 2.50, 5.00, 10.0, or 40.0 ng/ml) was added to the wells, followed by allowing to react at room temperature for 1 hour. Then the wells were washed with a washing solution having a composition of 500 mM NaCl, 0.05% Tween 20 and 20 mM Tris-HCl (pH 7.5). Thereafter, 100 μ/well of PBS(−)containing 10 μg/ml of the biotin-labeled anti-soluble HAI-1 polyclonal antibody prepared in Example 3 and 1% BSA was added to the wells and allowed to react at room temperature for 1 hour. After thoroughly washing the wells with the above-mentioned washing solution, 100 μl/well of PBS(−) containing 1% BSA with 2,000-fold dilution of HRP-labeled streptoavidin (manufactured by Amersham Pharmacia Biotech AB, Code RPN 1231) was added to the wells and allowed to react at room temperature for 1 hour.
[0102] After thoroughly washing the wells with the above-mentioned washing solution, citrate-phosphate buffer (pH 5.0) containing 0.4 mg/ml of o-phenylenediamine (OPD, P-9029, manufactured by Sigma AB) and 0.015 to 0.03% hydrogen peroxide solution was added to the wells and allowed to react at room temperature to effect color development. Thereafter, 100 μl/well of 1N H 2 SO 4 solution was added to the wells to stop the reaction and the measurement was performed at a measurement wavelength of 490 nm and a reference wavelength of 650 nm. Then a calibration curve was prepared from the concentration of standard soluble HAI-1 and an amount of developed color, and the concentration of soluble HAI-1 in the blood sera of healthy persons was calculated.
[0103] [0103]FIG. 2 shows the results obtained. In the blood sera of healthy persons (number of samples: 56), the concentration of soluble HAI-1 was in a range of from 0 to 13.5 ng/ml, with the average being 7.5 ng/ml.
Example 6
Measurement of HAI-1 in Patients Suffering from Various Diseases
[0104] By using the HAI-1-specific highly sensitive measurement system prepared in Example 3, soluble HAI-1 in the blood sera from patients suffering from various diseases was measured by the method described in Example 5. The number of patients was 5 for each disease. Each blood serum was stored under freezing after extraction and used by thawing just before the experiments. Table 2 shows the results obtained. It revealed that in the bloods of patients suffering from nephritis, hepatitis, pancreatitis, lung cancer, liver cancer, myocardial infarction, cerebral infarction, hepatocellular carcinoma and pancreas cancer, soluble HAT-1 existed in concentrations higher than those in the bloods of healthy persons (number of samples: 56, average value: 7.5 ng/ml).
TABLE 2 Patient Patient Patient Patient Patient Case 1 2 3 4 5 Nephritis 67.0 43.3 31.7 28.1 25.7 Hepatitis 85.6 75.8 67.7 61.8 60.6 Pancreatitis 40.8 29.4 24.9 23.8 23.4 Lung cancer 60.2 49.7 45.7 38.0 37.4 Liver cancer 53.7 50.9 47.4 32.8 28.3 Myocardial 20.7 19.9 17.8 15.8 15.4 infarction Cerebral 48.5 38.8 35.1 30.0 17.5 infarction Hepatocellular 29.5 30.9 73.6 42.0 33.3 Carcinoma Pancreas cancer 22.0 61.3 24.4 27.7 74.1
[0105] The application is based on Japanese patent application No. 2001-157082 which was filed on May 25, 2001 and Japanese patent application No. 2002-7443 which was filed on Jan. 16, 2002.
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A hybridoma is selected that produces a monoclonal antibody exhibiting high reactivity to soluble hepatocyte growth factor activator inhibitor-1 (soluble HAT-1), the target monoclonal antibody is prepared from culture supernatant of the obtained hybridoma, and by using the antibody soluble HAI-1 is measured.
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BACKGROUND OF THE INVENTION
I. Field of the Invention
Embodiments of the present invention relate to devices for removing materials from the ground. Particularly, embodiments of the present invention relate to post pullers. More particularly, embodiments of the present invention relate to post pullers operated by and/or controlled by powered vehicles.
II. Discussion of Related Art
There are countless applications for a grasping and lifting apparatus for heavy or awkward work pieces. One example is a post puller grasping an elongated object such as a fence post or a telephone pole and lifting it out of a post hole or positioning it in a post hole or simply moving it about from place to place. A typical post puller consists of some type of clamp attached to a machine with lifting power, for example a tractor or a skid-steer loader. The clamp may be nothing more complex than a length of heavy chain wrapped tightly around the post, securing the post to the lifting machine. Such a clamp enables a remotely located worker such as a farmer with no power machinery other than a tractor to use the power lifting capacity of the tractor to place and remove fence posts or other awkward or heavy objects including brush and trees.
A chain used as a clamp may require a person to hold the chain securely around the post during the lifting and moving operation. If the chain is attached to a tractor with lifting capability, it may be possible for one person to simultaneously hold the chain and operate the tractor, but at best this is clumsy, and it often poses safety issues, so a second person may be needed. Lifting machines such as tractors or skid-steer loaders generally lift by pivoting about a point, and this results in the lifting motion being arcuate rather than linear. When inserting a post into, or removing it from, a deep post hole, an arcuate lifting motion can cause the post to bind against the walls of the hole, damaging the hole or the post, or rendering the lifting operation impossible.
Accordingly, there has been a need for a lifting apparatus easily attached to a lifting machine in a remote location, safely and conveniently operated by a sole worker, and can lift clumsy or heavy objects. It would be desirable for such an apparatus to lift an object through a linear rather than an arcuate range of motion.
SUMMARY OF THE INVENTION
In some embodiments, an apparatus for pulling posts may include one or more of the following features: (a) a frame having a first fork aperture and a second fork aperture coupled by a support member, (b) a first post removal door coupled to the first fork aperture and a second post removal door coupled to the second fork aperture, the doors coupled with a butt hinge, (c) a V-shaped opening on an end opposite the support member, and (d) a blade coupled to the first post removal door.
In some embodiments, a method of removing a post may include one or more of the following steps: (a) positioning a post puller, having fork apertures coupled together by a support member, around a post, (b) elevating the post puller to pinch the post between post removal doors, (c) pulling the post from the ground, (d) coupling the post puller to a vehicle, (e) transporting the post puller to the post, (f) driving the vehicle to a drop location, (g) lowering the post puller, and (h) releasing the post.
In some embodiments, a post puller may include one or more of the following features: (a) a frame capable of being coupled to a vehicle, (b) a first and second post removal doors having an open side facing each other and an opposite end coupled to the frame, (c) a V-shaped opening located on the open side of the doors, (d) butt hinges along which couple the doors to the frame along a hinge axis, (e) a blade located on the open side of each door, and (f) a fork aperture for receiving a fork.
DESCRIPTION OF DRAWINGS
FIG. 1 shows a side profile of a forklift as in embodiments of the present invention;
FIG. 2 shows a front elevated profile view of a post puller coupled to a forklift in an embodiment of the present invention;
FIG. 3 shows a flow process diagram of the operation of a post puller in an embodiment of the present invention; and
FIG. 4 shows a post puller in operation in an embodiment of the present invention.
DESCRIPTION OF PREFERRED EMBODIMENT
The following discussion is presented to enable a person skilled in the art to make and use the present teachings. Various modifications to the illustrated embodiments will be readily apparent to those skilled in the art, and the generic principles herein may be applied to other embodiments and applications without departing from the present teachings. Thus, the present teachings are not intended to be limited to embodiments shown, but are to be accorded the widest scope consistent with the principles and features disclosed herein. The following detailed description is to be read with reference to the figures, in which like elements in different figures have like reference numerals. The figures, which are not necessarily to scale, depict selected embodiments and are not intended to limit the scope of the present teachings. Skilled artisans will recognize the examples provided herein have many useful alternatives and fall within the scope of the present teachings.
In embodiments of the present invention, a post puller can mount on a skid loader, a three-point hitch on a tractor, a tractor front end loader, an industrial wheel loader and a fork lift. The post puller operates by allowing an operator to place the post puller around a post or tree. The jaws of the post puller swing upward (depending on the size of the post or tree) as the post or tree push against the jaws to accommodate the post or tree. When the post or tree is in the post puller, the operator would then raise the post puller upward. As the post puller rises, the jaws of post puller pinch together, “bite into the post”. By raising the post puller upward the post or tree is pulled from the ground. To release the post or tree, the operator would simply lower the post puller until the post or tree hit the ground, which would push upward on the jaws, thus opening the jaws and releasing the post or tree.
As stated above, embodiments of the present invention can incorporate a skid loader. A skid loader or skid-steer loader is a rigid frame, engine-powered machine with lift arms used to attach a wide variety of labor-saving tools or attachments. Skid-steer loaders are four-wheel drive vehicles with the left-side drive wheels independent of the right-side drive wheels. By having each side independent of the other, wheel speed and direction of rotation of the wheels determine the direction the loader will turn. Skid-steer loaders can turn in their own tracks which make them extremely maneuverable and valuable for applications requiring a compact, agile loader. Unlike conventional front loaders, the lift arms in these machines are alongside the driver with the pivot points behind the driver's shoulders. Because of the operator's proximity to moving booms, early skid loaders were not as safe as conventional front loaders, particularly during entry and exit of the operator. Modern skid loaders have fully-enclosed cabs and other features to protect the operator. Like other front loaders, it can push material from one location to another, carry material in its bucket or load material into a truck or trailer. Most owners of skid steer loaders have a fork lift attachment also, making the post-puller easy to mount.
Embodiments of the present invention can incorporate a three-point hitch. The three-point hitch is made up of several components working together. These include the tractor's hydraulic system, attaching points, the lifting arms, and stabilizers. Three-point hitches are composed of three movable arms. The two outer arms—the hitch lifting arms—are controlled by the hydraulic system, and provide lifting, lowering, and even tilting to the arms. The center arm—called the top link—is movable, but is usually not powered by the tractor's hydraulic system. Each arm has an attachment device to connect implements to the hitch. Each hitch has attachment holes for attaching implements, and the implement has posts fitting through the holes. The implement is secured by placing a pin on the ends of the posts. The hitch lifting arms are powered by the tractor's own hydraulic system. The hydraulic system is controlled by the operator, and usually a variety of settings are available. There are several different hitch systems, called categories. Category Zero hitches are used with small farm or garden tractors. Category III hitches are found on the larger farm tractors, or those above 90 hp. The primary benefit of the three-point hitch system is to transfer the weight and stress of an implement to the rear wheels of a tractor.
With reference to FIG. 1 , a side profile of a forklift 10 as in embodiments of the present invention is shown. Forklift 10 is used for the discussion below in regards to the post puller for ease of understanding by the reader. However, most any vehicle which projects force upwards, such as a skid loader or a three-point hitch, can be used without departing from the spirit of the invention.
A forklift 10 can have a frame 12 which is the base of forklift 10 to which the mast, axles, wheels, counterweight, overhead guard and power source are attached. Frame 12 may have fuel and hydraulic fluid tanks constructed as part of the frame assembly. A counterweight 14 is a heavy cast iron mass attached to the rear of the forklift frame 12 . The purpose of counterweight 14 is to counterbalance the load being lifted. In an electric forklift 10 the large lead-acid battery itself may serve as part of the counterweight. Cab 16 is the area containing a seat for the operator along with the control pedals, steering wheel, levers, switches, and a dashboard containing operator readouts. Cab 16 may be open air or enclosed, but it is covered by cage-like overhead guard assembly 18 . Overhead guard 18 is a metal roof supported by posts at each corner of cab 16 helping protect the operator from any falling objects. On some forklifts 10 , overhead guard 18 is part of frame assembly 12 . Power source 20 may consist of an internal combustion engine powered by LP gas, CNG gas, gasoline or diesel fuel. Electric forklifts 10 are powered by either a battery or fuel cells providing power to electric motors. The motors may be either DC or AC types. Tilt cylinders 22 are hydraulic cylinders mounted to the frame 12 and the mast 24 . Tilt cylinders 22 pivot the mast 24 to assist in engaging a load.
Mast 24 is the vertical assembly raising and lowering the load. It is made up of interlocking rails providing lateral stability. The interlocking rails may either have rollers or bushings as guides. Mast 24 is either hydraulically operated by one or more hydraulic cylinders or it may be chain operated with a hydraulic motor providing motive power. It may be mounted to the front axle or frame 12 of forklift 10 . Carriage 26 is the component to which forks 28 or other attachments mount. Carriage 26 is mounted into and moves up and down the mast rails by means of chains or by being directly attached to the hydraulic cylinder. Like mast 24 , carriage 26 may have either rollers or bushings to guide it in the interlocking mast rails.
With reference to FIG. 2 , a front elevated profile view of a post puller coupled to a forklift in an embodiment of the present invention is shown. Post puller 30 is shown coupled to forks 28 of forklift 10 . Post puller 30 has a frame 32 with a pair of fork apertures 34 coupled by a tractor side support member 36 . Coupled by butt hinges 38 to fork apertures 34 are post removal doors 40 . Located on the interior of post removal doors 40 are metal blades 42 . Removal doors 40 present a V-shaped opening 44 at an opposite end 46 from support member 36 . V-shaped opening 44 allows for posts to be directed towards blades 42 should the operator not center the post within post puller 30 exactly. Post puller 30 is shown made of steel, however, it is fully contemplated post puller 30 could be made from most any material, such as iron, stainless steel, and plastic, without departing from the spirit of the invention.
With reference to FIGS. 3 and 4 , the operation of post puller 30 in an embodiment of the present invention is shown. Upon discovery of a post, tree, or most any other object embedded in the ground, the operator could begin the post removal process 100 by coupling post puller 30 to vehicle 10 by simply driving up to post puller 30 and carefully inserting forks 28 into fork apertures 34 at state 102 . The operator would then lift forks 28 and post puller 30 off the ground slightly to transport post puller 30 at state 104 . The operator could then drive vehicle 10 over to post 50 placing post 50 directly in front of opening 44 . The operator could then drive vehicle 10 forward allowing post 50 to enter opening 44 at state 106 .
As post 50 moves towards blades 42 and begins to contact doors 40 , doors 40 will move upward along butt hinges 38 , thus allowing post 50 to travel back to blades 42 . Butt hinges 38 allow small posts and large posts to enter into post puller 30 by rotating along hinge axis 48 . Doors 40 can rotate 90° allowing very small to very large posts 50 . Once post puller 30 is moved completely around post 50 and post 50 is engaged by blades 42 , the operator can begin to lift forks 28 and thus post puller 30 at state 108 . As post puller 30 elevates, blades 42 engage post 50 and pinch it between blades 42 . The upward force of forks 28 places a large pinching force on post 50 and, thus, post 50 is held securely. The operator continues to elevate post puller 30 with post 50 until post 50 is pulled from the ground at state 110 . The operator can then drive vehicle 10 to a desired location to drop off post 50 at state 112 . Once at a drop site, the operator could simply move forks 28 downward at state 114 . This action causes post 50 to lower until post 50 touches the ground. After this, the continued downward motion of post puller 30 causes doors 40 to move upward thus releasing post 50 at state 116 . Post 50 will fall to the ground or the operator can slide post 50 out of post puller 30 . The operator can now move to the next post for removal at state 118 repeating the prior steps as necessary.
Thus, embodiments of the POST PULLER are disclosed. One skilled in the art will appreciate the present teachings can be practiced with embodiments other than those disclosed. The disclosed embodiments are presented for purposes of illustration and not limitation, and the present teachings are limited only by the following claims.
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In some embodiments, a post puller may include one or more of the following features: (a) a frame capable of being coupled to a vehicle, (b) first and second post removal doors having an open side facing each other and an opposite end coupled to the frame, (c) a V-shaped opening located on the open side of the doors, (d) butt hinges along which couple the doors to the frame along a hinge axis, (e) a blade located on the open side of each door, and (f) a fork aperture for receiving a fork.
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RELATED APPLICATION
[0001] The present application claims priority to U.S. Provisional Patent Application No. 61/591,877 entitled SOFA WITH SHIPPING AND USE CONFIGURATIONS and filed Jan. 28, 2012 which is incorporated herein in its entirety.
FIELD OF THE INVENTION
[0002] The present invention is directed to a sofa that can be reconfigured between a use configuration and a shipping or storage configuration, wherein the shipping or storage configuration defines a more regular and compact geometric shape for more efficient shipping or storage of multiple sofas.
BACKGROUND OF THE INVENTION
[0003] Furniture items used thr seating typically comprise an upholstered and/or cushioned support structure for supporting the user's back and bottom. In particular, sofas typically comprise a seat base, a back rest and at least one arm rest. A common aesthetic and practical design consideration is assembling the subcomponents of the sofa with minimum gaps between the subcomponents to avoid strain on the fasteners from movement of the subcomponents and the aesthetically unpleasing appearance of the gaps. Accordingly, furniture items are typically fully assembled at the factory to ensure that the individual subcomponents are properly assembled and upholstered with minimal interspatial gaps.
[0004] The inherent drawback of assembling the furniture item at the factory is that the common L-shape of the assembled seating furniture typically prevents efficient packing of the furniture items for transport. Depending on the shape and size of the furniture item, the packing of the furniture item can result in a significant amount of dead space within the shipping container or truck. In addition to increasing the cost of transportation, the dead space can allow the furniture items to shift during transport resulting in safety risks, uneven weight distributions or damage to the furniture item. Although, the furniture item can be boxed for shipment, the L-shaped cross-section creates portion of the box that are unsupported and likely to collapse damaging the box and underlying furniture item. Similarly, assembled furniture items can be awkwardly shaped and difficult to navigate into the home or other structure without significant positioning and reorienting of the furniture item. The awkward maneuvering and positioning of the furniture item required to move the furniture item into the structure can result in injury to the movers and/or damage to the furniture or the structure.
[0005] An approach to addressing the drawbacks of factory assembled furniture items comprises providing individually upholstered subcomponents as a ready to assemble (“RTA”) furniture kit. The individual components can be more efficiently packed and allows the furniture item to be assembled in situ eliminating the need for navigating the furniture item through the building. However, inherent challenge of providing RTA furniture kits is that the consumers who assemble the furniture kits are typically untrained and may not have ready access to the tools or training necessary to properly assemble the subcomponents. In addition, aligning the heavy subcomponents to install the fasteners for connecting, the subcomponents can be difficult, particularly if a single individual is assembling the furniture item. If the fasteners art, not properly installed the structural integrity of the furniture item could be comprised result gin collapse and/or injury of users.
[0006] As such, there is a need for a means of providing furniture items that does not suffer from the drawbacks of factory assembled furniture and currently available RTA furniture kits. In RTA furniture, it is advantageous to minimize the number of components that need to be assembled, to have the assembly be simple, to provide the smallest possible shipping package, and the finished product be robust and sturdy.
SUMMARY OF THE INVENTION
[0007] The present invention is directed to an RTA or“knockdown” sofa comprising a seat base and a back rest that can be reconfigured between a use configuration in which the sofa is has a conventional L-shaped cross-section and a shipping or storage configuration in which the sofa is arranged in a more efficiently stacked rectangular cross-section. The rectangular cross-section allows the sofa to be more efficiently stacked with other sofas during shipping or storage. In addition, the rectangular cross-section reduces the dead spaces created when a L-shaped sofa is inserted into a box that can collapse during shipping or storage. Specifically, the back rest having a front side and a rear side and comprises an upper back rest portion and a lower back rest portion, the upper back rest portion having a first upward position and a second downward position. The upper back rest, when in the first upward position, comprises an engagement surface that is downwardly facing and that is substantially horizontal and confronts and engages an upwardly facing surface of the lower back rest portion. The upper back rest portion can be rotated forward toward the front of the sofa and downwardly into a nesting region against the top of the seat base about a pivot point provided by a hinge positioned at or proximate the front side of the back rest. In embodiments, the bottom of the upper back rest portion and the top of the lower back rest portion are positioned in a generally planar horizontal orientation when the upper back rest portion is rotated into the storage configuration.
[0008] The horizontal surface created by the rotation of the upper back rest portion into the lowered position provides a support surface that can support a portion of the box wall to prevent collapse of the box due to dead spaces formed by an irregularly shaped sofa. In certain embodiments; the combined width of the engagement surfaces of the upper back rest portion and the lower back rest portion can be at least four inches. In other embodiments, the combined width can be at least six inches. In other embodiments, the combined width can be at least eight inches. In these configurations, the engagement of the limit faces of the upper back rest portion and the lower back rest portion prevents over rotation of the upper back rest portion presenting a stable horizontal surface for supporting, the box wall. In certain embodiments, the vertical length of the front faces of the upper back rest portion and the lower back rest portion is at least six inches to provide sufficient support for the horizontal support surface. In other embodiments, the vertical length is at least eight inches. In other embodiments, the vertical length is at least ten inches.
[0009] In embodiments, each hinge comprises at least two leaf portions having a plurality of alternating knuckles and a pin or a spindle threaded through the knuckles. One of the leaf portions is affixed to the bottom of the upper back rest portion, while the opposing leaf portion is affixed to the top of the lower back rest portion. When the upper back rest is in the downward position, the leaf portions define a plane, wherein the knuckles are offset from the plane such that the knuckles defining a barrel are positioned above the plane. When the upper back rest is in the upward position, the leaf portions are overlaying one another are parallel or defining a slightly converging angle. The slightly converging angling also then is provided to the engagement surface of the upper back rest portion and upwardly facing surface of the lower backrest portion. Such angle increases the amount of force necessary to initiate the rotation of the upper back rest portion forward reducing the likelihood that the upper back rest portion will be inadvertently rotated into the stored configuration. Other hinge configurations may also be used.
[0010] In embodiments, the sofa can comprises removable back rest cushions that can be removed from the back rest before the upper back rest portion is rotated into the storage configuration. The back rest cushions can comprise Velcro, zippers, buttons, compression straps or other conventional means of releasably securing, the backrest cushions to the back rest. In this configuration, the back rest cushions can be positioned on the seat base or seat cushions to fill in any dead space and provide the rectangular cross-section.
[0011] In embodiments, the seat base can define an interior space for receiving the back rest cushions and/or seat cushions can be stored within the interior space during storage or transport. In this configuration, the sofa can further comprise a sheeting removable or replaceable sheeting secured to the seat base to enclose the interior space defined by the interior space. Alternatively, the sheeting can define at least one opening for accessing the interior space and having a closeable flap secured by a Velcro, zipper, button or other conventional releasable securing means.
[0012] In embodiments, the sofa can further comprise arm rests affixable to sides of the seat base, each arm rest can comprise an engagement bracket slidably engagable to a corresponding bracket affixed to the seat base that aligns the arm rest with the seat base and secures the arm rest to the seat base. Each arm rest can also comprise at least one fastener insertable through the seat base from the interior base to secure the arm rest to the seat base. In embodiments, the arm rests can be positioned in the interior space during shipping or storage to minimize the footprint of the sofa.
[0013] A RTA sofa, according to an embodiment of the present invention, comprises a seat base and a back rest. The seat base further comprises a rectangular frame comprising a top side, a front side, a back side, a left side and a right side and defining an interior space. The back rest is affixable to the back side of the seat base and comprises an upper back rest portion, a lower back at portion and at least one hinge, wherein the upper back rest portion is rotatably secured to the lower back rest portion by the hinge and lower back rest portion is affixed to the back side of the seat base. The binge can comprise two leaf portions each having a plurality of interlocking knuckles for rotatably receiving a spindle or pin. In embodiments, the sofa can further comprise at least one arm rest affixable to either the left or right side of the seat base.
[0014] In operation, the upper back rest portion is rotatable between an upright position in which the upper back rest portion is positioned above the lower back rest portion to define a continuous surface for receiving the user's back and a lowered position in which the upper back rest portion is positioned flush with or below the lower back rest. In embodiments, the upper back rest portion is rotatable between 150 and 190 degrees. In other embodiments, the upper back rest is rotatable between 170 and 185 degrees. In embodiments, the lower side of the upper back portion and the upper side of the lower back portion are substantially planar when the upper back portion is rotated into the lowered position thereby maximizing storage efficiency.
[0015] In an embodiment of the invention, a boxed RTA sofa has seat base with a lower back rest portion permanently affixed thereto, and a hinged upper backrest portion folded down toward the seat base. The lower back portion and hinged upper backrest providing a horizontal surface for facing an upper surface of the box. In embodiments, a pan of to-be-attached armrests is stowed in the seat base and accessible out of the bottom of the base when removed from the box. In embodiments, a pair of to-be-attached armrests, are stowed in the box on top of seat cushions and back rest cushions are stowed in the seat base. To-be-attached feet may be stowed in the base as well.
[0016] In an embodiment of the invention, a boxing rectilinear profile is defined by the fixed base and integral lower portion of the back rest with the arm rests removed. All other components are finable in the rectilinear profile in a box. In embodiments, the other components being seat cushions, back rest cushions, side arms, assembly hardware, instructions.
[0017] In an embodiment of the invention, a boxing rectilinear profile is defined by the fixed base and integral lower portion of the back rest and with integral arm rests. All other components are finable in the rectilinear profile in a box matching the rectilinear profile. In embodiments, the other components being seat cushions, back rest cushions, assembly hardware, instructions.
[0018] A feature and advantage of embodiments of the invention is that the components may be shipped in a smaller box than conventional box, compared to other RTA designs that provide a comparably sized finished sofa.
[0019] The above summary of the various representative embodiments of the invention is not intended to describe each illustrated embodiment or every implementation of the invention. Rather, the embodiments are chosen and described so that others skilled in the art can appreciate and understand the principles and practices of the invention. The figures in the detailed description that follow more particularly exemplify these embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] The invention can be completely understood in consideration of the following detailed description of various embodiments of the invention in connection with the accompanying drawings, in which:
[0021] FIG. 1 a is a front perspective view of a sofa in a use position according to embodiment of the present invention.
[0022] FIG. 1 b is a bottom view of a sofa, particularly the seat base, illustrating stowage regions.
[0023] FIG. 1 c is a side perspective view of a sofa or a storage or shipping configuration with the hinged top portion of the back rest pivoted downwardly in a storage or shipping configuration according to embodiment of the present invention.
[0024] FIG. 2 is a side view of a base and lower back portion and a raised upper back portion according to the inventions herein.
[0025] FIG. 3 is a side view of a base and lower back portion and a lowered upper back portion according to the inventions herein.
[0026] FIG. 4 is a perspective view of a sofa illustrating, the sizing of a box that would contain said sofa when in a shipping configuration according to an embodiment of the present invention.
[0027] FIG. 5 is a pictorial view of an sofa according to an embodiment of the invention in a shipping configuration.
[0028] FIG. 6 is a pictorial view of an sofa according to an embodiment of the invention in a shipping configuration.
[0029] FIG. 7 is a pictorial view of an sofa according to an embodiment of the invention in a shipping, configuration.
[0030] FIG. 8 is a cross sectional view through a sofa with the back rest rotated downwardly in accord with an embodiment of the invention.
[0031] FIG. 9 is a cross sectional view through a packaged sofa in a box according to the invention.
[0032] While the invention is amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and will be described in detail. It should be understood, however, that the intention is not to limit the invention to the particular embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the appended claims.
DETAILED DESCRIPTION
[0033] As depicted in FIGS. 1-4 , a sofa 20 , according to an embodiment of the present invention, comprises a seat base 22 and an upright lower back rest portion 30 integral with the seat base, “Integral” in that they are fixed together at the factory with permanent fasteners, glue, and may have common frame members and they are not detachable from one another without damage. Moreover, the upholstery may run continuous between the base and lower back rest portion. In embodiments, the sofa 20 can further comprise a pair of arm rests 24 , 26 . The seat base 22 comprises a box frame 40 comprising a rectangular shape and having a left side 54 , a left side outwardly facing surface 55 , a right side 56 , a right side outwardly facing surface, 58 , a front side 57 , a front side outwardly facing surface 59 . The back side 68 , a back side outwardly facing surface 69 , a bottom side 60 , and a top 50 comprising a top surface 52 . The box frame 40 defines an open interior space 62 . In embodiments, the seat base 22 can further comprise upholstery 46 , seat springs 42 and seat stretchers 44 . In embodiments, the seat base 22 comprises wood or wood products.
[0034] As depicted in FIGS. 1-4 , the lower back rest portion 30 comprises a front side 66 , a front surface 67 , a back side 68 a back side surface 69 , and an upwardly facing horizontal surface 69 . 1 that is a seating surface for an upper back rest portion 70 . The lower back rest portion 72 is affixed to the back side 68 of the seat base 22 . The upper back rest portion 70 is pivotally attached to the lower back rest portion 72 with at least one hinge 74 . The upper back rest portion 70 has an uptight position where it is seated and secured to the lower back rest portion as shown in FIGS. 2 and 4 . In said position the upper back rest portion 70 has an upper forward surface 68 . 1 and an upper rearward surface 68 . 2 and has a downward facing horizontal surface 68 . 4 . The upper back rest portion also has a lowered downward folded position as shown in FIGS. 1C , 3 , 7 , and 8 . In the upright position, the front surface 67 of the lower back rest portion 72 is aligned with the front surface of the upper back rest portion, and the rearward surface of the upper back rest portion 70 is in alignment with the rearward surface of the lower back rest portion 70 and the rearward surface of the base. In the folded position the horizontal surface 68 . 4 is aligned with the horizontal surface 69 . 1 of the lower back rest portion 70 to define a continual horizontal surface for supporting a box or stacked sofa 20 .
[0035] In certain embodiments, the combined width of the horizontal surface 68 . 4 of the upper back rest portion 70 and the horizontal surface 69 . 1 can be at least four inches. In other embodiments, the combined width can be at least six inches. In other embodiments, the combined width can be at least eight inches. The engagement of the forward surface 68 . 1 of the upper back rest portion 70 with the front surface 67 of the lower back rest portion 72 prevents further rotation of the tipper back rest portion 70 allowing the horizontal surface 68 . 4 of the upper back rest portion 70 to support a box wall. In certain embodiments, the vertical length of the engagement portion between the upper back rest portion 70 and the lower back rest portion 72 is at least six inches. In other embodiments, the vertical length of the engagement portion is at least eight inches. In other embodiments, the vertical length of the engagement portion is at least ten inches.
[0036] The hinge 90 may comprise at least two leaf portions 92 and a pin 94 . Each leaf portion 92 comprises a plurality of knuckles 96 arranged in an alternating fashion with the knuckles 96 of the opposing leaf portion 92 such that the pin 94 can be inserted through the knuckles 96 to rotatably secure the leaf portions 92 together. Each leaf portion 92 defines a plane, wherein the knuckles 96 are offset from the plane defined by the leaf portion 92 . Other hinges may include sheet material, fabric, or polymer living hinge. In operation, one leaf portion 92 is affixed to the upper back rest portion 70 , while the opposing leaf portion 92 is affixed to the lower back rest portion 72 such that the upper back rest portion 70 is rotatable with respect to the lower back rest portion 72 . The upper back rest portion 70 is rotatable between the upright position in which the upper back rest portion 70 is positioned over the lower back rest portion 72 to define a conventional L-shape seating shape and a lowered position in which the upper back rest portion 70 is rotated forwardly and downwardly such that the upper back rest portion and lower back rest portion folded together define a generally rectangular or rhombus or quadrilateral cross-section. In the upright position, the offset arrangement of the knuckles 96 angles the upper back rest portion 70 slightly downward in the rearward direction to minimize the risk that the upper back rest portion 70 inadvertently rotates toward the lowered position when a user is seated on the sofa 20 . In embodiments, the upper back rest portion 70 can further comprise a securing element 76 , while the lower back rest portion 72 can further comprise a cooperating securing element 78 . Hook and loop strips, known as Velcro material are suitable for the securing elements. In this configuration, the cooperating securing elements 76 , 78 are positioned such that the securing elements 76 , 78 are engaged together securing the upper back rest portion 70 to the lower back rest portion 72 when the upper back rest portion 70 is positioned in the upright position. As illustrated, the upper back rest portion 70 is rotated such that the front side 66 of the upper back rest portion 70 is positioned against the front side 66 of the lower back rest portion 72 . The
[0037] As depicted in FIGS. 5-7 , the sofa 20 can further comprise at least one back rest cushion 38 affixable to the front side 66 of the back rest 30 . In this configuration, the back rest cushion 38 can further comprise a releasable securing element $ 8 for releasably securing the back rest cushion 30 to the front side 66 of the back rest 30 . The releasable securing element 88 can comprise Velcro, a zipper, a button or other conventional means of releasable securing the back rest cushion 30 to the back rest 30 . In this configuration, the back rest cushions 3 $ can be removed from the back rest 30 and stored within the interior space 62 . Alternatively, the back rest cushions 38 can be positioned on the top 50 of the seat base 22 or on a seat cushion 36 secured to the top 50 of the seat base 22 to fill the dead space and create a rectangular cross-section for efficient packing.
[0038] Referring to FIGS. 2 and 3 , and generally the other figures, the arm rests 24 , 26 can be attached to the left side 54 and the right side 56 of the box frame 40 . In embodiments, the arm rests 24 , 26 can be releasably secured to the seat base 22 and lower back rest such that the arm rests 24 , 26 can be separated from the seat base 22 and stored within the interior space 62 during shipping or storage. The arm rests 24 , 26 can be secured with corresponding alignment brackets 80 , fasteners extending through respective walls or brackets of the arm rests and seat base apertures 82 and other known means.
[0039] When used herein “removably attachable” means without damage to the respectable components using brackets and threaded connectors.
[0040] As illustrated in FIGS. 4-8 , the configuration described herein provides significant packaging advantages. The lower base portion fixed to the base provides an inherently strong robust rectilinear box shape structure ideal for shipping. Securing the otherwise protruding armrests below the base provides a secure location for them. The two horizontal faces on each side of the hinge of the upper and lower back rest portions provide a structurally sound surface abutting, typically with padding, the inside surface 98 of the box 100 . A rotatable seat stretcher 108 may be rotated upwardly to accommodate stowage in the base and rotated downward to provide clearance for spring travel.
[0041] While the invention is amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and described in detail. It is understood, however, that the intention is not to limit the invention to the particular embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the appended claims.
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A ready to assemble or knockdown sofa having a back rest that can be reconfigured between a use configuration in which the sofa is has a conventional L-shaped cross-section and a shipping or storage configuration in which the sofa is arranged in a more efficiently stacked rectangular cross-section. The rectangular cross-section allows the sofa to be more efficiently stacked with other sofas during shipping or storage. The back rest has an upper back rest portion and a lower back rest portion in which the upper back rest portion can be rotated forward toward the front of the sofa and downwardly into a nesting region against the top of the seat base to provide a more efficient shape.
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BACKGROUND OF INVENTION
1. Field of the Invention
This invention relates to a high-efficiency electric motor of electronic commutation type.
2. Discussion of the Background
High-efficiency electrical machines of electronic commutation type, hereinafter known as ECMs, operate with pulse modulation and generally at ultrasonic frequencies, with absorption of very high ripple current pulses. Without the use of a costly and bulky L-C filter in the feed line, the conducted and radiated electrical disturbance levels would be greater than allowed by current regulations. To reduce costs, the filter can be replaced by one of active type able to decouple the current absorbed by the electric motor from the battery current. A known and particularly effective implementation, in terms both of cost and performance, is to interpose between the battery and the ECM a step-up converter current-controlled by means of R FB on the basis of control information C FB originating from the ECM, which is compared with a velocity input V set by known methods. This converter is characterised by operating with an output voltage V c greater than the battery voltage V b and by absorbing from the battery an essentially continuous current (of constant delivered power) with a ripple as small as desired, achieved by dimensioning the inductor L and the switching frequency by known methods. The waveform of the battery current i b is shown in FIG. 2, which shows the typical times associated with the operation: 1/T is the switching frequency, T on and T off are the on and off times of the electronic power switch P (FIG. 1); also shown are the ripple superimposed on the mean absorbed current and the composition of i b , consisting of the sum of i P and i D , this latter being integrated by the capacitor C to provide a mean current i 2 (from an essentially continuous V c ) which powers the ECM.
SUMMARY OF THE INVENTION
The object of the invention is to achieve the operability of the schematic of FIG. 1 essentially in terms of the waveform of the current absorbed from the battery, while significantly reducing cost and bulk by eliminating the inductance L and the switch P. As it is not possible to eliminate these components from an operational viewpoint, the invention proposes a solution which utilises certain switches and certain windings of the ECM, already present for its normal operation, to also perform the function of switch P and inductance L.
This object is attained according to the invention by a high-efficiency electric motor of electronic commutation type, having a single stator unit and a single rotor unit, including a first electrical submachine and a second electrical submachine, in which:
the first submachine is fed directly by a voltage source and is associated with a sensor for measuring the current absorbed from the feed; said first submachine including at least two windings characterised by an inductance, a resistance, an induced electromotive force and a switch connected in series;
the second electrical submachine is fed uniquely by a capacitor which is charged at a controlled voltage;
for each of said first windings there is provided a diode, having one of its poles connected to the end of the respective winding, which is connected to said switch, and the remaining pole connected to one of the ends of the capacitor thus charged at a controlled voltage;
the first submachine is pulse-modulation driven to obtain a closely DC current absorption from said voltage source with harmonics content as low as desired and, by charging the capacitor at the voltage via the diodes, said first submachine provides the unique power supply for said second submachine.
BRIEF DESCRIPTION OF THE DRAWINGS
A more complete appreciation of the invention and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, wherein:
FIG. 1 is a schematic block diagram of an electric motor of known type;
FIG. 2 shows the waveforms of the current through the motor of FIG. 1;
FIG. 3 is a schematic block diagram of the electric motor according to the invention;
FIGS. 4 and 5 are illustrations of two electromagnetic structures forming the electric motor of the invention;
FIG. 6 is a schematic block diagram of a specific electric motor of the invention;
FIG. 7 is an illustration of waveform diagrams illustrating the phase emfs of the motor of the invention;
FIG. 8 is a simplified schematic block diagram corresponding to that of FIG. 6;
FIG. 9 is a further schematic block diagram of the machine of the invention;
FIG. 10 is a waveform diagram;
FIG. 11 is a schematic block diagram of the motor of the invention provided with protection devices;
FIGS. 12 and 13 are further waveform diagrams; and
FIG. 14 is a schematic block diagram of an additional circuit for the electric motor of this invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings, wherein like reference numerals designate identical or corresponding parts throughout the several views.
Essentially according to the invention, the inductance L and switch P of FIG. 1 are integrated into a suitably structured ECM, controlled and dimensioned to add to its electric motor function the function of active filter, so covering by itself the overall operability of the schematic of FIG. 1. The first feature of the ECM proposed by the invention (FIG. 3) is that it operates as two submachines which mechanically combine their contributions at the same rotor of the ECM whereas electrically they operate and are controlled as two separate machines. The first, known hereinafter as M1, is powered by the battery at voltage V b , whereas the second, known hereinafter as M2, is powered by a capacitor C charged to a voltage C c by the operation of M1 as described hereinafter. The scheme is completed by the fast diodes D connected to the capacitor C as in FIG. 3. The velocity input V set and the signals of the Hall position sensors are also shown.
The second feature is that in order to also perform the function of the inductance L and the switch P of FIG. 1, the submachine M1 must be designed with a unipolar structure with two or more windings (depending on the number of phases to be determined and the number of windings to be powered in parallel) with the magnetic coupling between them as loose as possible. The inductances of its windings and the switches P already proposed for their normal PWM driving provide the L and P functions of FIG. 1.
The third feature is that the submachine M2 can have a different number of phases and windings than the submachine M1, with any magnetic coupling between them, but magnetically decoupled from the windings of M1.
The fourth feature is that the driver of M2 is totally independent of that of M1. It can therefore be of unipolar, bridging, linear or PWM type and is characterised by having a control function (for example a control feed-back on V c ) which ensures that under all operating conditions the current induced by the operation of M1 via the diodes D is totally absorbed by M2. Without limiting the generality of the aforedescribed principle of operation, for greater clarification and for providing the main design principles, reference will be made to a two-phase battery powered unipolar brushless motor of permanent magnet type.
Two electromagnetic structures which implement the aforesaid magnetic coupling conditions are shown in FIGS. 4 and 5 by way of non-limiting example.
In particular, for the same nominal ECM operating conditions and the same number of poles, the structure of FIG. 5 has a lower phase inductance and a lesser demagnetising reaction (1/3 of that of the structure of FIG. 4).
The specific schematic which achieves the said principles (FIG. 1 and FIG. 3) is shown in FIG. 6. To complete the control electronics, in addition to that already described it includes two signals V m2 for operating by known circuits (clamping circuits) a protection at overvoltages exceeding the VDSS allowed by the switches P2. These latter together with other circuit details are known and do not form part of the inventive idea, and will therefore not be referred to hereinafter. The chosen two-phase structure is for example of known type with four unipolar windings powered as two single-phase machines (at full half-wave). The first single-phase machine (consisting of PHASE 1 and PHASE 3) covers the role of the submachine N2 and is powered at V c . The emfs of each phase (e F1 , e F2 , e F3 , e F4 ) are shown in FIG. 7, where it can be seen that they are out of phase by 90 electrical degrees.
The magnetic structure, the seat of the magnetic flux generated by the currents in each winding of the submachine M1 (identified in FIGS. 4, 5 and 6 as PHASE 1 and PHASE 3), must be such as to ensure that the inductances of these windings are as mutually decoupled as possible to prevent absorbed current gaps during switching between one winding and the next in the driving sequence (a known problem when mutual inductance exists between the two) and that the inductive couplings with the sindings of M2 are marginal. This is achieved by the presence of non-wound decoupler teeth (indicated by T d ) and winding the two phases (PHASE 1 and PHASE 3) on physically separate teeth (see FIGS. 4 and 5). Said M2 windings also operate as an electric motor generating an active torque, as they suitably engage the pertinent emf half-wave by known methods (e.g. suitable decoding of Hall position sensors). The magnetic structure, the seat of flux generated by the currents in each winding of the submachine M2 (identified in FIGS. 4, 5 and 6 as PHASE 2 and PHASE 4), must ensure in this case a very tight magnetic coupling between them to enable the stored magnetic energy (from the windings which cease to conduct to those which begin to conduct) to be transferred during switching with minimum losses via the diodes D2 (known operation). This is achieved by winding said phases on the same teeth (see FIGS. 4 and 5).
As the two submachines operate in parallel in providing the desired mechanical power it is generally advantageous to dimension them such that, at least under nominal conditions, both the mechanical power supplied and the losses are divided into equal parts.
The design data for said operating point (n) are:
P mach (n) mechanical power
RPM(n) velocity
η(n) efficiency
V b feed voltage
Knowing the design data, the geometry and the materials chosen for constructing the machine, the iron, ventilation and friction losses P fe ,v,a(n) can be predicted by known methods.
The value of R FB is chosen such that the voltage drop across it can be considered negligible as a first approximation, so that to simplify the calculations the diode is simulated as an ideal diode with a resistor equal to R pi in series (see FIG. 8).
By way of example, for the machine of FIG. 8 the equivalent scheme shown in FIG. 6 can be used, which shows the essential components for dimensioning the two machines, these being:
L f1 inductance of each winding of M1
R f1 resistance of each winding of M1
E f1 mean emf per half wave at the nominal velocity of each winding of M1
R P1 internal resistance of the power switch (e.g. MOSFET) for each winding of M1.
FIG. 8 also shows the corresponding elements for M2.
The two submachines (M1) and (M2) must be designed as follows. Dimensioning of submachine M1:
The first element immediately obtainable is i 1 (n) from
η(n)=P.sub.mech(n) /V.sub.b(n) i.sub.1(n)
hence
i.sub.1(n) =P.sub.mech(n) /V.sub.b(n) N.sub.(n) (eq. 1)
Equation 1, together with cost considerations and other known operational aspects of the switch P1, enables its type to be identified and hence R P1 to be qualified as an item of data. Having identified i 1 (n) and R P1 , E f1 (n), E f1 (1000) and R f1 (n) can be obtained. From the known relationship P gap =P mech +P fe ,v,a =E·I and remembering that the power has to be distributed equally between the machines M1 and M2, the for M1:
E.sub.f1(n) i.sub.1(n) =[V.sub.b(n) i.sub.1(n) η.sub.(n) +P.sub.fe,v,a(n) ]/2
hence
E.sub.f1(n) =1/2[V.sub.b(n) η(n)+P.sub.fe,v,a(n) /i.sub.1(n) ]
which by replacing i 1 (n) by eq. 1 gives:
E.sub.f1(n) =1/2V.sub.b(n) η(n)[1+P.sub.fe,v,a(n) /P.sub.mech(n) ](eq. 2a)
As P fe ,v,a(n) is negligible compared with P mech (n), (eq. 2a) can 5 be rewritten as
E.sub.f1 (n)≈1/2V.sub.b(n) η(n) (eq. 2b)
from which E f1 (1000) can be obtained as follows:
E.sub.f1 (1000)=[E.sub.f1(n) /RPM(n)]·1000 (eq. 3)
Hence using known formulas the number of turns of the winding and the value of L f1 can be calculated. To obtain R f1 (n) an energy balance can be used in which the machine M1 absorbs 50% of the total power. Hence:
[E.sub.f1(n) +(R.sub.f1 +R.sub.P1)i.sub.1(n) ]i.sub.1(n) =1/2V.sub.b(n) i.sub.1(n)
giving
E.sub.f1 (n)+(R.sub.f1 +R.sub.P1)i.sub.1(n) =1/2V.sub.b(n)
from which
R.sub.f1 =[V.sub.b(n) /2-E.sub.f1(n) ]/i.sub.1(n) -R.sub.P1 (eq. 4)
Dimensioning of submachine M2:
Defining T on and T off as the on and off times of the switches P1 respectively,
T=T.sub.on +T.sub.off, D=T.sub.on /T, T.sub.off /T=(1-D).
Regardless of the voltage V c across the capacitor C, its charging current can be obtained from the always valid relationship:
i.sub.2 =i.sub.1 T.sub.off /T=i.sub.1 (1-D)
which at the nominal operating point can be written as
i.sub.2 (n)=i.sub.1(n) (1-D(n)) (eq. 5)
The relationships between M2 and M1 for their respective characterising elements can now be obtained. Remembering the condition of equal power, then:
E.sub.f2(n) ·i.sub.2(n) =E.sub.f1(n) ·i.sub.1(n)
hence
E.sub.f2(n) =E.sub.f1(n) ·i.sub.1(n) /i.sub.2 (n)
and finally
E.sub.f2(n) =E.sub.f1(n) /(1-D.sub.(n)) (eq. 6)
Remembering also the condition of equal dissipated power, then:
R.sub.f2(n) ·i.sub.2 (n).sup.2 =R.sub.f1(n) ·i.sub.1(n).sup.2
hence
R.sub.f2(n) =r.sub.f1(n) ·(i.sub.1(n) /i.sub.2(n)).sup.2
and finally
R.sub.f2(n) =R.sub.f1(n) /(1-D.sub.(n)).sup.2 (eq. 7)
The only unknown is D.sub.(n), which can be obtained from
Δi.sub.1,Ton =Δi.sub.1,Toff
from which, having assumed RD=Rp1
(V.sub.b -[E.sub.f1 +(R.sub.f1 +R.sub.P1)i.sub.1 ])T.sub.on /L.sub.f1 T=(R.sub.P1i1 +V.sub.c -[V.sub.b -(E.sub.f1 +R.sub.f1 i.sub.1)])T.sub.off /L.sub.f1 T (eq. 8)
Putting A=V b -[E f1 +(R f1 +R P1 )i 1 ], then:
D=(V.sub.c -A)/V.sub.c (eq. 9)
Hence, remembering (eq. 4),
1-D.sub.(n) =v.sub.b(n) ·V.sub.c(n) /2 (eq. 10)
from which it can be seen that having fixed V b , (1-D.sub.(n)) is defined unabmiguously by V c (n).
The three ensuing conditions help to define V c (n) unambiguously. These are:
Condition 1
In order for current not to circulate through that winding of the submachine M1 which with its emf, the sum of the motional part E f1 (n) and the transformer part E m1 (n) due to undesirable coupling between the windings of the submachine M1 and between these and those of the submachine M2, would give a negative contribution to the development of mechanical power, the voltage V DS1 (off) across the power switch P 1 (off) connected to said winding must be less than the voltage across the capacitor C. Only in this manner can the diode D 1 (off) be polarised inversely and hence current cannot pass therethrough. The following condition must therefore be satisfied (see FIGS. 8 and 9):
V.sub.c(n) ≧V.sub.DS1(off) =V.sub.b(n) +E.sub.f1(n) +E.sub.m1(n)(cond. 1)
Condition 2
As the maximum voltage v DS2 (off) across the power switch P2 occurs during the time interval in which that winding of the submachine M2 connected to it is inactive, then:
V.sub.DS2(off) =V.sub.c(max) +E.sub.f2(max) =2V.sub.c(max) ;
hence in order for the rupture voltage V DSS2 of the power switch P2 not to be exceeded, the following condition must be satisfied:
2V.sub.c(max) <V.sub.DSS2 (cond. 2)
Condition 3
Remembering that:
the coupling between the windings of the submachine M2 must, as stated, be as high as possible;
the transfer of magnetic energy, which occurs through D2 during switching between the windings of submachine M2, is less dissipative the higher the difference between the feed voltage, which in this case is V c , and the transient overvoltage V ts2 (off,t) (made as close as possible to V DSS2 by said clamping circuits) which appears across the power switch P2 when it opens;
the cost of the capacitor C increases with its rated voltage; it is apparent that V c (n) must be as low as possible (cond. 3).
Given that in practice:
E.sub.f1(n) +E.sub.m1(n) ≈1/2V.sub.b(n)
then (see (cond. 1))
V.sub.c(n) ≈3/2 V.sub.b(n) (eq. 11).
From (eq. 10) and (eq. 11) the following are also obtained:
i.sub.2(n) =i.sub.1(n) /3 (eq. 12.1)
E.sub.f2(n) =3E.sub.f1(n) (eq. 12.2)
R.sub.f2(n) =3.sup.2 R.sub.f1(n) (eq. 12.3)
P.sub.p2(n) =3.sup.2 r.sub.P1(n) (eq. 12.4)
Equations 12.1-12.4, which unambiguously determine the dimensioning of the submachine M2, show an interesting aspect from the constructional viewpoint, namely that for the two submachines, wire of the same cross-section can be used, with a different number of wires in parallel for the two submachines.
If 1 m is the mean turn length identical for all windings of the two submachines, S c1 the wire cross-section of each winding of the submachine M1 and S c2 the wire cross-section of each winding of the submachine M2, then:
R.sub.f1 =ρ(l.sub.m N.sub.s1)/C.sub.c1 (eq. 13.1)
R.sub.f2 =ρ(l.sub.m N.sub.s2)/C.sub.c2 (eq. 13.2)
Given that from (eq. 12.2) it can be deduced that the number of turns N s1 of each winding of the submachine M1 must be 1/3 the number N s2 of each winding of the submachine M2:
N.sub.s1 =1/3·N.sub.s2 (eq. 13.3)
From (eq. 12.3) and (eq. 13.1-13.3):
ρ(l.sub.m ·N.sub.s2)/S.sub.c2 =3.sup.2 ρ(l.sub.m ·N.sub.s1)/S.sub.c1 =3.sup.2 ρ(l.sub.m ·N.sub.s2 /3)/S.sub.c1
hence
S.sub.c1 =3S.sub.c3 (eq. 14)
This latter shows that the winding of the submachine M1 can be formed by positioning in parallel three wires of cross-section identical to that of the single wire used for the winding of the submachine M1. A PWM control strategy at fixed frequency is normally implemented on step-up converters of the type shown in FIG. 1. Given that, as clarified in the description of the inventive idea, the function of the inductor L of FIG. 1 is performed by windings which are the seat of induced emf, a strategy such as the aforegoing would make it difficult to contain the battery current ripple within predetermined limits. For this reasom the control strategy adopted is of hysteresis type, which acts only on the on phase of the submachine M1 and, in accordance with known methods, maintains the current is absorbed by the ECM, as measured through the resistor R FB , within predetermined maximum and minimum values such as to make the ripple as small as desired compatible with the technical limitations related to the state of the art of the switching devices used. This naturally means that the switching frequency of the power switches of the submachine M1 is not set but is directly related to its electrical parameters (inductance, emf, feed voltage). Conveniently, a control strategy is used for the voltage V c across the capacitor C which for each delivered torque and rotational velocity condition satisfies the said (cond. 1), while maintaining the difference between V c and V DS1 (off) as small as desired by known methods. The said strategy enables the battery current to be fully-controlled during switching between windings of the submachine M1. If during switching between windings of the submachine M1 it happens that the current in the phase which is switched off decreases more rapidly than the current increase in the phase which is switched on, the current is fails to below the minimum set value. If in contrast when one phase is switched off the current decreases more slowly than the current increase in the phase which is switched on, the is control maintains it within the preset limits. To obtain this condition it is necessary that during the switching time the average value of E f1 , known as E f1 ,avg is such that
V.sub.b -E.sub.f1,avg >V.sub.c -(V.sub.b -E.sub.f1,avg)
As V c ≈3/2 V b , necessarily E f1 ,avg <0.25 V b .
Given that this is achieved by simply anticipating switching (already necessary for operation of the submachine M2 and easily implemented), the absorbed current ripple is hence easily controllable in any event. A filter for eliminating conducted and radiated electrical disturbances is conveniently positioned in the ECM feed line (see FIG. 11) and is of much smaller cost and size than that required for an ECM which does not implement the inventive idea. The simplest way of protecting a battery-powered ECM is to connect a power diode in series with the operating relay. Besides being costly and bulky, this diode introduces a voltage drop (typically 0.7 Volt) and hence reduces the EM efficiency (for equal absorbed power). The operating relay, which is key-operated, has to withstand a switch-on current which is so high as to require: unacceptable overdimensioning. According to the schematic shown in FIG. 11 the ECM is instead directly powered by the battery via the relay RL controlled by the electronic control unit ECU. A lower-power diode D P and a ballast resistor R z are connected as shown in FIG. 11. Given that the electronic control unit which controls the relay RL is key-powered via D p , the ECM is protected against polarity inversion. The ballast resistor R z prolongs the duration of the current pulse which charges the capacitors C and C F when the starting switch is operated, so limiting the extent of the dV/dt to which the capacitors are subjected and preventing passage of destructive current through the switch. The electronic control unit ECU measures the voltage across the resistor R z and enables the relay RL only when this voltage, and hence the switch-on current, fails below a predetermined safety level.
Referring to eq. (11) V c ≈3/2 V b , there are some cases (for instance to lower the rms current through the capacitor C, to lower the current through the switches of submachine M2, etc.) in which it is necessary to have V c >3/2 V b . In that case it could happen that during the commutation between the phases of the submachine M1, the current in the phase which is switched off decreases more rapidly than the current increase in the phase which is switched on: the battery current will fall out of the prescribed tolerance-band.
To avoid the fall of the battery current it is necessary to add an electronic circuit (FIG. 14) to control the current in the phase which is switched off. This is attained, as described below, by artificially prolonging the conduction interval of each phase of submachine M1, feeding to the gate of the corresponding MOSFET a clock signal logically anded with the pwm signal that normally controls the phases of submachine M1 in order to maintain the battery current within the prescribed tollerance-band. The decrease of the phase current vs time (slope) is controlled at a value such to avoid battery current to fall out of the above mentioned.
The logic keeps the MOSFET definitively off when the phase current reaches zero. The behaviour of the circuit will be explained for one of the two phases (named 1) of submachine M1, providing and complementary circuitry is used for the other(s).
Referring to FIGS. 12 and 13, let the phase 1 switched off.
V D1 =voltage at the drain of MFT1
V C =voltage across the capacitor C
clock=square wave with duty-cycle value less than 50% the duty-cycle of the pwm signal and frequency value at least greater than three times the frequency of pwm signal
hall=the Hall effect sensor signal which switches on phase 1
pwm=signal which normally controls the phases of submachine M1 in order to maintain the battery current within the prescribed tolerance-band.
When HALL goes down to <low>, MFT1 is switched (momentary) off, V D1 becomes greater than V C , b 1 goes to <high>, y i goes to <high> and q 1 will latch clock, out 1 =clock:MFT1 will be controlled by pwm anded with the clock one (see FIG. 12).
When the current through the phase 1 reaches zero and q 1 (latched to clock) switches off MFT1, V D1 cannot override V c , B 1 goes to <low> and when clock goes to <low>, y 1 goes to <low>; suddenly q 1 will go to <low>, out 1 will go down to <low> and MFT1 will be definitively switched off (see FIG. 13).
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An electronic commutation motor including a stator unit configured as a pulse-modulation driven stator unit including at least two winding circuits in which an induced electromagnetic force is produced, and a phase switching switch; and a rotor unit powered by charge stored on a capacitor, wherein the capacitor is charged by diodes coupled between the capacitor the first winding circuits of the stator unit. In this way, the stator unit, serving as a first submachine, performs the function of power supply for the rotor unit serving as a second submachine, by charging of the capacitor via the diodes.
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CROSS-REFERENCE TO RELATED APPLICATION PARAGRAPH
This application claims the benefit of Chinese Patent Application No. 200910140562.5, filed on May 2, 2009, the content of which is hereby incorporated by reference in its entirety.
FIELD OF THE INVENTION
This invention related to a pharmaceutical composition for prophylaxis and/or treating of wasting diseases (such as cachexia and anorexia), and in particular to a cachexia caused by a cancer. The pharmaceutical composition of this invention comprises a lanostane compound as active ingredient. A proper source of the lanostane compound is a Poria extract. Further, the lanostane compound may obtain from Cordyceps sinensis, Antrodia cinnamomea or Granodema lucidum.
BACKGROUND OF THE INVENTION
Cachexia is a state with an unhealthy fatigue state, and is usually caused by anorexia from diseases and changes of endocrine system and immune system, resulting in wasting, loss of muscle and visceral proteins, finally in loss of body weight.
Cachexia is a syndrome used to be found in patients with chronic diseases or critical care. In particular to patients with stomach cancers or pancreas cancers among patients with cancers, and there are about 70% patients who will develop this syndrome. At the late stage of cancer, there are about 80% patients who will develop cachexia no matter what kind cancer they have. Cachexia is characterized by that there is no way to prevent or terminate loss of patients' body weight, even if you increase the food amount and enhance the nutrients intake for the patient. Hormonal appetite enhancer (such as megestrol, medroxyprogesterone acetate) is usually used in the treatment, however, someone has pointed out that it only results to a temporary increase of body weight (water and fat increase only), and there is no increase of body muscle, and there is no improvement on activity ability and physical activity. Contrarily, some drug side-effects are observed such as thrombus, edema, hemorrhage, hyperglycemia and hypertension and the like.
Catabolic wasting or cachexia is a syndrome characterized by spontaneously progressive wasting of fat and skeletal muscle, refractory body weight loss to increase nutrition import, increase of resting energy expenditure (REE), decrease of protein synthesis, change of carbohydrate metabolism (Cori cycle activity increase), over catabolism of ATP-ubiquitin dependent proteasomes pathway through protein solvent, and over catabolism of adipose tissue through adipose solvent (Body J J, Curr Opin Oncol 11: 255-60, 1999, Muscaritoli M, et al: Eur J Cancer 42: 31-41, 2006). In general, a patient will not be diagnosed cachexia until 5% or 5 pounds body weight loss at least. About half of patients with cancers experience certain level of catabolic wasting, and a higher attack rate is found in the cases with lung, pancreas and gastrointestinal malignant diseases (Dewys W D, et al: Am J Med 69: 491-7, 1980). The syndrome is found in patients with immunodeficiency diseases such as AIDS and patients with bacterial and parasitic diseases, rheumatoid arthritis, chronic diseases associated with bowel, liver, lung and heart. Cachexia also relates to anorexia, which may be a situation of aging or a result of body injury or burn. Cachexia syndromes reduce patients' functional ability and living quality, deteriorate potent situation, and reduce drug tolerance. The level of cachexia is inverse proportional to the survival time of patient, which usually means a poor prognosis. In recent years, diseases associated aging and disable has become a major issue in health care.
Anorexia (a medical term for appetite loss) is a deterioration of many malignant diseases, and is often found in patients with cancer, infectious diseases, chronic organ failure and trauma. Anorexia is a sever syndrome because it will cause a decrease calorie intake and dystrophy. Symptoms of anorexia include decrease of gestation and olfaction, early satiety, decrease of hunger sensation and even complete food aversion, and nausea and vomit may be found in some cases. The reasons of anorexia are not well known, and there are only limited options available for effective therapy. Some research has mentioned that a combination of hormone, social factor and psychological factor might be an important factor for the onset and progression of this syndrome.
It is not clarified a consistent relationship between cachexia onset and tumor size, disease stage, type and period of a malignant disease although cachexia is usually associated with cancer actually. The cancer cachexia usually associates with decrease of calorie intake, increase of resting energy expenditure, and metabolic change of protein, fat and carbohydrate. For example, some significant abnormality of carbohydrates includes: increase of total glucose conversion, increase of glyconeogenesis, glucose impaired tolerance and hyperglycemia. It is usually found an increase of fat solvent, increase conversion of free fatty acid and glycerol, hyperlipidemia, and decrease of lipoprotein lipase activity. It should be concerned that cachexia-associated body weight loss is not only caused by body fat storage loss but also related to body total protein mass loss and pervasive skeletal muscle wasting. An increase of protein conversion and impaired regulation of amino acid oxidation might be critical factors for this syndrome deterioration. Further, specific host influence factors produced corresponding to cancers, such as pro-inflammatory cytokines (tumor necrosis factor-α (TNF-α), interleukin-1, interleukin-6 and γ-interferon), acute phase protein (e.g. C-reactive protein) and specific prostaglandin, are likely to associate with cancer cachexia.
In Chinese traditional herbal medicine, it is recommended that aged people take Poria galenical everyday, and it will help aged people to delay aging and have long life in addition to not easy to be sick.
The applicant of the present application in EP 1535619 A1 discloses a pharmaceutical composition for enhancing immunity in human body, which contains a lanostane compound as a potent component. This composition is able to enhance immunity and is useful in the prophylaxis and treatment of virus infections. On the other hand, the Poria extract and lanostanes purified therefrom show an inhibition effect on immunity, and are used in the prophylaxis and treatment of IgE-mediated allergies (asthma). This inhibition effect is disclosed in US2009 0318399 A1 and WO 2009/155/730 A1. These applications indicate that Poria extract and lanostanes are able to adjust immunity. The applicant of the present application in US 2009/0247496-A1 and WO 2009/124420 A1 discloses that Poria extract and lanostanes purified therefrom have an effect on human intestines and enhance the uptake of nutrients: absorption of glucose, amino acids, and vitamins (folic acid).
Therefore, Poria extract ingredient, particularly lanostane compounds, might help in improving and treating cachexia associated with nutrition and immunology. In this invention, whether or not the Poria extract ingredient and lanostane compounds have a treating effect on cachexia was evaluated by performing experiments with mice transplanted with human lung cancer cells, wherein the human lung cancer cell transplanted mice were observed as to whether they had normal appetite and had normal body weight without gradually losing their body weight in comparison with normal mice.
SUMMARY OF THE INVENTION
A primary objective of the present invention is to provide a pharmaceutical composition of prophylaxis or treatment of a wasting disease (such as cachexia and anorexia), and in particular to a cachexia caused by a cancer.
Another objective of the present invention is to provide a use of Poria extract prepared from Poria cocos (Schw) Wolf in the prophylaxis or treatment of a wasting disease (such as cachexia and anorexia), and in particular to a cachexia caused by a cancer.
A further objective of the present invention is to provide a new use of lanostane in the prophylaxis or treatment of a wasting disease (such as cachexia and anorexia), and in particular to a cachexia caused by a cancer.
A method for the prophylaxis or treatment of a wasting disease (such as cachexia and anorexia) disclosed in the present invention comprises administering to a mammal in need thereof an effective amount of a lanostane compound having the following chemical formula (I), or a pharmaceutically acceptable salt thereof:
wherein R 1 is —H or —CH 3 ; R 2 is —OCOCH 3 , ═O, or —OH; R 3 is —H or —OH; R 4 is —C(═CH 2 )—C(CH 3 ) 2 R a , wherein R a is —H or —OH, or —CH═C(CH 3 )R b , wherein R b is —CH 3 or —CH 2 OH; R 5 is —H or —OH, and R 6 is —CH 3 or —CH 2 OH.
Preferably, the lanostane compound (I) has the following chemical formula:
Preferably, the lanostane compound (I) is administered to the mammal as a Poria extract comprising 1-60% of the lanostane compound (I), based on the weight of the Poria extract. More preferably, said Poria extract is substantially free of secolanostane. Most preferably, said Poria extract comprises, based on the weight of the Poria extract, 5-35% of the lanostane compound (I).
Preferably, said Poria extract is prepared by a method comprising the following steps:
a) extracting metabolites, fermentation products or sclerotium of Poria cocos (Schw) Wolf by water, methanol, ethanol, or a mixed solvent thereof;
b) concentrating the resulting liquid extract from step a);
c) introducing the resulting concentrated substance from step b) into a silica gel column;
d) eluting the silica gel column with an eluent having a low polarity, and collecting the resulting eluate; and
e) concentrating the eluate to form a concentrated eluate.
Preferably, the concentrated eluate from step e) has a chromatographic value, Rf, not less than 0.1 in accordance with a thin layer chromatography, which is developed by a mixed solvent of dichloromethane:methanol=96:4 and is detected by an ultraviolet lamp and iodine vapor.
Preferably, the extraction in step a) is carried out by using 95% ethanol.
Preferably, the extraction in step a) comprises extracting metabolites, fermentation products or sclerotium of Poria cocos (Schw) Wolf by boiling water; adding a base to the resulting extraction aqueous solution until a pH value thereof is 9-11; recovering the basic aqueous solution; adding an acid to the basic aqueous solution until a pH value thereof is 4-6 to form a precipitate; recovering the precipitate; extracting the precipitate with ethanol; and recovering a liquid extract.
Preferably, the concentrated substance resulted from step b) is further extracted with a two-phase solvent containing methanol and n-hexane in a volumetric ratio of 1:1, a methanol layer is separated from the two-phase solvent extraction mixture, and the methanol layer is concentrated to form a concentrate, which is used as a feed to the silica gel column in step c).
Preferably, the low polarity eluent in step d) is a mixed solvent containing dichloromethane and methanol in a volumetric ratio of 96.5:3.5.
Preferably, the lanostane compound (I) is administered together with a nutrient, for examples glucose, an amino acid, a vitamin, or a combination thereof.
Preferably, the lanostane compound (I) or a pharmaceutically acceptable salt thereof is administered to the mammal as an isolated compound together with a pharmaceutical acceptable carrier or diluent.
Preferably, the administering is oral intake.
Preferably, the mammal is a human.
Preferably, the wasting disease of the present invention is a cachexia; more preferably, the cachexia is caused by a cancer, such as lung cancer, stomach cancer, pancreas cancer, colorectal cancer, breast cancer, oral cavity cancer or nasopharyngeal cancer.
Preferably, the wasting disease of the present invention is caused by cancer, anorexia, aging, body injury or burn.
Preferably, the administration of lanostane (I) or a pharmaceutically acceptable salt thereof is not less than 8.4 mg/day.
The present invention use a lanostane compound represented by formula (I) or pharmaceutically acceptable salt thereof, or the above Poria extract to treat anorexia, serious loss of boty weight in cancer patients. In addition to cancer, cachexia-associated diseases include the cachexia caused by AIDS, aging, rheumatoid arthritis, pulmonary tuberculosis, fibrocyst, Crohn's disease, infective diseases and the like. It is required to have a nutrient supplement (amino acids, glucose, and vitamins) to improve the wasting state caused by surgery or cancer patients who receive chemotherapy or radiotherapy. The active ingredient of the present invention may be added into milk powder, drink, or food for the purpose of nutritional supplement. Also, it may be formulated into a tablet, capsule, granules, liquor, injection and the like, for medicinal purpose.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 shows body weight changes of mice in each group mice in the first test in Example 7, wherein + represents the blank group; black circle represents the control group; and diamond, square and triangle respectively represent the drug administration groups PC-A, PC-B and PC-C, wherein mice were administered lanostane in an amount of 17.6 mg, 8.8 mg and 4.4 mg per kg body weight, respectively.
FIG. 2 shows body weight changes of mice in each group in the second test in Example 7; wherein diamond represents the blank group; square represents the control group; and triangle represents the drug administration group PC-D, wherein mice were administered lanostane in an amount of 8.8 mg per kg body weight.
FIG. 3 shows food intake changes of mice in each group in the second test in Example 7; wherein diamond represents the blank group; triangle represents the control group; and circle represents the drug administered group PC-D, wherein mice were administered lanostane in an amount of 8.8 mg per kg body weight.
FIG. 4 shows blood albumin concentration of mice in each group in the first test in Example 7 at 22 days.
FIG. 5 shows blood albumin concentration of mice in each group in the second test in Example 7 at 22 days.
FIG. 6 shows evaluation of overall nutritional status of Group I cancer patients (chemotherapy+one Poria extract capsule) in Example 8, who were evaluated by according to PG-SGA assessment (Patient-Generated Subjective Global Assessment) used by clinician.
FIG. 7 shows evaluation of overall nutritional status of Group II cancer patients (chemotherapy+two Poria extract capsules) in Example 8, who were evaluated according to PG-SGA assessment used by clinician.
FIG. 8 shows evaluation of overall nutritional status of control group cancer patients (chemotherapy) in Example 8, who were evaluated according to PG-SGA assessment used by clinician.
DETAILED DESCRIPTION OF THE INVENTION
Cachexia means human body is at a fatigue state, and the reasons causing cachxia have many theories; however there is no such a mechanism can be assured. As to cancer, it is known so far that cancer cells release factors or the immune reaction of human body to cancer cells will cause release of various factors, either directly or indirectly, resulting in anorexia, creating changes of endocrine system and immune system in the human body, so that patients start dislike food intake, and thus fat and proteins in muscles gradually decrease, which lead to phenomena of body fragile gradually and body weight loss gradually.
Cachexia-associated diseases include cancer, infectious disease (such as pulmonary tuberculosis, AIDS), autoimmune diseases (rheumatoid arthritis), aging, fibrocyst, and Crohn's disease. There are about 70% of the cancer patients who will develop this syndrome, and more often found in patients with stomach cancer and pancreas cancer. At the late stage of cancer, there are about 80% of the cancer patients who will develop cachexia no matter what kind cancer they have. There is no way to prevent or terminate loss of patients' body weight, even if increasing the food intake or other methods through gavages or intravenous injection to increase nutrition have been applied in the treatment. Hormone appetite enhancer (such as megestrol, medroxyprogesterone acetate) is usually used in the treatment; however, someone has risen that it only results in a temporary increase of body weight (water and fat increase only), and there is no increase of body muscle, and there is no improvement on physical activity. Contrarily, some drug side-effects are observed such as thrombus, edema, hemorrhage, hyperglycemia and hypertension.
An extract of Poria for enhancing nutrient uptake by mammals (for example, humans) disclosed in the present invention can be prepared by a process similar to that disclosed in US2004/0229852 A1, which includes extracting Poria cocos (Schw) Wolf with the conventional extraction methods to obtain a crude extract, separating the crude extract by chromatography into a low polarity fraction of lanostane (with an eluent of dichloromethane:methanol of 96:4) and a high polarity fraction of secolanostane (with eluents of dichloromethane:methanol of 90:10, and 0:100), wherein the lanostane fraction is detected by a thin layer chromatography having a chromatographic value, Rf, not less than 0.1 in accordance, when it is developed by a mixed solvent of dichloromethane:methanol=96:4; the Rf is less than 0.1 for the secolanostane fraction. Several lanostanes are separated from the lanostane fraction by subjecting the lanostane fraction to silica gel column chromatography eluted, wherein the eluents used are dichloromethane:methanol=97:3 to 95:5.
The following examples are provided for describing the present invention in further details, but should not be used to limit the scope of the present invention.
Percentages and other amounts referred to in this specification are by weight unless indicated otherwise. Percentages are selected from any ranges used to total 100%.
Example 1
26 kg of Poria grown in Yunnan was extracted with 260 liters of 75% aqueous alcohol solution under heating. The extraction were repeated three times; the resulting three extraction solutions were combined and vacuum concentrated to yield an extract of 225.2 g. Quantitative analyses were subsequently carried out on the extract, which indicated that 76.27 mg of lanostanes could be found in every gram thereof, wherein K1 (pachymic acid) took up 33.4 mg; K1-1 (dehydropachymic acid) took up 9.59 mg; K2-1 (tumulosic acid) occupied 19.01 mg; K2-2 (dehydrotumulosic acid) occupied 6.75 mg; K3 (polyporenic acid C) occupied 5.06 mg, and K4 (3-epidehydrotumulosic acid) occupied 2.46 mg.
Example 2
125 g of the alcohol extract from Example 1 was further extracted six times with 1.3 liters of dichloromethane; the resulting six extraction solutions were combined and concentrated to obtain an extract of 22.26 g. The dichloromethane extract were dissolved in heated 95% alcohol and left to cool, followed by filtering and discarding the insoluble substances. A small amount of water was added into the filtrate until the alcohol concentration reached 45% therein, which resulted in precipitation; from which a precipitate of 17.4 g was obtained by centrifugation consequently. Subsequent quantitative analyses on the precipitate indicated that each gram thereof comprised 264.78 mg of lanostanes, wherein K1-1 occupied 159.7 mg; K1-2 occupied 56.96 mg; K2-1 occupied 24.43 mg; K2-2 occupied 8.8 mg; K3 occupied 9.84 mg, and K4 occupied 5.05 mg. The method of thin layer chromatography (TLC) with silica gel was used to confirm the precipitate did not comprise any secolanostane.
Example 3
100 kg of Poria was boiled with 800 kg of water for 3 hours, then left for cooling to 50° C. and a pH value thereof was adjusted to pH 11 by using a 5N NaOH solution, followed by stirring the resulted solution for 3 hours. A centrifugation machine was used to separate the liquid from the solid, followed by adding another 800 kg of water to the separated solids. The aforesaid procedures were repeated, including adjusting pH value with NaOH to pH 11, stirring, and removing the solids by centrifugation. The two resulting liquids were combined, and then vacuum concentrated to a solution of 100 kg at 50° C., followed by the adjustment of pH value to pH 6.5 by using 3N HCl so as to produce a precipitate. Said precipitate was separated from the solution, subsequently rinsed with 40 L H2O, and centrifuged in order to recover the precipitate; the precipitate was sprayed dry with 8 L of water, which yielded 380 g of powder. Afterwards, the powder was extracted three times by using 4 L of alcohol, and the extraction solutions were combined and concentrated to result in 238.9 g of alcohol extract. The 238.9 g of alcohol extract was proved containing no secolanostane compounds by the TLC analysis, and then was subjected to HPLC separation, which gave 214 mg of K2, 23 mg of K3, 24 mg of K4, and 4.52 mg of K1 in per gram of the extract. In other words, each gram of the extract has approximately 265 mg of lanostane compounds.
Or the powder was extracted by using 4 L of 50% aqueous alcohol solution, and then had the 50% aqueous alcohol solution removed in order to obtain an insoluble powder; the extraction was repeated three times to yield 245.7 g of a substance insoluble in 50% aqueous alcohol solution. The insoluble substance was confirmed having no secolanostane compounds by the TLC analysis, and then underwent separation and purification processes by HPLC, which yielded 214 mg of K2, 23 mg of K3, 24 mg of K4, and 4.52 mg of K1 in each gram of the extract, which is equivalent to approximately 261 mg of lanostane compounds in each gram of the extract.
Example 4
A Poria powder was made of 30 kg of the China-grown Poria cocos (Schw) Wolf. The Poria powder was extracted with 120 L 95% alcohol for 24 hours. The mixture was filtered to obtain a filtrate. The residue was extracted and filtered for another three cycles. The filtrates were combined and concentrated to bring about a dried extract in an amount of 265.2 g. The dry extract underwent a distribution extraction with a two-phase extraction agent (n-hexane:95% methanol=1:1), and the methanol layer was removed therefrom, which is then concentrated to obtain a dry solid in an amount of 246.9 g. A separation of the dry solid was carried out by means of a silica gel column, which was filled with silica gel 10-40 times of the weight of the dry solid. The silica gel having a diameter of 70-230 mesh was made by Merck Corporation with a code of Silica Gel 60. The column was eluted by the following eluates in sequence: a mixed solvent of dichloromethane:methanol=96:4; a mixed solvent of dichloromethane:methanol=90:10, and pure methanol. The eluates were tested by the thin layer chromatography (TLC), wherein an ultraviolet lamp and iodine vapor were used for detecting, and a mixed solvent of dichloromethane:methane=96:4 was used as a developing liquid. The eluates having similar constituents in the TLC were combined.
The elution carried out with the mixed solvent of dichloromethane:methanol=96:4 resulted in a PCM portion in an amount of 78 g. The PCM showed 6 trace points in the thin layer chromatography. The resulted eluates from the elutions carried out with the eluents of dichloromethane:methanol=90:10 and pure methanol were combined to obtain a PCW portion in an amount of 168 g.
The PCM portion was further separated by means of an eluent of dichloromethane:methanol=96.5:3.5 and the same silica gel column to obtain purified lanostane components of K1 (K1-1 and K1-2), K2 (K2-1 and K2-2), K3, K4, K4a, K4b, K5, K6a and K6b. Further details of the separation steps and identification analysis data can be found in US2004/0229852 A1.
The aforesaid K1 to K6b compounds have the following structures:
The amounts of the lanostane compounds K1 to K6b separated from the PCM portion are listed in the table below. The PCM portion contains approximately 15 wt % of the lanostane compounds K1 to K6b.
K1
K2
K3
K4
K4a
K4b
K5
K6a
K6b
3.0 g
6.2 g
1.93 g
0.55 g
66 mg
86.8 mg
47.6
21.4
90.7
mg
mg
mg
Example 5
Capsules having the PCM portion prepared in Example 4 were prepared basing on the following composition:
Per 30,000
Components
Per Capsule
Capsules
PCM prepared in Example 4 (containing
11.2 mg
336.0 g
approximately 15 wt % of K1-K6
compounds)
Sodium silicoaluminate
5.0 mg
150.0 g
Starch Potato
378.8 mg
11,364.0 g
Magnesium Sterate
5.0 mg
150.0 g
Total
400 mg
12,000.0 g
The PCM portion and sodium silicoaluminate were sifted by using a #80 mesh, and the starch potato was sifted by using a #60 mesh; while magnesium sterate was sifted by using a #40 mesh. Subsequently, the aforesaid components were mixed evenly in a mixer, followed by filling the resulting mixture into No. 1 empty capsules. Each capsule contains approximately 1.68 mg (0.42 wt %) of effective components K1-K6.
Example 6
The Poria extracts prepared in Example 2 and 3 were formulated into an agent as shown in Table 1, as a test material to evaluate the changes of body weight, food intake and protein level in serum of animals suffering a cancer, and the overall nutritional status of patients with cachexia caused by a cancer after administration of Poria extract.
TABLE 1
Dose of Poria extract contained in the test material
PORIA
ANIMAL DOSE OF
CORRESPONDING
AGENT
EXTRAXCT*
LANOSTANE
HUMAN DOSE
PC-A
EXAMPLE 2
17.6 mg/kg
33.6 mg/kg
PC-B
EXAMPLE 2
8.8 mg/kg
16.8 mg/kg
PC-C
EXAMPLE 2
4.4 mg/kg
8.4 mg/kg
PC-D
EXAMPLE 3
8.8 mg/kg
16.8 mg/kg
*The Poria extract contains 26% of lanostane compounds.
Example 7
This example is an animal test by using the agents shown in Table 1 for treating cachexia caused by a cancer. The mice having human lung cancer cell transplantation were used to clarify whether or not the Poria extract has a therapeutic effect on cachexia. The change of body weight, food intake and serum albumin level of mice having human lung cancer cell transplantation and normal mice were observed to evaluate the drug efficacy of treatment on cancer cachexia.
Experiment Animals
CB-17 SCID mice (6-8 weeks) were obtained from Laboratory Animal Center of the National Taiwan University (Taipei, Taiwan). Animals were kept in stainless steel cage under room temperature of 25±2° C., humidity of 40-70%, 12 hrs alternations of light and dark, without water restriction. Animals were given an adaptive phase in animal house after purchased, and animals body weight were weighed randomly. Animals with similar body weight were classified into the same group by random number, and it was confirmed that there was no significant difference of body weight between groups by statistic analysis. Cultivation of human lung cancer strain H460
H460 strain was removed from a liquid nitrogen container and thawed at 37° C. water bath. 8 mL of DMEM medium supplied with 10% FBS was taken and subjected to centrifugation at 1200 rpm for 10 mins. The supernatant was collected, to which cells were added. The cells were cultivated in a culture oven with 5% CO 2 at 37° C. until reaching the required cell amount.
Orthotopic Transplantation of Lung Cancer Strain H460 into Mice
Mice were deep anaesthetized by using pentobarbital, and No. 29 gauge 0.5 mL insulin needle was used to transplant 0.1 mL of H460 cell strain (1×10 6 /ml) into thoracic cavity of mice. Mice were housed in the original cages after cells transplantation to allow recovery.
Drug Preparation
Poria extract prepared in Example 2 was weighed 67.7 mg, sterilized water was added to 10 mL, and then ultrasonic treatment was performed to make the extract suspended in water, which was named PC-A agent. PC-B agent was obtained by taking 5 mL PC-A agent to adding sterilized water to 10 mL; and PC-C agent was obtained by taking 5 mL PC-B agent and adding sterilized water to 10 mL. The mice were administered according to their body weight, 0.25 cc agent/25 gm of body weigh, through tube feeding until dose shown in Table 1 was done. The test was performed twice. Mice in the Blank Group were fed with distilled water (cultivation PBS was used instead of H460 was injected into the thoracic cavity of mice). Distilled water was used to feed lung cancer mice in the Control Group. Feeding method was performed by using Injection syringe (1 cc) connected to No. 18 (5 cm length) steel tube. When tube feeding was performed, using left hand to open mice oral cavity, the tube feeding steel tube was carefully set into stomach, then an agent or distilled water was given through the tube, volume for each administration was limited to 0.3 cc.
In the first test, there were total five Groups (one Blank Group, one Control Group and three Administration Groups), 9 mice per group. Agent PC-A, PC-B and PC-C prepared by using the Poria extract from Example 2 were administered into the lung cancer mice of three Administration Groups, mice in each group were administered lanostane 17.6 mg, 8.8 mg and 4.4 mg per kg body weight, as shown in Table 1.
In the second test, there were total three Groups (one Blank Group, one Control Group and one Administration Group), 3 mice per group. Agent PC-D prepared by using the Poria extract from Example 3 was administered to the lung cancer mice of the Administration Group, wherein each mice was administered lanostane 8.8 mg per kg body weight, as shown in Table 1.
Collection of Serum Albumin Sample
Whole blood was taken from canthus at the 22 nd day, and the whole blood was kept at room temperature for one hour. After centrifugation at 3,000 rpm twice, the serum was collected and stored at −20° C. until the content analysis of serum albumin was carried out later.
Concentration Determination of Serum Albumin
Mouse albumin ELISA kit (Bethyl Laboratories Inc., Texas, US) was used to perform the analysis. Anti-mouse albumin was diluted 10× with TBS, and used to coat micro titer plate with 100 μl/well. The plate was incubated at room temperature for 1 hour, then washed with TBST three time followed by 1% BSA 200 μl/well for blocking. After incubation at room temperature for 1 hour, the plate was washed with TBST three times. Samples or standards were added, the plate was incubated at room temperature for 1 hour, followed by washing with TBST 5 times. 100 μl/well of goat anti-mouse albumin-HRP conjugate dilution (diluted 10,000× with TBS containing 1% BSA and 0.05% Tween 20) was added and incubated at room temperature for 1 hour. After washing with TBST for 5 times, 100 μl of substrate TMB (3,3′,5,5′-tetramethyl benzidine) was added and reacted at dark and at room temperature for 15 minutes. 100 μl/well of 2N HCl was added to quench the reaction. The absorption at A 450 nm was determined.
Statistic Method
The data was represented as Mean±SD. First, one-way ANOVA was used to test the variation between the groups. If p<0.05, Dennett's multiple range t-test was used to test the significance of difference between the groups, wherein each group was compared to the Control Group.
Changes of Body Weight and Food Intake
The changes of food intake and body weight were observed for mice in each group in the first test and the second test.
Results
Changes of Body Weight of Mice
In the first test, changes of body weight of lung cancer mice during tube feeding of Poria extract is shown as FIG. 1 . Body weight of mice in the Control Group significantly decreases after the transplantation of H460 lung cancer cells. Compared to lung cancer cells transplanted mice, further administration of low dose Poria extract PC-C (4.4 mg/kg) and PC-B (8.8 mg/kg) do not make any difference among them. That is no improvement for cachexia syndrome. In the high dose Group (17.6 mg/kg of PC-A), it is observed that a significant slow down of body weight loss. Accordingly, the Poria extract improves the body weight loss caused by transplantation of H460 lung cancer. In the second test, changes of body weight of lung cancer mice using the different Poria extract, extract PC-D (8.8 mg/kg), is shown in FIG. 2 . As shown in FIG. 1 , body weight significantly decreases in the Control Group after the transplantation of H460 lung cancer cells. Only a little increase of body weight is observed in the normal mice (Blank Group without transplantation of H460 cells). It is found that mice in the Administration Group (PC-D Group) keep their body weight unchanged as at the beginning of test. Accordingly, it is proved that the Poria extract can be used to treat cachexia.
Changes of Food Intake of Mice with Cancer
The changes of food intake of lung cancer mice after tube feeding of the Poria extract are shown in FIG. 3 . Food intake of the mice in the Control Group gradually decreases after the transplantation of H460 lung cancer cells. Contrarily, mice in the Poria extract administration Group (PC-D Group) after the transplantation of lung cancer cells show no gradually decrease of food intake, similar to the normal mice in the Blank Group (without the transplantation of H460 lung cancer cells). There is no food intake difference between these two groups. Accordingly, the Poria extract improve or treat the impaired food intake caused by cachexia.
Changes of Serum Albumin Content of Lung Cancer Mice
The changes of serum albumin content of mice in each group in the first test and the second test are shown in FIG. 4 and FIG. 5 . Compared to the Blank Group (without H460 transplantation), mice in the Control Group with transplantation of H460 lung cancer cells have a decreasing tendency of serum albumin content. In the Poria extract Administration Groups (PC-A, PC-B, PC-C), the serum albumin content increases as the lanostane dose increase, and a significant increase is observed in the PC-A Group with a lanostane dose of 17.6 mg/kg. Also, a significant result is observed in the Poria extract Administration Group PC-D (8.8 mg/kg dose).
Animal body produces an inflammatory reaction to lung cancer cells, and this reaction changes production of hepatocyte protein, wherein some proteins decrease in production and some proteins (or induction of proteins) increase in production. Thus, one way to evaluate cachexia is to monitor serum albumin in addition to changes of body weight and food intake. The decrease of serum albumin means an influence of lung cancer cells on the albumin production in hepatocytes, and as a result the release of albumin to blood decreases. As shown in FIGS. 4 and 5 , albumin content in blood decreases in mice with cachexia, but not in mice with cachexia and with the administration of the Poria extract. That is the Poria extract has a function of treating cachexia.
Example 8
Clinical study in human of Poria extract in treating cachexia caused by cancer:
(1) Observation of improvement of overall nutritional status in patients.
(2) Observation of improvement of body weight in patient.
(A) Grouping of cancer patients and drug administration.
15 cancer patients with continuing body weight loss, 3 for stomach cancers, 3 for pancreas cancers, 3 for colorectal cancers, 4 for breast cancers, 1 for oral cavity cancer, and 1 for nasopharyngeal cancer, were divided in to 3 groups randomly, 5 for each group. Group I was administered with low dose Poria extract (Extract prepared in Example 3, 16.8 mg/capsule), one capsule per day. Group II was administered with a higher dose of Poria extract, two capsules per day. Group III was not administered with Poria extract and received chemotherapy drug as control group.
(B) Treatment Segment
Those 15 patients received chemotherapy for 6 weeks, patients in Group I and II were administered Poria extract for 4 weeks (for week 5 th and 6 th chemotherapy only), and the body weight and nutrition evaluation were recorded weekly.
(C) Results (1):
An improvement of body weight was observed, a comparison of body weight was made between therapy completion (week 6 or day 42 nd ) and day 1 st after treatment, the results are listed as following:
BODY
BODY
WEIGHT
BODY
TREATING METHOD
WEIGHT
UN-
WEIGHT
GROUP
(CHEMOTHERAPY)
GAIN
CHANGE
LOSS
GROUP I
Add 16.8 mg of Poria
3
1
1
extract
GROUP II
Add 33.6 mg of Poria
3
1
1
extract
GROUP
1
0
4
III
From the results, it is understood that maintenance or improvement of body weight in the chemotherapy/ Poria extract Groups were superior than in Group III (only chemotherapy without Poria extract). A body weight loss was observed in Group III, i.e. the boy weight lower than the 1 st day after treatment.
(D) Results (2): Improvement of Overall Nutritional Status in Patients
The evaluation of overall nutritional status of patients was made according to PG-SGA (Patient-Generated Subjective Global Assessment) used by the clinician. Patients of Groups I to III were evaluated by gaining the total scores of (1) body weight improvement, (2) food intake improvement, (3) syndrome alleviation and (4) physical activity improvement, as shown in FIGS. 6 , 7 , and 8 . FIG. 6 is the results observed in Group I (chemotherapy+one capsule of Poria extract), FIG. 7 is the results observed in Group II (chemotherapy+two capsules of Poria extract), and FIG. 8 are results observed in Group III (control group, chemotherapy). The lower score of PG-SGA, the more improvement in patients, overall tendency directs forward to healthy.
From these treating results, the improvement for cachexia patients in health/living quality observed in the groups administered with Poria extract combined with chemotherapeutic drug is significantly better that observed in the chemotherapy Group, and there is a significant meaning in statistic analysis.
According to the results of this Example, it is found that a combination of Poria extract and chemotherapy drug can inhibit body weight loss of cancer patients, while the improvement in the overall nutritional status of the patients is significantly superior to the patients only receive chemotherapy.
The present invention has been described with preferred examples thereof and it is understood that many changes and modifications to the described examples can be carried out without departing from the scope and the spirit of the invention that is intended to be limited only by the appended claims.
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A pharmaceutical composition for treating cachexia, and in particular for treating cancer cachexia. The composition contains a lanostane compound as a potent component. A suitable source of the lanostane compound is a Poria extract from metabolite, sclerotium, or fermentation product of Poria cocos (Schw) Wolf. The Poria extract contains 1-60% of the lanostane compounds by weight of the extract, and is devoid of secolanostane.
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BACKGROUND OF THE INVENTION
This invention relates to the stabilization of fibers of polypropylene or predominantly propylene-containing copolymers (together referred to hereafter as "PP fibers" for brevity) colored with a specific pigment namely Red 144 (common name). It is known that several stabilizers, particularly hindered amine light stabilizers ("HALS"), provide excellent stabilization of the PP fibers, but not to the red coloration of Red 144-pigmented PP fibers. These pigmented PP fibers lose their pigmentation, due to chemical degradation of the pigment, long before the fibers themselves are degraded past the point where they serve their intended use. The problem is exacerbated because increasing the concentration of Red 144 pigment in the fibers accelerates their degradation.
Red 144 (referred to as such for brevity and convenience) is an azo condensation pigment, more correctly identified as [2-napahthalenecarboxamide, N,N'-(2-chloro-p-phenylene)bis[4-[2,5-dichlorophenyl)azo]-3-hydroxy (reg. no. 5280-78-4), available as the commercial product Cromophtal Red BRN, from Ciba-Geigy, and Red BR PR144/45415 from Ampacet.
Commercially available PP fibers today have good resilience and heat stability, and have successfully been stabilized against ultraviolet (uv) light degradation with a wide spectrum of HALS. But such stabilized PP fibers have poor dyeability because PP is essentially unreactive with most dyes. This poor dyeability of PP dictates that PP fibers must be pigmented for long-term stability of PP fibers colored with many popular colors. With particular respect to red PP fibers which are in high demand, an effective red pigment now in use is Red 144. The problem is that the use of Red 144, both hastens the degradation of the PP fibers when exposed to sunlight, and degrades their physical properties over time, so that combined, the fibers are subjected to a two-pronged attack on their longevity in normal use, thus vitiating their marketability.
Fabrics made from Red 144 pigmented PP fibers are especially popular in automobiles, boats, outdoor clothing, and other such uses where the fibers degrade at such an unacceptably high rate upon exposure to sunlight, that they are soon transformed into nonuniformly colored articles sporting a wide spectrum of shades of pink and orange. The obvious way to cope with this color degradation problem is to use far more pigment than is required to provide the desired color, so that upon suffering the expected color degradation, the coloration of the remaining non-degraded pigment will maintain acceptable, if not the original, color. Except that `loading up` the HALS-stabilized fibers with more Red 144 pigment to maintain tinctorial strength, simply accelerates degradation of the PP fibers because Red 144 has a high proclivity towards reaction with commonly used HALS, and other additives such as antioxidants and antiozonants, used to provide melt-stability to the PP.
Typically, several additives are combined in PP before it is melt extruded into fiber, each additive specifically designed to provide a different zone of stabilization, the main zones being (a) melt extrusion stability, (b) long term thermal stability during conditions expected to be encountered during use, (c) uv light stability in bright, direct sunlight, and by no means of least importance, (d) stable tinctorial strength to maintain the desired color. Combining several additives known to be effective for each specific purpose, in PP fibers particularly, is likely not to produce the desired results because of objectionable side effects due to interaction between the additives.
For example, thiodipropionate compounds such as dilauryl (DLTDP) and distearyl (DSTDP) help control melt-stability despite an odor problem, and certain phosphites control melt flow while depressing the tendency of PP fibers to yellow because the fibers usually contain a hindered phenol antioxidant. The hindered phenol antioxidant increases long term stability but accelerates yellowing. It is known that a hindered phenol antioxidant and a thiodipropionate are most effective when used together. Certain HALS provide not only excellent uv stability but also such good long term thermal stability that the PP fibers will outlast some of the pigments used to color them. Therefore a HALS is combined with a hindered phenol antioxidant and a phosphite.
Pigments are selected with an eye to their effect on the processing of the PP fibers, the stability requirements of the end product, the pigment's interaction with the other additives to be used, the color requirements, and the cost of producing the pigmented PP fibers. The intense thrust towards using inexpensive PP fibers in the automobile industry where the color red is in high demand decreed that, despite its high cost, Red 144 be used, because of its intense tinctorial strength and color stability; and, that Red 144 be combined with a compatible uv stabilizer. It was found that the most damaging factor in the stability of Red 144-pigmented PP fibers was their interaction with the hindered amine uv stabilizers used.
The commercial use of red PP fibers requires that the color stability of the PP fiber be such that it equals the useful life of a fabric or other article containing the fiber, which article is exposed to heat and light. Because the stabilizers used generally affect color, though they are not regarded as colorants, and pigments may affect thermal and uv light stability even if they are not known to have such activity, one cannot estimate what the net effect of the interactions might be. (see "Influence of Pigments on the Light Stability of Polymers: A Critical Review" by Peter P. Klemchuk, Polymer Photochemistry 3 pg 1-27, 1983).
We continued our tests with numerous combinations of stabilizers in Red 144-pigmented fibers, screening the samples to determine whether an unacceptable level of color loss was obtained before the fibers disintegrated. We measured the degree of degradation of the pigmented fibers both by visual observation, and by "scratch testing" (described herebelow) the surfaces of exposed fibers.
Fiber degradation is a phenomenon which is easily visible to the naked eye upon inspection of a degrading pigmented yarn exposed either in a Weather-O-Meter in presence of moisture, or, to bright sun (tests are conducted in the Florida sun) under ambient conditions of humidity. Unstabilized Red 114-pigmented PP fibers exposed to the Florida sun show no fading because the pigmented fibers degrade far more rapidly than the pigment, which results in continual sloughing off of layers of fiber exposing bright undegraded pigment. Degradation of stabilized PP fibers is characterized (i) by a fuzzy, peach-skin-like appearance of the surface of the fabric (made with the pigmented fibers), and (ii) the problem of fading color.
Of particular interest is the peculiar uv-stabilization effect of N-(substituted) α-(3,5-dialkyl-4-hydroxy-phenyl)-α,α-disubstituted acetamides in which one of the substituents on the N atom is a 2-piperazinone group. More correctly, the compounds are "N-(substituted)-1-(piperazin-2-one alkyl)- c -(3,5-dialkyl-4-hydroxyphenyl)-α,α-substituted acetamides", which are hereinafter referred to as "3,5-DHPZNA" for brevity. This 3,5-DHPZNA stabilizer is disclosed in U.S. Pat. No. 4,780,495 to John T. Lai, for its uv-light stabilization in PP, and, because of the presence of a polysubstituted piperazinone (PSP) group in the molecule, was routinely tested in PP plaques for such stabilization-effectiveness as 3,5-DHPZNA might have. Since the majority of PP articles are extruded or molded shapes other than fibers, most testing for stabilization is conventionally done with plaques, not fibers, because plaques are more conveniently prepared. The plaques deteriorated rapidly. Only by chance was 3,5-DHPZNA also tested in Red 144-pigmented PP fibers, and its remarkable effectiveness noted.
As one would expect, some pigments enhance heat and light stability of PP fibers stabilized with a particular antioxidant and hindered amine stabilizer. Other pigments have the opposite effect. Until tested, one cannot predict with reasonable certainty, what the effect will be. For example, with a nickel-containing stabilizer, Red 101 (iron oxide) is a prodegradant. With the more effective hindered amine stabilizers, both Yellow 93 and Red 144 are prodegradants. The effect of these pigments in stabilized PP fibers could not have ben predicted by their behavior in unstabilized pigmented fibers, or by their behavior with a different stabilizer. With a nickel-containing stabilizer, Red 144 (unlike Red 101) is a stabilizer (not a prodegradant), but Red 144 is a prodegradant with Tinuvin 770. Yellow 93, a stabilizer when no other stabilizer is present, is neutral with nickel stabilization but is a prodegradant with Tinuvin 770 (see "Stabilization of Polypropylene Fibers" by Marvin Wishman of Phillips Fibers Corporation). Specifically with respect to red PP fibers, the problem was to find a combination of stabilizers which circumvented the proclivity of Red 144 to degrade the PP fibers when the pigment is combined with a conventional AO and uv light stabilizer. Because Red 144 was a prodegradant it seemed desirable to use only as much of it as would provide the desired tinctorial effect for the required period of time, namely the useful life of the stabilized PP fiber.
The effect of a large number of pigments on the stability of PP fibers stabilized with Tinuvin 770 has been reported by Steinlin and Saar (see "Influence of Pigments on the Degradation of Polypropylene Fibers on Exposure to Light and Weather", paper presented at the 19th International Manmade Fiber Conference, September 1980 in Austria).
In the same vein, like other workers before us, we tested a large number of combinations with Red 144, and tested them in fibers. We confirmed that Tinuvin 144 in combination with Red 144, stabilizes fiber but does not stabilize the red color, acting more like a prodegradant for color stability. Tinuvin 144 is a HALS molecule of comparable size to that of 3,5-DHPZNA, and like 3,5-DHPZNA is a hybrid molecule. Tinuvin 144 combines a hindered phenol with a substituted piperidyl rather than with a substituted piperazinone. But this combination of hindered phenol and piperidyl groups in one molecule is not as effective with Red 144 as the combination of hindered phenol and piperazinone. Chimassorb 944 provides excellent stabilization to Red 144-pigmented PP fibers, but Chimassorb 944, like Tinuvin 144, provide excellent uv stabilization only of the PP, not the color, which degrades rapidly. With Tinuvin 770, there is greater negative interaction than with Tinuvin 144 as evidenced by decreased stability of the PP.
Generally, if a stabilizer is effective in fibers it is effective in plaques, but the opposite is not true. Red 144-pigmented PP fibers are stabilized with 3,5-DHPZNA against heat and light and it is reasonable to expect a comparable effect in Red 144-pigmented PP plaques. Moreover, 3,5-DHPZNA-stabilized PP fibers pigmented with Red 144 do not require the added presence of a conventional hindered phenol antioxidant, though a small amount up to about 0.1 phr, may be used to provide a high level of melt-stability when the Red 144-pigmented PP is extruded from a spinneret.
U.S. Pat. No. 4,797,438 to Kletecka et al discloses that hindered amines with a specific structure known to exhibit excellent uv stabilization in numerous host polymers without notably distinguishing one polymer from another as far as their relative susceptibility to uv stabilization is concerned, are surprisingly effective to stabilize PP against degradation by gamma-radiation. Moreover, such stabilization extends to articles of arbitrary shape, including fibers, and these amines are more effective when used without an AO, phosphite or thioester. It was not known, however, nor could we reasonably predict, what the interaction of the 3,5-DHPZNA stabilizer in particular, would be with Red 144 pigment.
The peculiarly distinguishing structural feature of the stabilizers in the '438 Kletecka et al composition, is that they, like 3,5-DHPZNA, contain as an essential portion of their basic structure, a PSP having an N 1 -adjacent carbonyl in the PSP group, and at least the C 3 (carbon atom in the 3-position in the ring) has two substituents (hence "polysubstituted or substituted"), which may be cyclizable, that is, form a cyclic substituent. But unlike 3,5-DHPZNA, those stabilizers do not contain a hindered phenol group in the same molecule.
Though 3,5-DHPZNA compounds referred to in the aforementioned '495 Lai patent were known to be excellent UV stabilizers in colorless organic materials when used in combination with antioxidants, there was nothing to suggest that its incorporation in PP fibers, alone among other polymers tested, in the presence of less than 0.1 phr of each of a conventional hindered phenol antioxidant and phosphite which provide melt-stabilization, would provide effective stabilization against discoloration of Red 144 pigment.
SUMMARY OF THE INVENTION
It has been discovered that N-(substituted)-1-(piperazin-2-one alkyl)-α-(3,5-dialkyl-4-hydroxyphenyl)-α,α -disubstituted acetamide, namely 3,5-DHPZNA, having a N-(substituted)-1-(piperazine-2-one alkyl) group at one end and a (3,5-dialkyl-4-hydroxyphenyl)-α,α-disubstituted acetamide at the other, provides a hybrid stabilizer for Red 144-pigmented PP fiber. The 3,5-DHPZNA combines a hindered amine with a hindered phenol through a disubstituted alpha carbon atom of the acetamide in a single molecule. When this hybrid is incorporated into PP fibers pigmented with Red 144 pigment, the hybrid affords the advantages of each group and minimizes the discoloration typically generated by interaction of two or more stabilizers each containing one of the groups of the hybrid; further, woven or non-woven articles made from Red 144pigmented PP fibers stabilized with such a hybrid, have improved strength and discoloration resistance, compared to that of articles made from identically pigmented PP fibers stabilized with several other commercially available hindered amines tested by exposing the articles similarly exposed to infrared, visible and actinic radiation.
It has also been discovered that 3,5-DHPZNA in Red 144-pigmented PP fibers, stabilizes the discoloration attributable to degradation of the pigment in the PP fibers, when the fibers are exposed to bright sunlight for 6 months at 45° South (exposure) in the Florida sun, if the 3,5-DHPZNA is used in an amount in the range from about 0.1 phr to 5 phr, and the Red 144 pigment is used in as small an amount as in the range from about 0.1 phr to about 1 phr in PP fibers.
It is therefore a general object of this invention to provide Red 144-pigmented PP fibers which have been stabilized against exposure to sunlight, with an effective amount of the 3,5-DHPZNA stabilizer sufficient to stabilize the fibers so that, after exposure to bright sunlight for 6 months at 45° South, they exhibit essentially no fading of the red pigment and essentially no polymer degradation.
It is also a general object of this invention to provide a method for imparting improved strength and discoloration resistance to stabilized, Red 144-pigmented PP fibers, which method comprises incorporating into PP fibers only as much of a conventional hindered phenol or phosphite antioxidant, no more than 0.1 phr, as is desired for melt-stabilization of the fiber, and, an effective amount of the 3,5-DHPZNA in combination with Red 144 pigment, said amount being sufficient to decelerate discoloration of the red PP fibers, as evidenced by color fading during the useful life of an article made with the red fibers.
It is a specific object of this invention to provide a method for stabilizing articles made from Red 144-pigmented woven and non-woven PP fibers, which method comprises, exposing said Red 144-pigmented PP fibers to bright sunlight for 6 months at 45° South, without fading of the pigment; said PP fibers being essentially free of both a phosphite and a hindered phenol antioxidant, but the fibers having incorporated therein (i) from 20 parts per million (ppm) to about 1 phr, preferably from 0.1 to 0.8 phr, of Red 144; and (ii) from 20 parts per million (ppm) to about 2.0%, preferably from 0.1% to 0.5%, of 3,5-DHPZNA, based upon the weight of the PP in the fibers.
It is another general object of this invention to provide woven, non-woven and other fabricated articles, made from Red 144-pigmented PP fibers and subjected to bright sunlight for the useful life of the articles, with improved strength and discoloration resistance, provided the PP fibers have incorporated therein a 3,5-DHPZNA stabilizer, in an effective amount, sufficient to decelerate oxidative degradation of the PP fibers.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and other objects and advantages of my invention will appear more fully from the following description, made in connection with the accompanying graphs which illustrate the result-effectiveness of the combination of 3,5-DHPZNA and Red 144 pigment in PP fibers essentially free of a secondary stabilizer, that is, having no more than 0.1 phr of each melt-stabilizing antioxidant such as a conventional hindered phenol and phosphite.
FIG. 1 presents data on the fading of a fabric made of Red 144-pigmented PP fibers, in four curves, one for each of four stabilizers. The curves show the fading of the fabric as change in color (delta E) plotted as a function of time in a Weather-O-Meter.
FIG. 2 presents five curves, one of which is for X-146 with no secondary stabilizer. The curves present data for the fading of a fabric made of Red 144-pigmented PP fibers containing HALS with no more than 0.1 phr of a melt stabilizing antioxidant. The curves show fading upon exposure to direct Florida sun.
FIG. 3 presents four curves, one for each of four HALS. The curves present data for the fading of a fabric made of Red 144-pigmented PP fibers containing HALS with no more than 0.1 phr each of a melt stabilizing antioxidant, and a phosphite stabilizer, but under glass in the Florida sun.
FIG. 4 presents three curves representing the color change (delta E) plotted as a function of time for Red 144-pigmented PP fibers containing different stabilizers.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
In a particular embodiment, this invention provides an article made from a woven or non-woven fabric of Red 144-pigmented PP fibers. Woven fabrics are produced from yarn by any one of several weaving techniques. Non-woven fabrics of PP may have a carded fiber structure or comprise a mat in which the fibers or filaments are distributed in a random array. The fibers may be bonded with a bonding agent such as a polymer, or the fibers may be thermally bonded without a bonding agent. The fabric may be formed by any one of numerous known processes including hydroentanglement or spun-lace techniques, or by air laying or melt-blowing filaments, batt drawing, stitchbonding, etc. depending upon the end use of the article to be made from the fabric.
Incorporated in the PP, and preferably uniformly distributed in the PP melt before it is spun into filaments, is (i) a small amount, less than 2 phr of Red 144 pigment, preferably less than 1 phr, and typically from 0.05 phr to about 0.75 phr; (ii) no more than 0.1 phr each of a hindered phenol AO and a phosphite, required for melt-stabilization of the PP; and (iii) from about 20 ppm to about 2.0% by weight (based on the weight of all the polymer from which the article is formed), and more preferably from about 0.1 phr to about 1.0 phr, of a N-(substituted)-1-(piperazin-2-one alkyl)-α-(3,5-dialkyl-4-hydroxyphenyl)-α,α-substituted acetamide (3,5-DHPZNA). Details for preparation of numerous substituted acetamides having the 3,5-DHPZNA moiety are disclosed in the aforementioned '495 Lai patent, the disclosure of which is incorporated by reference thereto as if fully set forth herein.
As will presently be evident from data graphically presented in FIG. 4 which will be referred to herebelow, it is not sufficient to have a hindered phenol group in the molecule of an effective Red-144 color stabilizer, nor a substituted piperazinone or piperidyl group, nor an alpha carbon atom which is disubstituted; nor any combination of two of the foregoing groups. It is essential that a combination of each of three groups, namely the hindered phenol, the substituted pipearazinone, and the disubstituted alpha carbon atom, all be present in a single molecule, to provide the color stabilization for Red 144 pigment, and also the stabilization of the PP fibers against degradation; and, they are so present in the 3,5-DHPZNA molecule.
The 3,5-DHPZNA structure is found in a stabilizer which combines the foregoing groups in the same molecule, and acid addition salts of 3,5-DHPZNA which is represented by the structure: ##STR1## wherein, R 1 , R 2 and R 5 each represent hydrogen, C 1 -C 12 alkyl, phenyl, naphthyl, C 4 -C 12 cycloalkyl, and, alkylsubstituted cycloalkyl, phenyl and naphthyl, each alkyl substituent being C 1 -C 8 , and at least one of R 1 and R 2 is t-C 4 -C 12 alkyl;
R 3 and R 4 independently represent C 1 -C 18 alkyl, and C 5 -C 12 cycloalkyl, phenyl and naphthyl, and, alkyl-substituted cycloalkyl, phenyl and naphthyl, each alkyl substituent being C 1 -C 8 , and, when together cyclized, R 3 with R 4 may represent C 4 -C 12 cycloalkyl, and C 1 --C 8 alkyl-substituted cycloalkyl;
R 6 , R 7 , R 8 and R 9 each represent C 1 -C 12 alkyl, or, when together cyclized, R 6 with R 7 , and R 8 with R 9 , may represent C 4 -C 12 cycloalkyl, and C 1 -C 8 alkyl-substituted cycloalkyl;
R 10 is selected from the group consisting of hydrogen, C 1 -C 8 alkyl and ##STR2## wherein R 13 represents hydrogen, C 1 -C 18 alkyl or alkenyl, phenyl or naphthyl;
R 11 and R 12 independently represent hydrogen and C 1 -C 18 alkyl; and,
n is an integer in the range from 1 to about 8.
Specific examples of such 3,5-DHPZNA stabilizers are identified by the following code numbers and structures in which CH 2 groups at the intersection of lines are not otherwise identified, and projecting lines represent CH 3 groups.
The substituents on the alpha-C atom of the acetamide are critical in the above-identified stabilizer compound.
It will be appreciated that when R 10 is to be acyl, it is introduced by an acylation step after formation of the 3,5-DHPZNA in which there is no substituent on the N 4 atom of the diazacycloalkane ring.
The process for preparing the foregoing 3,5-DHPZNA compounds comprises reacting a 2,6-dialkylphenol with at least equimolar quantities of an aliphatic, cycloaliphatic or alkaryl ketone and a 4-amino-polysubstituted piperazine or 4-amino-polysubstituted piperazin-2-one in the presence of an alkali metal hydroxide, preferably at a temperature in the range from about -10° C. to about 50° C.
The 2,6-dialkylphenol reactant is represented by the structure ##STR3## wherein R 1 and R 2 have the same connotations set forth hereinabove.
The 4-amino-polysubstituted piperazin-2-ones are N-substituted cyclic alkyleneimines represented by the structure ##STR4## wherein R 5 , R 6 , R 7 , R 8 , R 9 and R 10 have the same connotation as that given hereinbefore. Two or more of the 4-amino-polysubstituted piperazinone moieties may be present on a single molecule, for example, when the moiety is a substituent in each of the two primary amine groups of an alkane diamine; or, of a triamine or tetramine.
The 3,5-DHPZNA is then produced by the ketoform reaction. As before, at least a stoichiometric amount of the 4-amino-polysubstituted piperazine is used, relative to the amount of 2,6-dialkylphenol, an excess of amine being preferred for good yields. Most preferred is up to a fourfold excess.
The ketone reactant may be a dialkylketone, a cycloalkanone, or alkylcycloalkanone, represented by the structure ##STR5## wherein, R 3 and R 4 are independently selected from C 1 -C 8 alkyl.
The 3,5-DHPZNA product is readily isolated from the reaction mass by filtration, and washing the filtrate with aqueous inorganic acid, typically HC1 or H 2 SO 4 . The filtrate is dried with a dessicant such as sodium sulfate, then heated to dryness. The product obtained may be recrystallized from a solvent if greater purity is desired. Additional details relating to the procedures for preparing and recovering the compounds are found in the aforementioned '495 Lai patent. ##STR6##
The propylene polymer is typically polypropylene homopolymer, but may be a random or block copolymer of propylene and a monoolenfinically unsaturated monomer X, (P-co-X) with up to about 30% by wt of X wherein X represents vinyl acetate, or a lower C 1 -C 4 alkyl acrylate or methacrylate. Blends of such propylene polymers with other polymers such as polyethylene are also included within the scope of this invention. For convenience, homopolymer PP and copolymer P-co-X are together referred to herein as "propylene polymer" PP. The PP has a number average mol wt Mn in the range from about 10,000 to about 500,000, preferably about 30,000 to about 300,000 with a melt flow index from 0.1 to 30 g/10 min when measured according to ASTM D-1238.
To avoid the interaction of known antioxidants (AOs) with Red 144 pigment and/or the 3,5-DHPZNA, our stabilized PP fibers are preferably produced from a propylene polymer melt which has no more than 0.1 phr each of a hindered phenol AO, and a phosphite, as secondary, specifically melt stabilizers.
Solely for the purpose of facilitating the melt extrusion of the propylene polymer, a metal stearate such as calcium or zinc stearate in an amount insufficient to deleteriously affect the color of the fibers, preferably in the range from about 100 ppm to about 1500 ppm, and less than about 0.1 phr of a secondary stabilizer may be blended into the PP.
Since a predominant concern is the desired red color, only enough Red 144 pigment is added to the normally water white propylene polymer to produce the color, but no more than 2 phr.
The Red 144 pigment and 3,5-DHPZNA stabilizer may readily be incorporated into the PP by any conventional technique at a convenient stage prior to the melt extrusion of the PP fibers. For example, the pigment and stabilizer may be mixed with the PP in dry powder form, or a suspension or emulsion of the stabilizer may be mixed with a solution, suspension, or emulsion of the polymer.
The preferred Red 144-pigmented, 3,5-DHPZNA-stabilized, PP has so small an amount of antioxidant added to it, no more than 0.1 phr of an AO, that it does not make a sufficiently noticeable adverse contribution towards negative interaction upon exposure to sunlight, and is tolerable. Such a small amount of AO may be present in commercially available AO-free PP fibers, added thereto for process stability to facilitate its manufacture. Additives other than an AO, may be added if it is known they do not adversely affect the desired color, or help degrade the physical properties of the PP fibers when exposed to sunlight. Such additives may include lubricants in addition to alkaline earth metal stearates, near-colorless or white fillers such as glass fibers or talc, and optical brighteners.
Articles made of Red 144-pigmented, stabilized PP fibers, once placed in service, are likely to be used for several years but are not likely to be exposed continuously to 12 months of bright sunshine at 45° South (exposure). When noticeable fading of the pigment does eventually occur, the article has provided so large a proportion of its useful life that its color degradation is not objectionable.
In the comparative tests made and recorded in the following FIGS. 1-3, color change is measured according to the Standard Method for Calculation of Color Differences from Instrumentally Measured Color Coordinates, ASTM D 2244-85. The change in color measured in this manner does not reflect the peach-skin appearance due to broken fibers of degraded yarn. The useful life of the fabric is terminated when its surface becomes fuzzy as a peaches'. Visual inspection under an optical microscope shows that individual fibers in the matrix of the yarn are broken.
Polymer degradation is measured qualitatively by placing a sample of fabric under a low power optical microscope and scraping the surface of the yarn with a blunt spatula. When fibers are readily broken while the yarn is being scraped, the fabric has been degraded even if the color change is acceptably low.
FIG. 1 presents four curves, one for each of four stabilizers, in which curves the change in color (delta E) is plotted as a function of time in a Xenon Weather-O-Meter, for Red 144-pigmented PP fibers containing 0.75 phr of Red 144, and 0.4 phr of a HALS in each sample. The Weather-O-Meter tests are conducted as described in ASTM G-77, Method A, using 2 hr exposure cycles in which the fabric samples are exposed to light for 102 min, followed by 18 min of light with a water spray. The black panel temperature is 63° C.
In FIG. 1, the color change is plotted as a function of time to record the fading of Red 144-pigmented fabric during the accelerated aging for samples containing each of the four stabilizers compared. The curve identified by reference numeral 1 is for fiber stabilized with 0.4 phr Cyasorb UV 3346; curve 2, for Chimassorb 944; curve 3, for Tinuvin 144; curve 4 for Goodrite®X-146. Tinuvin 144 contains one or more hindered piperidinyl groups, and, in Chimassorb 944 and Cyassorb UV-3346 the piperidinyl groups are associated with triazine rings. It is evident that there is essentially no color change (ignoring the slight decrease shown as being attributable to a slight darkening) for the X-146 stabilized fabric, and that this is a unique result-effective property attributable to X-146.
The curve for each sample terminates at at the point in time when it was found that it had a peach fuzz appearance, or, scraping the fabric with the spatula destroyed the fabric. Tests for surface-shedding showed a high level of surface-shedding at the point where the fabric failed. There is essentially no fuzzy peach-skin appearance on the X-146 sample until 980 hrs.
FIG. 2 presents five curves, one of which is for X-146 with no secondary stabilizer. The other curves are for Red 144-pigmented PP fibers containing HALS with 0.1 phr of Goodrite® 3114 and 0.08 phr Ultranox 626 for process stabilization. The curve identified by reference numeral 5 is for fiber stabilized with 0.4 phr Cyasorb UV 3346; curve 6, for Chimassorb 944; curve 7, for Tinuvin 144; curve 8 for Goodrite X-146; curve 9 for Godrite X-146 with no secondary stabilizer. Each curve represents the color change (delta E) as a function of time (nine months) during which the fibers were exposed to the direct rays of the Florida sun, at an angle of 45° S. The same amount of secondary stabilizer is present in each fabric sample, in combination with various HALS, each HALS present in the amount 0.4 phr. The fifth curve presents data for PP fibers containing 0.4 phr of a 3,5-DHPZNA (X-146), with no hindered phenol or other secondary stabilizer.
Referring to FIG. 2, it is evident that after 3 months of exposure to direct sunlight, the color change with X-146 is about the same as that with Tinuvin 144, and Chimassorb 944, but the color change for X-146 does not increase during the following three months, while the color change increases for the other stabilizers. As in the set exposed under glass, the color change with each stabilizer is greatest during the subsequent three month period, but after 9 months the test was stopped because all the samples showed unacceptable degradation of the fibers, and, because a color difference of 20 points is very large, easily noticeable at a distance, and highly objectionable.
FIG. 3 is a graph in which the color change (delta E) is plotted as a function of time during which the fibers were exposed under a sheet of clear glass to the rays of the Florida sun, at an angle of 45° S. Exposure under glass simulates exposure of fabric within a typical automobile exposed to direct sunlight, with the automobiles's windows closed.
Referring to FIG. 3, the curve identified by reference numeral 10 is for fiber stabilized with 0.4 phr Cyasorb UV 3346; curve 11, for Chimassorb 944; curve 12, for Tinuvin 144; and curve 13 for Goodrite X-146. It is seen that after 3 months of exposure under glass the color change is greatest in X-146, though not substantially greater than the others, but the change actually decreases during the following three months, while the color change increases for the other stabilizers. For each stabilizer, the color change is greatest during the subsequent three month period, but after 9 months, the fabrics still do not show a large color change. However, at the end of a year, the fabrics were unacceptably degraded. At that time, it is seen that the color change of about 14 for Cyasorb UV-3346 is about twice that obtained with X-146, which is about 7; the curves 11 and 12 lie in between. A color change of 5 is easily noticeable to the naked eye when it is compared side-by-side with the original color of the fabric, and a color change greater than 5 is generally deemed objectionable.
FIG. 4 graphically presents data obtained in a Weather-O-Meter in the presence of a water spray, in a graph in which the color change (delta E) is plotted as a function of time for PP fibers containing stabilizers as follows: (i) curve 14, for PP fibers with a HALS (identified as Goodrite X-141) disclosed in U.S. Pat. No. 4,547,538; (ii) curve identified by reference numeral 15 is for PP fibers with a hindered phenol (commercially available as Goodrite X-144); and (iii) curve 16, for PP fibers with Goodrite X-146; each stabilizer present in the amount of 0.4 phr. ##STR7## Thus it is seen that a compound with the disubstituted alpha C atom (alpha to the triazine ring), and having the substituted piperazin-2-one (in X-141) is not as effective as X-146; nor is a compound having the disubstituted alpha C atom (alpha to the hydroxyphenyl ring) in the substituted acetamide (in X-144) which does not have a substituted piperazin-2-one group.
PROCEDURE
Woven fabrics of PP fiber containing 0.4 phr of Red 144 pigment and 0.75 phr of a stabilizer, were exposed to the conditions of heat and light for which conditions the comparative tests are to be made.
It was observed that, before exposure, all samples of fabric were uniformly bright red. Immediately after irradiation, there is a distinct change in color, and the change in color is in the same portion of the spectrum for each sample.
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Excellent stabilization to bright sunlight, is obtained in polypropylene (PP) fibers pigmented with Red 144, by combining the pigment with N-(substituted)-1-(piperazin-2-one alkyl)-α-(3,5-dialkyl-4-hydroxyphenyl)-α,α-substituted acetamide ("3,5-DHPZNA" for brevity). Stabilization of the red color is obtained for as long as the PP fibers themselves are stabilized by the 3,5-DHPZNA. 3,5-DHPZNA is a known hybrid stabilizer having a hindered amine N-(substituted)-1-(piperazin-2-one alkyl) group at one end, and a hindered phenol (3,5-dialkyl-4-hydroxyphenyl) group at the other. This particular hybrid, containing a piperazinone group, combined through a disubstituted alpha carbon atom of the acetamide in a single molecule, affords the advantages of each group with respect to its stabilization of the fiber against degradation, but without the expected adverse interaction of each group with Red 144 pigment. With 3,5-DHPZNA and Red 144 pigment, essentially no secondary stabilizer is necessary. Red PP fibers so stabilized, exhibit an acceptably low level of discoloration (color fading) due to degradation of the pigment, over the useful life of the PP fibers. When exposed to sunlight for 6 months in Florida at a 45° South exposure, the red PP fibers suffer essentially no loss of color due to degradation of the pigment. Retention of red color in articles exposed to sunlight over their useful life, is of great practical value in clothing and household goods made from woven or non-woven fabrics of Red 144-pigmented PP fibers.
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ORIGIN OF THE INVENTION
The invention described herein was made in the performance of work under a NASA contract and by an employee of the United States Government and is subject to the provisions of Section 305 of the National Aeronautics and Space Act of 1958, as amended, Public Law 85-568 (72 Stat. 435, 42 U.S.C. §2457), and may be manufactured and used by or for the Government for governmental purposes without the payment of any royalties thereon or therefore.
FIELD OF THE INVENTION
This invention relates generally to position sensors and more particularly to single coil absolute position sensors and inductive gap sensors.
BACKGROUND OF THE INVENTION
Single coil absolute position sensors that are used to sense the position of an object require an excitation signal that is of the form of a constant frequency sinusoidal wave. The output of the sensor is an amplitude modulated signal, modulated by the position of the object. The single coil absolute position sensor usually includes an excitation coil, and a sensor component. The sensor component is typically affixed to the object that is being sensed, whereas the excitation coil is not affixed to the object that is being sensed. Additionally, the excitation coil and the object being sensed are free to move relative to one another. In some aspects, the position of the excitation coil is fixed while the object being sensed and the affixed sensor component are free to move in a linear motion or in an angular motion. In other aspects, the position of the object being sensed and the affixed sensor component is fixed whereas the excitation coil is free to move in a linear motion or angular motion.
The function of the excitation coil is to transmit the excitation signal to the sensor component. The sensor component receives the excitation signal and uses this received excitation signal to output an amplitude modulated signal, modulated by the position of the object being sensed.
The amplitude modulated signal that is output by the single coil absolute position sensor may be demodulated to recover the position of the object being sensed. Conventional demodulator circuits may perform this demodulation of the amplitude modulated signal, but their performance is typically very sensitive to any variations in the amplitude of the excitation signal. Such variations in the amplitude of the excitation signal are quite common, and may result from degradation in the signal due to the air gap between the source of the excitation signal and the demodulator circuit.
Conventional demodulator circuits are usually composed of many individual components which each act on the excitation signal and the amplitude modulated signal. These extensive stages of electronics induce more noise and error in the demodulated signal. Additionally, conventional demodulator circuits yield a demodulated signal that contains ripples.
For the reasons stated above, and for other reasons stated below which will become apparent to those skilled in the art upon reading and understanding the present specification, there is a need in the art for a demodulator apparatus that is insensitive to variations in the amplitude of the excitation signal, does not induce significant noise in the demodulated signal due to extensive stages of processing of the signals, and do not include ripples in the demodulated output signal. There is also a need for improved methods of accurately sensing the position of an object.
BRIEF DESCRIPTION OF THE INVENTION
The above-mentioned shortcomings, disadvantages and problems are addressed herein, which will be understood by reading and studying the following specification.
Systems, methods and apparatus are provided through which an amplitude modulated signal, modulated by the position of an object being sensed, is demodulated such that the demodulation system, method and apparatus is insensitive to variations in the amplitude of an excitation signal, does not induce significant noise in the demodulated signal due to extensive stages of electronics to process the signals, and does not induce ripples in the demodulated output signal.
In one aspect, an apparatus to sense the position of an object includes a first receiver that is operable to receive an excitation signal, a second receiver that is operable to receive an amplitude modulated signal, modulated by the position of an object being sensed, and a demodulator that is operable to demodulate the amplitude modulated signal from the received excitation signal and is further operable to output a signal that is proportional to the position of the object being sensed.
In another aspect, an apparatus to sense the position of an object being sensed includes a receiver operable to receive an excitation signal, a position sensing device which is operable to output an amplitude modulated signal, modulated by the position of the object being sensed, a demodulator that is operable to demodulate the amplitude modulated signal from the received excitation signal and is further operable to output a signal that is proportional to the position of the object being sensed, and an excitation coil which is free to move relative to the rest of the apparatus.
In yet another aspect, a method to determine the position of an object being sensed includes receiving an excitation signal, receiving an amplitude modulated signal, modulated by the position of the object being sensed, and demodulating the amplitude modulated signal by dividing the amplitude modulated signal by the excitation signal to produce an output signal that is proportional to the position of the object being sensed.
Apparatus, systems, and methods of varying scope are described herein. In addition to the aspects and advantages described in this summary, further aspects and advantages will become apparent by reference to the drawings and by reading the detailed description that follows.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagram illustrating a system-level overview of an implementation to sense the position of an object.
FIG. 2 is a diagram of apparatus, according to an implementation to demodulate an amplitude modulated signal, modulated by the position of an object, from an excitation signal according to an implementation.
FIG. 3 is a diagram of apparatus, according to an implementation to receive, sample and demodulate an amplitude modulated signal, modulated by the position of an object, from an excitation signal according to an implementation.
FIG. 4 is a cross section block diagram of an apparatus to sense the position of an object, such that the output signal is insensitive to variations due to an air gap between a source of an excitation signal and the object being sensed.
FIG. 5 is a cross section block diagram of an apparatus to sense the position of an object by demodulating an amplitude modulated signal, modulated by the position of the object being sensed.
FIG. 6 is a flowchart of a method to demodulate an amplitude modulated signal according to an implementation.
FIG. 7 is a flowchart of a method to demodulate a degraded amplitude modulated signal according to an implementation.
DETAILED DESCRIPTION OF THE INVENTION
In the following detailed description, reference is made to the accompanying drawings that form a part hereof, and in which is shown by way of illustration specific implementations which may be practiced. These implementations are described in sufficient detail to enable those skilled in the art to practice the implementations, and it is to be understood that other implementations may be utilized and that logical, mechanical, electrical and other changes may be made without departing from the scope of the implementations. The following detailed description is, therefore, not to be taken in a limiting sense.
The detailed description is divided into four sections. In the first section, a system level overview is described. In the second section, apparatus of implementations are described. In the third section, implementations of methods are described. Finally, in the fourth section, a conclusion of the detailed description is provided.
System Level Overview
FIG. 1 is a cross section block diagram of an overview of a system to sense the position of an object. System 100 solves the need in the art to demodulate an amplitude modulated signal, such that significant noise is not induced in the demodulated output signal, and ripples are not induced in the demodulated output signal.
System 100 includes a first receiver 102 that is operable to receive an excitation signal, a second receiver 104 that is operable to receive an amplitude modulated signal, modulated by the position of the object being sensed, an analog to digital converter 106 that is operable to sample the excitation signal and the amplitude modulated signal at exactly the same times when the excitation signal is non-zero, and a micro-controlled 108 that is operable to divide the amplitude modulated signal by the excitation signal, and further operable to output a signal that is proportional to the position of the object being sensed.
The system level overview of the operation of an implementation is described in this section of the detailed description. In some aspects an apparatus to sense the position of an object includes a first receiver that is operable to receive an excitation signal, a second receiver that is operable to receive an amplitude modulated signal, modulated by the position of the object being sensed, and a demodulator that is operable to demodulate the amplitude modulated signal from the received excitation signal, and further operable to output a signal that is proportional to the position of the object being sensed.
In other aspects, the demodulator includes an analog to digital converter that is operable to sample the excitation signal and the amplitude modulated signal at exactly the same time when the excitation signal is non-zero, and a micro-controller that is operable to divide the amplitude modulated signal by the excitation signal. In other aspects, the analog to digital converter includes an analog to digital converter with a dual simultaneously sampled sample/hold circuit. This provides a method to sample and hold the excitation signal and the amplitude modulated signal at the same moment in time.
In yet other aspects, the analog to digital converter is operable to sample the excitation signal and amplitude modulated signal at times close to the time corresponding to the peak amplitude of the excitation signal. As a result the signal to noise ratio in the samples is reduced since the rate of change of an arbitrary sinusoidal signal is less at or near the peak of the arbitrary sinusoidal signal.
While the system 100 is not limited to any particular receivers, demodulator circuits, analog to digital converters, or micro-controllers, for sake of clarity a simplified demodulator circuit which includes an analog to digital converter and micro-controller is described.
Apparatus Embodiments
In the previous section, a system level overview of the operation of an implementation was described. In this section, the particular apparatus of such an implementation are described by reference to a series of diagrams.
FIG. 2 is a cross section block diagram of apparatus 200 to demodulate an amplitude modulated signal, modulated by the position of an object, from an excitation signal according to an implementation. Apparatus 200 solves the need in the art to demodulate an amplitude modulated signal, such that significant noise is not induced in the demodulated output signal, and ripples are not induced in the demodulated output signal.
Apparatus 200 includes a first receiver 202 that is operable to receive an excitation signal, a second receiver 204 that is operable to receive an amplitude modulated signal, modulated by the position of an object, a demodulator 206 that is operable to demodulated the amplitude signal from the received excitation signal, and is further operable to output a signal that is proportional to the position of the object, and an output buffer 208 that is operable to receive the demodulated output signal that is proportional to the position of the object being sensed.
In some aspects, the excitation signal is a constant frequency periodic signal, and in other aspects, the excitation signal is a constant frequency sinusoidal signal of the form K*Sin(wt), where K is a constant value, w is the frequency of the sinusoidal signal, t is a variable representing time, and Sin(•) represents the sinusoidal function applied to the arguments within the parentheses.
In some aspects, the amplitude modulated signal is a constant frequency periodic signal modulated whose amplitude is modulated by the position of an object being sensed. In other aspects, the amplitude modulated signal is a constant frequency sinusoidal signal whose amplitude is modulated by the position of an object being sensed, where the amplitude modulated signal is of the form K1(t)*K*Sin(wt), where K1(t) is the position of the object being sensed, K is a constant value, w is the frequency of the sinusoidal signal, t is a variable representing time, and Sin(•) represents the sinusoidal function applied to the arguments within the parentheses.
In some aspects, determining the position of the object being sensed includes determining the value of K1(t) by using a demodulator circuit to divide the amplitude modulated signal by the excitation signal resulting in a normalized, ripple free signal that is proportional to the position of the object being sensed.
FIG. 3 is a cross section block diagram of apparatus 300 to receive, sample and demodulate an amplitude modulated signal, modulated by the position of an object, from an excitation signal according to an implementation. Apparatus 300 solves the need in the art to demodulate an amplitude modulated signal, such that significant noise is not induced in the demodulated output signal, and ripples are not induced in the demodulated output signal.
Apparatus 300 includes a first receiver 302 that is operable to receive an excitation signal, a second receiver 304 that is operable to receive an amplitude modulated signal, modulated by the position of an object, an analog to digital converter 306 that is operable to sample the excitation signal and the amplitude modulated signal at exactly the same times when the excitation signal is non-zero, a micro-controlled 308 that is operable to divide the amplitude modulated signal by the excitation signal, and further operable to output a signal that is proportional to the position of the object being sensed, a sync squared block 310 that is operable to generate a square wave that is exactly in phase with the excitation signal, a reference signal block 312 which normalizes the excitation signal and amplitude modulated signal to lie within a particular range, and an output buffer block 314 which stores the demodulated output signal.
In some aspects the sync squared block includes a circuit that generates a square wave synchronized with the excitation signal. The square wave is an input to the micro-controller.
In some aspects the micro-controller is operable to use the square wave signal from the sync squared block to determine the appropriate sampling times corresponding to the peaks of the excitation signal. The micro-controller reads the square wave signal from the sync squared block and determines the frequency of the excitation signal, and uses the frequency to delay the sampling of the excitation signal and amplitude modulated signal in order to sample the signal at the time corresponding to the peak in the excitation signal. Sampling at the times close to the peak in the excitation signal prevents the sampled excitation value from being zero which would make the demodulated output signal unstable.
In other aspects, the sampling of the excitation signal is performed several times and the average value of the samples is used as the value of the sampled excitation signal, and the sampling of the amplitude modulated signal is performed several times and the average value of the samples is used as the value of the sampled amplitude modulated signal.
FIG. 4 is a cross section block diagram of an apparatus 400 to sense the position of an object, such that the output signal is insensitive to variations due to an air gap between a source of an excitation signal and the object being sensed. Apparatus 400 solves the need in the art to sense the position of an object demodulating an amplitude modulated signal, modulated by the position of the object being sensed, such that the demodulated output signal is insensitive to variations in the amplitude of an excitation signal due to an air gap between a source of the excitation signal and the object being sensed.
Apparatus 400 includes a receiver 402 that is operable to receive a received excitation signal, a position sensing device 404 , an analog to digital converter 406 that is operable to sample the received excitation signal and an amplitude modulated signal, modulated by the position of an object being sensed, at exactly the same times when the received excitation signal is non-zero, a micro-controlled 408 that is operable to divide the amplitude modulated signal by the received excitation signal, and further operable to output a signal that is proportional to the position of the object being sensed, and an excitation coil 410 that is free to move relative to the rest of the apparatus.
In some aspects, the excitation coil is operable to transmit a transmitted excitation signal to the receiver and to the position sensing device, and the receiver and the position sensing device are each operable to receive the received excitation signal.
In other aspects, the position sensing device is further operable to use the received excitation signal to output an amplitude modulated signal, modulated by the position of the object being sensed, and transmit the amplitude modulated signal to a demodulator, and the demodulator is operable to receive the amplitude modulated signal.
In other aspects, the demodulator includes an analog to digital converter that is operable to sample the received excitation signal and the amplitude modulated signal at exactly the same time when the received excitation signal is non-zero, and a micro-controller that is operable to divide the amplitude modulated signal by the received excitation signal. In other aspects, the analog to digital converter includes an analog to digital converter with a dual simultaneously sampled sample/hold circuit. This provides a method to sample and hold the received excitation signal and the amplitude modulated signal at the same moment in time.
In other aspects, the analog to digital converter is operable to sample the received excitation signal and amplitude modulated signal at times close to the time corresponding to the peak amplitude of the received excitation signal. As a result the signal to noise ratio in the samples is reduced since the rate of change of an arbitrary sinusoidal signal is less at or near the peak of the arbitrary sinusoidal signal.
In other aspects, the demodulator includes a sync squared block that is operable to generate a square wave that is exactly in phase with the received excitation signal. In other aspects, the micro-controller is operable to use the square wave generated by the sync squared block to determine the appropriate sampling times corresponding to the peaks of the received excitation signal. In other aspects, the sampling of the excitation signal is performed several times and the average value of the samples is used as the value of the sampled excitation signal, and the sampling of the amplitude modulated signal is performed several times and the average value of the samples is used as the value of the sampled amplitude modulated signal.
In some aspects, the position sensing device includes a single coil absolute position sensor. In yet other aspects, the position sensing device includes an inductive gap sensor.
FIG. 5 is a cross section block diagram of an apparatus 500 to sense the position of an object by demodulating an amplitude modulated signal, modulated by the position of the object being sensed. Apparatus 500 solves the need in the art to sense the position of an object by demodulating an amplitude modulated signal, modulated by the position of the object being sensed, such that the demodulated output signal is insensitive to variations in the amplitude of an excitation signal due to an air gap between a source of the excitation signal and the object being sensed, and such that significant noise is not induced in the demodulated output signal, and ripples are not induced in the demodulated output signal.
Apparatus 500 includes a receiver 502 that is operable to receive a received excitation signal, a position sensing device 504 that is operable to receive the received excitation signal and output an amplitude modulated signal, modulated by the position of an object, a demodulator 506 that is operable to demodulated the amplitude signal from the received excitation signal, and is further operable to output a signal that is proportional to the position of the object, an output buffer 508 that is operable to receive the demodulated output signal that is proportional to the position of the object being sensed, and an excitation coil 510 that is free to move relative to the rest of the apparatus.
In some aspects, the transmitted excitation signal is a constant frequency periodic signal, and in other aspects, the transmitted excitation signal is a constant frequency sinusoidal signal of the form K*Sin(wt), where K is a constant value, w is the frequency of the sinusoidal signal, t is a variable representing time, and Sin(•) represents the sinusoidal function applied to the arguments within the parentheses.
In some aspects, the amplitude modulated signal is a constant frequency periodic signal modulated whose amplitude is modulated by the position of an object being sensed. In other aspects, the amplitude modulated signal is a constant frequency sinusoidal signal whose amplitude is modulated by the position of an object being sensed, where the amplitude modulated signal is of the form K1(t)*K*Sin(wt), where K1(t) is the position of the object being sensed, K is a constant value, w is the frequency of the sinusoidal signal, t is a variable representing time, and Sin(•) represents the sinusoidal function applied to the arguments within the parentheses.
In other aspects, the received excitation signal is a constant frequency sinusoidal signal that has been degraded by noise due to the air gap between the excitation coil and the receiver, and due to the excitation coil and the position sensing device, where the received excitation signal is of the form K(t)*Sin(wt), where K(t) is the noise due to the air gap, w is the frequency of the sinusoidal signal, t is a variable representing time, and Sin(•) represents the sinusoidal function applied to the arguments within the parentheses.
In other aspects, the amplitude modulated signal is a constant frequency sinusoidal signal that has been degraded due to noise, whose amplitude is modulated by the position of an object being sensed, where the amplitude modulated signal is of the form K1(t)*K(t)*Sin(wt), where K1(t) is the position of the object being sensed, K(t) is the noise due to the air gap, w is the frequency of the sinusoidal signal, t is a variable representing time, and Sin(•) represents the sinusoidal function applied to the arguments within the parentheses.
In some aspects, determining the position of the object being sensed includes determining the value of K1(t) by using a demodulator circuit to divide the amplitude modulated signal by the received excitation signal resulting in a normalized, ripple free signal that is proportional to the position of the object being sensed.
Method Embodiments
In the previous section, apparatus of the operation of an implementation was described. In this section, the particular methods performed by the various constituents of such an implementation are described by reference to a series of flowcharts.
FIG. 6 is a flowchart of a method 600 to demodulate an amplitude modulated signal according to an implementation. Method 600 solves the need in the art to provide a method to sense the position of an object by demodulating an amplitude modulated signal, such that significant noise is not induced in the demodulated output signal, and ripples are not induced in the demodulated output signal.
Method 600 includes receiving an excitation signal 602 , receiving an amplitude modulated signal 604 , modulated by the position of the object being sensed, dividing the amplitude modulated signal by the excitation signal 606 , and producing a demodulated signal that is proportional to the position of the object being sensed.
FIG. 7 is a flowchart of a method 700 to demodulate a degraded amplitude modulated signal according to an implementation. Method 700 solves the need in the art to provide a method to sense the position of an object by demodulating a degraded amplitude modulated signal, modulated by the position of the object being sensed, such that the demodulated output signal is insensitive to the degradation of the amplitude modulated signal.
Method 700 includes receiving a degraded excitation signal 702 , receiving an amplitude modulated degraded excitation signal 704 , modulated by the position of the object being sensed, dividing the degraded amplitude modulated signal by the degraded excitation signal 706 , and producing a demodulated output signal that is proportional to the position of the object being sensed and insensitive to the degradation of the excitation signal and amplitude modulated signal.
In some implementations, methods 600 - 700 are implemented as a computer data signal embodied in a carrier wave, that represents a sequence of instructions which, when executed by a processor, cause the processor to perform the respective method. In other implementations, methods 600 - 700 are implemented as a computer-accessible medium having executable instructions capable of directing a processor, to perform the respective method. In varying implementations, the medium is a magnetic medium, an electronic medium, or an optical medium.
CONCLUSION
An apparatus through which an amplitude modulated signal, modulated by the position of an object being sensed, is demodulated such that the apparatus is insensitive to variations in the amplitude of an excitation signal, does not induce significant noise in the demodulated signal due to extensive stages of electronics to process the signals, and does not induce ripples in the demodulated output signal is described. A technical effect of the demodulation system is to detect the absolute position of an object by producing an output signal which is proportional to the position of the object being sensed. Although specific implementations are illustrated and described herein, it will be appreciated by those of ordinary skill in the art that any arrangement which is calculated to achieve the same purpose may be substituted for the specific implementations shown. This application is intended to cover any adaptations or variations. For example, although described in terms of an electronic circuit, one of ordinary skill in the art will appreciate that implementations can be made in firmware, software or other electronic circuits that provides the required function.
In particular, one of skill in the art will readily appreciate that the names of the methods and apparatus are not intended to limit implementations. Furthermore, additional methods and apparatus can be added to the components, functions can be rearranged among the components, and new components to correspond to future enhancements and physical devices used in implementations can be introduced without departing from the scope of implementations. One of skill in the art will readily recognize that implementations are applicable to future position sensing devices, and different methods of sensing the position of object based on demodulating an amplitude modulated signal.
The terminology used in this application meant to include all demodulator circuits, analog to digital converters, micro-controllers, receiver and transmitter environments and alternate technologies which provide the same functionality as described herein.
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Systems, methods and apparatus are provided through which in some implementations determine the amplitude of an amplitude modulated signal, modulated by the position of an object being sensed. In some aspects, the apparatus accepts an excitation signal and the amplitude modulated signal and divides the amplitude modulated by the excitation signal to produce an output signal that is proportional to the position of the object being sensed. In other aspects, the division is performed only when the excitation signal is non-zero, such as close to the peaks in the excitation signal. In other aspects, the excitation signal and amplitude modulated signal are degraded due to an air gap and the degraded signals are used to correct for amplitude fluctuations due to the air gap, and produce an output signal, tolerant of the air gaps, that is proportional to the position of the object being sensed.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This patent application claims priority from U.S. Ser. No. 61/662,393 filed Jun. 21, 2012 and U.S. Ser. No. 61/663,513 filed Jun. 22, 2012; and is related to U.S. Ser. No. 13/164,456 filed Jun. 20, 2011; U.S. Ser. No. 12/968,151 filed Dec. 14, 2010; U.S. Ser. No. 13/140,029 filed Dec. 18, 2009; U.S. Ser. No. 61/500,561 filed Jun. 23, 2011; U.S. Ser. No. 61/500,560 filed Jun. 23, 2011; and U.S. Ser. No. 61/638,454 filed Apr. 25, 2012; the disclosures of which are incorporated herein by reference.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH
[0002] Not applicable
BACKGROUND
[0003] Many energy storage devices like batteries, capacitors and photovoltaics can utilize a binder and/or an electrolyte and separator film to provide enhanced performances in mechanical stabilization, improved electrical conduction of the powder used in cathodes or electrodes and ion transport in the electro- or photoactive material and electrolyte.
[0004] Lithium ion batteries are used extensively for portable electronic equipment and batteries such as lithium ion and lead-acid are increasingly being used to provide electrical back-up for wind and solar energy. The salts for the cathode materials in lithium ion batteries are generally known to have poor electrical conductivity and poor electrochemical stability which results in poor cycling (charge/discharge) ability. Both cathode and anode materials in many battery types such as lithium ion based batteries exhibit swelling and deswelling as the battery is charged and discharged. This spatial movement leads to further separation of some of the particles and increased electrical resistance. The high internal resistance of the batteries, particularly in large arrays of lithium ion batteries such as used in electric vehicles, can result in excessive heat generation leading to runaway chemical reactions and fires due to the organic liquid electrolyte.
[0005] Lithium primary batteries consist, for example, of lithium, poly(carbon monofluoride) and lithium tetrafluoroborate together with a solvent such as gamma-butyrolactone as an electrolyte. These lithium primary batteries have excellent storage lifetimes, but suffer from only being able to provide low current and the capacity is about one tenth of what is theoretically possible. This is ascribed to the poor electrical conductivity of the poly(carbon monofluoride). In some cases a portion manganese dioxide is added to aid in the electrical conductivity and power of the lithium battery.
[0006] Attempts to overcome the deficiencies of poor adhesion to current collectors and to prevent microcracking during expansion and contraction of rechargable batteries have included development of binders. Binders such as polyacrylic acid (PAA), for cathodes, poly(styrene butadiene), carboxymethylcellulose (CMC), styrene-butadiene (SBR), for anodes, and particularly polyvinylidene fluoride (PVDF) for cathodes and anodes, are used in lithium based batteries to hold the active material particles together and to maintain contact with the current collectors i.e., the aluminum (Al) or the copper (Cu) foil. The PAA and SBR are used as aqueous suspensions or solutions and are considered more environmentally benign than organic solvent based systems such as n-methyl 2 pyrrolidone (NMP) with PVDF.
[0007] A cathode electrode of a lithium ion battery is typically made by mixing active material powder, such as lithium iron phosphate, binder powder, i.e., high molecular weight PVDF, solvent such as NMP if using PVDF, and additives such as carbon black, into a slurry (paste) and pumping this slurry to a coating machine. An anode electrode for a lithium ion battery is made similarly by typically mixing graphite, or other materials such as silicon, as the active material, together with the binder, solvent and additives. The coating machines spread the mixed slurry (paste) on both sides of the Al foil for the cathode and Cu foil for the anode. The coated foil is subsequently calendared to make the electrode thickness more uniform, followed by a slitting operation for proper electrode sizing and drying.
[0008] For zinc-carbon batteries, the positive electrode can consist of a wet powder mix of manganese dioxide, a powdered carbon black and electrolyte such as ammonium chloride and water. The carbon black can add electrical conductivity to the manganese dioxide particles, but is needed at high weight percentages in the range about 10 to 50% by weight of manganese dioxide. These high amounts of carbon black needed for improved electrical conductivity, or reduced impedance of the battery, diminish the capacity per unit volume of the battery as less manganese dioxide can be employed per unit volume of the positive paste mix. Thus, in general, there is a need to improve the impedance of a battery while maximizing the amount of active material per unit volume.
[0009] For a lead-acid battery the anode can be made from carbon particles together with a binder to provide higher specific capacity (capacity per unit weight). The anode of a zinc-carbon battery is often a carbon rod typically made of compressed carbon particles, graphite and a binder such as pitch. The carbon particle anodes tend to have poor mechanical strength leading to fracture under conditions of vibration and mechanical shock.
[0010] The characteristics of the binder material are important for both manufacturing and performance of the battery. Some of these characteristics of relevance are electrical and ionic conductivity, tensile strength and extensibility, adhesion to particles as well as the foils, and swelling of electrolyte. Improvement of electrical and ionic conductivity is needed for improved battery capacity and power. Materials such as lithium manganese oxide for cathodes and silicon particles for anodes exhibit much lower practical specific capacity than theoretically available. A higher electrical and ionic conductivity binder material would be most beneficial to achieve specific capacities closer to their theoretical values. It is desirable to improve the tensile and adhesive strength of binders so that less binder material can be employed and also improve the battery cycling lifetime. Addition of conductive particles, such as carbon black decreases the tensile strength and extensibility of binders. Controlled swelling of the binder in electrolyte is also important. If too much swelling occurs, this separates the particles and significantly increases the inter-particle ohmic resistance. Also, since the particles of the anode or cathode are coated with binder, the layer thickness of the binder can be as thin as 50 to 100 nanometers. This layer thickness precludes uniform distributions of particles of sizes larger than the binder layer thickness. For example, multiwall carbon nanotubes as usually made in a gas phase reactor consist of bundles with diameters ranging from about 50 to 500 microns in diameter and would therefor reside only at the interstitial spaces between the particles.
[0011] Impurities, such as non-lithium salts, iron, and manganese to name a few, with the binder can also be highly deleterious to battery performance. Typically, high purity of the binder material, and other additives comprising the binder material such as carbon black to improve electrical conductivity, is an important factor to minimize unwanted side reactions in the electrochemical process. For example in alkaline-manganese dioxide batteries the total iron in the manganese dioxide is less than 100 ppm to prevent hydrogen gassing at the anode. Commercially available carbon nanotubes such as Baytubes® (Bayer AG) or Graphistrength® (Arkema) can contain as much as ten percent or more by weight of residual metal catalysts and are not considered advantageous for batteries at these levels of impurity.
[0012] For photovoltaics, lines of conductive paste ink, made from solvents, binders, metal powder and glass frit, are screen-printed onto solar panel modules. The binders are usually polymer based for improved printability, such as ETHOCEL™ (Dow Chemical Company). During the burning off of the polymer and cooling the lines can crack due to shrinkage forces and so increase impedance. It is highly desirable to have a more robust conductive paste ink to prevent cracking during heating and cooling.
[0013] Efforts to improve the safety of lithium ion batteries have included using non-flammable liquids such as ionic liquids, for example, ethyl-methyl-imidazolium bis-(trifluoromethanesulfonyl)-imide (EMI-TFSI), and solid polymer, sometimes with additional additives, for example, polyethylene oxide with titanium dioxide nanoparticles, or inorganic solid electrolytes such as a ceramic or glass of the type glass ceramics, Li 1 +x+yTi 2 −xAl x Si y P 3 −yO 12 (LTAP). The electrical conductivity values of organic liquid electrolytes are in the general range of 10 −2 to 10 −1 S/cm. Polymer electrolytes have electrical conductivity values in the range of about 10 −7 to 10 −4 S/cm, dependent on temperature, whereas inorganic solid electrolytes generally have values in the range 10 −8 to 10 −5 S/cm. At room temperature most polymer electrolytes have electrical conductivity values around 10 −5 S/cm. The low ionic conductivities of polymer and inorganic solid electrolytes are presently a limitation to their general use in energy storage and collection devices. It is thus highly desirable to improve the conductivity of electrolytes, and particularly with polymer and inorganic electrolytes because of their improved flammability characteristics relative to organic liquids. Also, it is desirable to improve the mechanical strength of solid electrolytes in battery applications requiring durability in high vibration or mechanical shock environments, as well as in their ease of device fabrication.
[0014] In alkaline batteries the electrolyte is typically potassium hydroxide. Alkaline batteries are known to have significantly poorer capacity on high current discharge than low current discharge. Electrolyte ion transport limitations as well as polarization of the zinc anode are known reasons for this. An increase in the electrolyte ion transport is highly desirable.
[0015] Amongst new generation thin film photovoltaic technologies, dye sensitized solar cells (DSSCs) possess one of the most promising potentials in terms of their cost-performance ratio. One of the most serious drawbacks of the present DSSCs technology is the use of liquid and corrosive electrolytes which strongly limit their commercial development. An example of an electrolyte currently used for DSSCs is potassium iodide/iodine. Replacement of the presently used electrolytes is desirable, but candidate electrolytes have poor ion transport.
[0016] Typical electrolytic capacitors are made of tantalum, aluminum, or ceramic with electrolyte systems such as boric acid, sulfuric acid or solid electrolytes such as polypyrrole. Improvements desired include higher rates of charge and discharge which is limited by ion transport of the electrolyte.
[0017] A separator film is often added in batteries or capacitors with liquid electrolytes to perform the function of electrical insulation between the electrodes yet allowing ion transport. Typically in lithium batteries the separator film is a porous polymer film, the polymer being, for example a polyethylene, polypropylene, or polyvinylidene fluoride. Porosity can be introduced, for example, by using a matt of spun fibers or by solvent and/or film stretching techniques. In lead-acid batteries, where used the separator film is conventionally a glass fiber matt. The polymer separator film comprising discrete carbon nanotubes of this invention can improve ion transport yet still provide the necessary electrical insulation between the electrodes.
[0018] The present invention comprises improved binders, electrolytes and separator films for energy storage and collection devices like batteries, capacitors and photovoltaics comprising discrete carbon nanotubes, methods for their production and products obtained therefrom.
SUMMARY
[0019] In one embodiment, the invention is a composition comprising a plurality of discrete carbon nanotube fibers, said fibers having an aspect ratio of from about 10 to about 500, and wherein at least a portion of the discrete carbon nanotube fibers are open ended, wherein the composition comprises a binder material, an electrolyte material or a separator film of an energy storage or collection device.
[0020] In another embodiment, the composition comprises a plurality of discrete carbon nanotube fibers have a portion of discrete carbon nanotubes that are open ended and ion conducting. The composition can further comprise at least one polymer. The polymer is selected from the group consisting of vinyl polymers, preferably poly(styrene-butadiene), partially or fully hydrogenated poly(styrene butadiene) containing copolymers, functionalized poly(styrene butadiene) copolymers such as carboxylated poly(styrene butadiene) and the like, poly(styrene-isoprene), poly(methacrylic acid), poly(acrylic acid), poly(vinylalcohols), and poly(vinylacetates), fluorinated polymers, preferably poly(vinylidine difluoride) and poly(vinylidene difluoride) copolymers, conductive polymers, preferably poly(acetylene), poly(phenylene), poly(pyrrole), and poly(acrylonitrile), polymers derived from natural sources, preferably alginates, polysaccharides, lignosulfonates, and cellulosic based materials, polyethers, polyolefines, polyesters, polyurethanes, and polyamides; homopolymers, graft, block or random co- or ter-polymers, and mixtures thereof.
[0021] In yet another embodiment of this invention, the plurality of discrete carbon nanotube fibers are further functionalized, preferably the functional group comprises a molecule of mass greater than 50 g/mole, and more preferably the functional group comprises carboxylate, hydroxyl, ester, ether, or amide moieties, or mixtures thereof.
[0022] A further embodiment of this invention comprising a plurality of discrete carbon nanotube fibers further comprising at least one dispersion aid.
[0023] In a yet further embodiment of this invention, the plurality of carbon nanotubes further comprise additional inorganic structures comprising of elements of the groups two through fourteen of the Periodic Table of Elements.
[0024] Another embodiment of this invention comprises a plurality of carbon wherein the composition has a flexural strength of at least about ten percent higher than a comparative composition made without the plurality of discrete carbon nanotubes.
[0025] Yet another embodiment of this invention is a binder, electrolyte or separator film composition comprising a plurality of discrete carbon nanotube fibers having a portion of discrete carbon nanotubes that are open ended and ion conducting further comprising non-fiber carbon structures. The non-fiber carbon structures comprise components selected from the group consisting of carbon black, graphite, graphene, oxidized graphene, fullerenes and mixtures thereof. Preferably the graphene or oxidized graphene have at least a portion of discrete carbon nanotubes interspersed between the graphene or oxidized graphene platelets.
[0026] A yet further embodiment of this invention is a composition comprising a plurality of discrete carbon nanotube fibers where the binder material has an impedance of less than or equal to about one billion (1×10 9 ) ohm-m and the electrolyte material has a charge transfer resistance of less than or equal to about 10 million (1×10 7 ) ohm-m.
[0027] Another embodiment of this invention comprises an electrolyte or separate film composition comprising a plurality of discrete carbon nanotube fibers wherein the carbon nanotubes are oriented. The orientation is accomplished by fabrication techniques such as in a sheet, micro-layer, micro-layer with vertical film orientation, film, molding, extrusion, or fiber spinning fabrication method. The orientation may also be made via post fabrication methods, such as tentering, uniaxial orientation, biaxial orientation and thermoforming.
[0028] A further embodiment of this invention is a composition comprising a plurality of discrete carbon nanotubes wherein the portion of open ended tubes comprise electrolyte. For an electrolyte comprising polymer, the polymer is preferred to comprise a molecular weight of the polymer less than 10,000 daltons, such that the polymer can enter within the tube. The electrolyte may contain liquids.
[0029] An additional embodiment of this invention comprises a composition including a plurality of discrete carbon nanotube fibers, said fibers having an aspect ratio of from about 10 to about 500, and wherein at least a portion of the discrete carbon nanotube fibers are open ended, preferably wherein 40% to 90% by number of the carbon nanotubes have an aspect ratio of 30-70, and more preferably aspect ratio of 40-60, and 1% to 30% by number of aspect ratio 80-140,most preferably an aspect ratio of 90 to 120. In statistics, a bimodal distribution is a continuous probability distribution with two different modes. These appear as distinct peaks (local maxima) in the probability density function. More generally, a multimodal distribution is a continuous probability distribution with two or more modes. The discrete carbon nanotubes can have a unimodal, bimodal or multimodal distribution of diameters and/or lengths. For example, the discrete carbon nanotubes can have a bimodal distribution of diameters wherein one of the peak values of diameter is in the range 2 to 7 nanometers and the other peak value is in the range 10 to 40 nanometers. Likewise, the lengths of the discrete carbon nanotubes can have a bimodal distribution such that one peak has a maximum value in the range of 150 to 800 nanometers and the second peak has a maximum value in the range 1000 to 3000 nanometers. That composition is useful in binders and electrolytes of the invention.
[0030] In yet another embodiment, the invention is an electrode paste, preferably an anode paste, for a lead acid battery, the paste comprising discrete carbon nanotubes having an average length from about 400 to about 1400 nm, polyvinyl alcohol, water, lead oxide and sulfuric acid. Preferably, the carbon nanotubes, polyvinyl alcohol and water form a dispersion, and the dispersion is then contacted with lead oxide followed by sulfuric acid to form the electrode paste.
BRIEF DESCRIPTION OF FIGURES
[0031] The following drawings form part of the present specification and are included to further demonstrate certain aspects of the present invention. The invention may be better understood by reference to one or more of these drawings in combination with the detailed description of specific embodiments presented herein.
[0032] FIG. 1 shows discrete carbon nanotubes of this invention with a bimodal length distribution where the maximum of one peak is about 700 nanometers and the maximum of the second peak is about 1600 nanometers. The lengths were determined by deposition of the discrete carbon nanotubes on a silicon wafer and by using scanning electron microscopy.
DETAILED DESCRIPTION
[0033] In the following description, certain details are set forth such as specific quantities, sizes, etc., so as to provide a thorough understanding of the present embodiments disclosed herein. However, it will be evident to those of ordinary skill in the art that the present disclosure may be practiced without such specific details. In many cases, details concerning such considerations and the like have been omitted inasmuch as such details are not necessary to obtain a complete understanding of the present disclosure and are within the skills of persons of ordinary skill in the relevant art.
[0034] While most of the terms used herein will be recognizable to those of ordinary skill in the art, it should be understood, that when not explicitly defined, terms should be interpreted as adopting a meaning presently accepted by those of ordinary skill in the art. In cases where the construction of a term would render it meaningless or essentially meaningless, the definition should be taken from Webster's Dictionary, 3rd Edition, 2009. Definitions and/or interpretations should not be incorporated from other patent applications, patents, or publications, related or not, unless specifically stated in this specification.
[0035] In the present invention, discrete oxidized carbon nanotubes, alternatively termed exfoliated carbon nanotubes, are obtained from as-made bundled carbon nanotubes by methods such as oxidation using a combination of concentrated sulfuric and nitric acids and sonication. The bundled carbon nanotubes can be made from any known means such as, for example, chemical vapor deposition, laser ablation, and high pressure carbon monoxide synthesis. The bundled carbon nanotubes can be present in a variety of forms including, for example, soot, powder, fibers, and bucky paper. Furthermore, the bundled carbon nanotubes may be of any length diameter, or chirality. Carbon nanotubes may be metallic, semi-metallic, semi-conducting, or non-metallic based on their chirality and number of walls. They may also include amounts of nitrogen within the carbon wall structure. The discrete oxidized carbon nanotubes may include, for example, single-wall, double-wall carbon nanotubes, or multi-wall carbon nanotubes and combinations thereof. The diameters and lengths of the discrete carbon nanotubes can be determined by deposition of the discrete carbon nanotubes from dilute solution on a silicon wafer and by using scanning electron microscopy.
[0036] One of ordinary skill in the art will recognize that many of the specific aspects of this invention illustrated utilizing a particular type of carbon nanotube may be practiced equivalently within the spirit and scope of the disclosure utilizing other types of carbon nanotubes.
[0037] Functionalized carbon nanotubes of the present disclosure generally refer to the chemical modification of any of the carbon nanotube types described hereinabove. Such modifications can involve the nanotube ends, sidewalls, or both. Chemical modifications may include, but are not limited to covalent bonding, ionic bonding, chemisorption, intercalation, surfactant interactions, polymer wrapping, cutting, solvation, and combinations thereof.
[0038] Any of the aspects disclosed in this invention with discrete carbon nanotubes may also be modified within the spirit and scope of the disclosure to substitute other tubular nanostructures, including, for example, inorganic or mineral nanotubes. Inorganic or mineral nanotubes include, for example, silicon nanotubes, boron nitride nanotubes and carbon nanotubes having heteroatom substitution in the nanotube structure, such as nitrogen. The nanotubes may include or be associated with organic or inorganic elements or compounds from elements such as, for example, carbon, silicon, boron and nitrogen. The inorganic elements can comprise of elements of the groups two through fourteen of the Periodic Table of Elements, singly or in combination. Association may be on the interior or exterior of the inorganic or mineral nanotubes via Van der Waals, ionic or covalent bonding to the nanotube surfaces.
[0039] Dispersing agents to aid in the dispersion of discrete carbon nanotubes or other components of this invention are, for example, anionic, cationic or non-ionic surfactants, such as sodium dodecylsulfonate, cetyltrimethyl bromide or polyethers such as the Pluronic made by BASF. They can be physically or chemically attached to the discrete carbon nanotubes. In some cases the dispersing aid can also act as a binder. For example, with lead-acid batteries polyvinylalcohol can be used to disperse discrete carbon nanotubes of this invention in water among the paste particles then on addition of sulfuric acid the polyvinylalcohol is considered to deposit on the paste particle and act as a binder. The polyvinylalcohol is preferred to have an average molecular weight less than about 100,000 daltons.
[0040] In some embodiments, the present invention comprises a composition for use as a binder material, an electrolyte material or a separator film material of an energy storage or collection device, comprising a plurality of discrete carbon nanotube fibers The nanotube fibers may have an aspect ratio of from about 10 to about 500, and at least a portion of the discrete carbon nanotube fibers may be open ended. The portion of discrete carbon nanotubes that are open ended may be conducting.
[0041] In some embodiments of the present invention, the composition may further comprise at least one polymer. The polymer may be selected from the group consisting of vinyl polymers, such as poly(styrene-butadiene), partially or fully hydrogenated poly(styrene butadiene) containing copolymers, functionalized poly(styrene butadiene) copolymers such as carboxylated poly(styrene butadiene), poly(styrene-isoprene), poly(methacrylic acid), poly(methylmethacrylate), poly(acrylic acid), poly(vinylalcohols), poly(vinylacetates), fluorinated polymers, polyvinylpyrrolidone, conductive polymers, polymers derived from natural sources, polyethers, polyesters, polyurethanes, and polyamides; homopolymers, graft, block or random co- or ter-polymers, and mixtures thereof.
[0042] In further embodiments, the composition of the present invention may comprise carbon nanotubes which are further functionalized. The composition of the present invention may comprise additional inorganic structures comprising elements of the groups two through fourteen of the Periodic Table of Elements. The composition of the present invention may further comprise at least one dispersion aid.
[0043] The composition of the present invention may further comprise an alcohol, such as polyvinyl alcohol.
[0044] In some embodiments, the present invention comprises a binder material further comprise non-fiber carbon structures, for example carbon black, graphite, graphene, oxidized graphene, fullerenes, and mixtures thereof. In some embodiments, at least a portion of discrete carbon nanotubes are interspersed between graphene and/or oxidized graphene plates. In this embodiment, the binder material may have an impedance of less than or equal to about one billion ohm-m.
[0045] In further embodiments, the composition of the present invention comprises an electrolyte material or separator film. The composition may have a charge transfer resistance of less than or equal to about 10 million ohm-m.
[0046] In further embodiments, the carbon nanotubes of the present invention are oriented, for example in a sheet, micro-layer, micro-layer with vertical film orientation, film, molding, extrusion, or fiber spinning fabrication method. Orientation may be accomplished using post fabrication methods, such as tentering, uniaxial orientation, biaxial orientation and thermoforming.
[0047] In some embodiments of the present invention, a portion of open ended tubes comprise electrolyte. The electrolyte may comprise a polymer or a liquid.
[0048] In further embodiments of the invention, 40% to 90% by number of the discrete carbon nanotubes have an aspect ratio of 30-70. In other embodiments, 1% to 30% by number of carbon nanotubes have an average aspect ratio 80-140.
[0049] In some embodiments, the present invention comprises an electrode paste for a lead-acid battery comprising discrete carbon nanotubes having an average length from about 400 to about 1400 nm. The electrode paste may further comprise an alcohol, for example polyvinyl alcohol.
[0050] The present invention also comprises a method for making a composition for use as a binder material, an electrolyte material or a separator film material for an energy storage or collection device. The method comprises the steps of a) adding carbon nanotubes to a liquid, solvent or polymer melt b) vigorous mixing such as with a sonicator or high shear mixer for a period of time; and c) optionally adding further materials, such as PVDF, and inorganic fillers such as carbon black and continued mixing until a homogenous dispersion is obtained. The mixture can then be further fabricated into shapes by such methods as film extrusion, fiber extrusion, solvent casting, and thermoforming. The method may further comprise adding a polymer, a dispersion aid, additional inorganic structures, or an alcohol, such a polyvinyl alcohol.
Electrolytes
[0051] The term electrolyte is defined as a solution able to carry an electric current. An ionic salt is dissolved in a medium which allows ion transport. Ion transport is defined as the movement of ions through the electrolyte. The ions are preferably a single type of ion, but can be a mixture of types of ions. The medium can be solid, liquid or semi-solid, for example gelatinous. For example, in a lead-acid battery the electrolyte medium is preferred to be liquid or gelatinous. For a lithium based battery the electrolyte medium is preferred to be gelatinous and more preferably a solid at use temperature to prevent high concentrations of flammable organic liquids which could escape on battery failure by shorting or penetration. The electrolyte has to be sufficiently non-electrically conductive to prevent poor storage stability or shorting.
[0052] A separator film is often added in batteries with liquid electrolytes to perform the function of electrical insulation between the electrodes yet allowing ion transport. Typically in lithium batteries the separator film is a porous polymer film, the polymer being, for example a polyethylene, polypropylene, or polyvinylidene fluoride. Porosity can be introduced, for example, by using a matt of spun fibers or by solvent and/or film stretching techniques. In lead-acid batteries, where used the separator film is conventionally a glass fiber matt. The separator film comprising discrete carbon nanotubes of this invention can improve ion transport yet still provide the necessary electrical resistivity. The degree of electrical conductivity can be controlled by the amount of discrete carbon nanotubes within the binder or separator film medium. In a binder it may be advantageous to use higher levels of discrete carbon nanotubes, for example in the range 10 to 50% by weight of the binder medium, for the optimum balance of low electrical resistivity, for example, less than 1×10 7 ohm-m, with strength, than for the electrolyte medium or separator film where it may be advantageous to use less than 10% weight of discrete carbon nanotubes to maintain electrical resistivity greater than about 1×10 7 ohm-m. The use of discrete carbon nanotubes to improve the strength and ease of battery assembly of the thin electrolyte or separator films is also considered valuable.
[0053] The flexural strength or resistance to cracking of the solid electrolytes can be determined by flexural bending of a film or sheet of the solid electrolyte on a thin aluminum or copper film in a 3-point bending fixture and an Instron Tensile Testing machine. The test is analogous to standard test procedures given in ASTM D-790. The resistance to deformation and stress to crack the solid electrolyte through the solid electrolyte film thickness is recorded. Units are in MPa.
[0054] Ionic salts can be added to a polymeric medium such as polyethylene oxide to produce electrolytes. For example, for lithium ion batteries ionic salts, such as lithium perchlorate, lithium tetrafluoroborate, lithium trifluoromethanesulfate, lithium bistrifluoromethanesulfonimide, lithium bisoxalatoborate can be added to the polymer, by solvent or to the polymer melt. Solvents can be those that are retained as an electrolyte medium, for example, ethylene carbonate, propylene carbonate, or solvents which are then removed by drying such as acetonitrile.
[0055] The electrolyte or separator film containing polymeric material may have a polymer, or a combination of polymers that are dissimilar by molecular weight and or by type. For example, in an electrolyte containing polyethylene oxide a portion of the polyethylene oxide can be of molecular weight above about 200,000 daltons and a portion less than about 10,000 daltons. As another example, the polyethylene oxide can be partially replaced by another polymer, such as polyvinylidene fluoride, polyvinylpyrrolidone, or polymethylmethacrylate.
Procedure for Impedance and Swelling Evaluation of Binder Materials
[0056] Each dried sample film is obtained using a 22 mm diameter punch. Films are also obtained saturated with neat electrolyte (a 50/50 composition of ethylene carbonate and propylene carbonate) and electrolyte and 50% by weight of lithium perchlorate by immersing the films for 1-20 days at room temperature. The films are evaluated for swelling by weight increase and tested for impedance using an LCR meter, (Agilent 4263B) at 25 degrees centigrade and under about 70 psi, (0.483 MPa) pressure at 1 Khz. The units of impedance are usually given as ohm-meter.
[0057] The flexural strength or resistance to cracking of the pastes can be determined by flexural bending of the paste on a thin aluminum or copper film in a 3-point bending fixture and an Instron Tensile Testing machine. The test is analogous to standard test procedures given in ASTM D-790. The stress to crack the paste through the paste thickness is recorded. Units are in MPa.
[0058] The adhesive strength of the pastes can be determined by using lap shear strength procedures and the Instron Tensile Testing Machine. The test is analogous to EN 1465. The specimen consists of two rigid substrates, for example aluminum sheets or copper sheets, bonded together by the paste in a lapped joint. This causes the two ends of the specimen to be offset from the vertical load line of the test. The paste is placed between two strip of material. The stress to failure on pulling the lapped specimen is recorded. Units are in MPa.
Procedure for Charge Transfer Resistance Evaluation of Electrolyte Materials
[0059] Electrolyte films are placed between two electrodes the resistance and reactance determined at frequencies of 100 Hz, 120 Hz, 1 KHz, 10 KHz and 100 KHz using an LCR meter, (Agilent 4263B) at 25 degrees centigrade and a 2 volt dc bias with a sinusoidal test level of 20 mv. A Nyquist plot is constructed of the real and imaginary components of the impedance from which the charge transfer resistance is obtained.
EXAMPLES 1-3
Compositions Consisting of Discrete Carbon Nanotubes in Poly(vinylidene Fluoride) for Binders and Separator Films.
[0060] General procedure. A dispersion of discrete carbon nanotubes in n-methyl-2-pyrrolidone (NMP) is first made by adding carbon nanotubes of about 2% weight of oxidized moieties and average aspect ratio about 60 to NMP under vigorous stirring. Following addition, sonication is applied for about 15 minutes to exfoliate the carbon nanotubes. An amount of PVDF is slowly added to the system over a period of 30 minutes to obtain the desired weight fraction of carbon nanotube to PVDF. Vigorous stirring and sonication is continued until a homogenous dispersion was obtained. A uniform black colored film of PVDF is obtained by removing the NMP in vacuo to constant weight.
[0061] Examples 1-3 are dried PVDF films containing discrete carbon nanotubes in the weight percentage 2.5, 7.5 and 10%, respectively, and are shown in Table 1.
[0062] Control 1 is made in a similar manner as Example 1 except that no discrete carbon nanotubes are added. The resultant dried film is a pale yellow. The impedance measurements of the dry films and films swollen for 20 days in a mixture of ethylene carbonate and propylene carbonate 50/50 and 50% by weight of lithium perchlorate are provided in Table 1.
[0063] The results shown in Table 1 demonstrate that Examples 1-3 with discrete oxidized carbon nanotubes of this invention in PVDF gave significantly lower values of impedance than the control 1 of PVDF film alone. Furthermore, inclusion of carbon nanotubes of this invention in PVDF demonstrate higher mass uptake of the LiClO 4 solvent mixture which enables improved ion transport. These improved properties on addition of discrete carbon nanotubes of this invention should lead to much enhanced performance as a binder or separator film.
[0000]
TABLE 1
% mass
Volume
Volume resistivity
uptake in
resistivity
swollen with
% wt Carbon
ECO/PCO
Dry
ECO/PCO & LiClO 4 ,
PVDF
nanotubes
and LiClO 4
Ohm-m
ohm-m
Control 1
0
6
1.579 × 10 12
3.035 × 10 11
Example 1
2.5
7
1.315 × 10 11
1.403 × 10 10
Example 2
7.5
9
3.326 × 10 7
1.239 × 10 9
Example 3
10
14
1.216 × 10 8
3.694 × 10 8
EXAMPLES 4 AND 5
[0064] Binder Composition of Discrete Carbon Nanotubes (w/w) in SBR Latex
[0065] A polyether (BASF, Pluronic F-127) as a dispersing aid for the discrete carbon nanotubes is dissolved in water cleaned by reverse osmosis at a weight ratio of 1.5 to 1 of the polyether to dry oxidized carbon nanotubes, then oxidized carbon nanotubes are added at a concentration of 1.5 weight/volume carbon nanotubes to water and sonicated for a period of 30 minutes to disperse the oxidized carbon nanotubes. SBR latex (Dow Chemical Company, grade CP 615 NA, 50% solids content) is added directly to the exfoliated carbon nanotubes at the desired carbon nanotube to SBR weight ratio and stirred vigorously until homogenous. A black film is obtained on drying the mixture in air, followed by drying in vacuo until constant weight of the film is obtained.
[0066] Example 4 is made with five weight percent of discrete carbon nanotubes to dry SBR.
[0067] Example 5 is made with seven point five weight percent of discrete carbon nanotubes to dry SBR.
[0068] Control 2 is made as example 4 and 5 except no discrete carbon nanotubes are added. The film is clear.
[0069] The impedance measurements of the dry films and films swollen for 2 days in a mixture of ethylene carbonate, ECO, and propylene carbonate, PCO, 50/50 and 50% by weight of lithium perchlorate are provided in table 2. The results demonstrate inclusion of discrete carbon nanotubes of this invention with SBR provide a significant reduction in impedance.
[0000]
TABLE 2
% mass
% weight
uptake*
Volume
carbon
ECO/PCO
resistivity
SBR
nanotubes
LiClO 4
Ohm-m
Control 2
0
−3
9.99 x 10 11
Example 4
5
−2
4.241 x 10 11
Example 5
7.5
−2
1.073 x 10 11
*2 day swell
EXAMPLE 6
[0070] Formation of a Solid Electrolyte Contained Discrete Carbon Nanotubes Wherein the Tubes are Further Functionalized with Polyethylene Oxide.
[0071] Oxidized carbon nanotube fibers are made by first sonicating the carbon nanotube fiber bundles (CNano, grade 9000) at 1% w/v in a mixture of concentrated sulfuric acid/nitric acid for 2 hours or more at about 30° C. After filtering and washing with water the pH of the final washing is about 4. The oxidized carbon nanotube fibers are dried in vacuo for 4 hours at about 80° C. The resultant oxidized tubes generally contain about 1.5-6% by weight of oxygenated species as determined by thermogravimetric analysis in nitrogen between 200 and 600° C. and at least a portion of the tubes are open ended as determined by secondary electron microscopy. The residual ash after burning the oxidized carbon nanotubes in air to 800° C. is about 0.5 to 2% w/w. Monohydroxy poly(ethylene glycol), PEG-MH, of molecular weight about 1900 daltons (Sigma Aldridge) is added in excess to the dried oxidized nanotubes together with a small amount of sulfuric acid as a catalyst and the mixture heated to 100° C. while sonicating for about 1 hour. After cooling and addition of water the functionalized carbon nanotubes are filtered followed by washings to remove excess PEG-MH and sulfuric acid. The functionalized carbon nanotubes are dried in vacuo at 40° C. overnight. 0.5% w/w of the carbon nanotubes reacted with PEG-MH are added to PEG-MH, heated to 60° C. and sonicated for 30 minutes. A uniform black liquid is obtained which on examination while in the liquid state by optical microscopy up to 150× magnification revealed no discernible aggregates of carbon nanotubes, i.e. the tubes are discrete and dispersed On cooling, the PEG-MH with discrete carbon nanotubes the PEG-MH is observed to crystallize and carbon nanotubes are observed to be between crystal lamellae, i.e., in the amorphous regions of the solid polymer. This is considered very advantageous as ions are recognized to travel preferentially in the amorphous regions.
EXAMPLES 7-15
[0072] Solid Electrolyte Compositions with Discrete Carbon Nanotubes
[0073] Discrete carbon nanotubes of oxidation about 2% and an average aspect ratio of 60, with a portion of the carbon nanotubes being open-ended are dried in vacuo at 80° C. for four hours. Compositions are made up as detailed in table 3 by first making solutions of the components using acetonitrile (Sigma Aldridge, 99.8% anhydrous) as a solvent; a 1% w/v solution of the discrete carbon nanotubes, a 2.5% v/v of polyethylene oxide, PEO, (Alfa Aesar) consisting of a ratio of two PEO's, one of molecular weight 300,000 daltons and the other molecular weight 4000 daltons in the weight ratio 1:0.23, respectively, and 5% w/v solution of lithium trifluoromethanesulfate (Aldrich). The dried discrete carbon nanotubes are first sonicated in acetonitrile for 30 minutes using a sonicator bath. The solutions are made to the various compositions (parts per hundred of PEO) given in Table 3, then sonicated for 30 minutes at around 30° C. in a sonicator bath (Ultrasonics). The mixtures are then transferred to a glass dish and the acetonitrile evaporated for 4 hours to give films. The films are dried in vacuo at 50° C. for 2 hours followed by compression molded at 120° C. for 3 minutes and 20 tons platen pressure between polyethylene terephthalate sheets, cooled to room temperature and stored in a dessicator before testing.
[0074] The results in Table 3 show that significant improvements are gained in the conductivity of the solid electrolyte films with addition of discrete carbon nanotubes of this invention compared to the controls. The electrolyte films made with discrete carbon nanotubes are also seen to have higher strength than the controls as judged by their ability to be handled without tearing.
[0000]
TABLE 3
LiCF 3 SO 3
PEO
Discrete Carbon
Conductivity at 10
phr
phr
nanotubes phr
KHz, 25° C., S/cm
Control 3
15
100
0.0
3.89 × 10 −5
Control 4
20
100
0.0
1.49 × 10 −5
Control 5
30
100
0.0
4.90 × 10 −6
Example 7
15
100
1.5
6.21 × 10 −4
Example 8
20
100
1.5
5.74 × 10 −4
Example 9
30
100
1.5
4.32 × 10 −4
Example 10
15
100
2.0
1.27 × 10 −4
Example 11
20
100
2.0
2.27 × 10 −4
Example 12
30
100
2.0
2.67 × 10 −4
Example 13
15
100
3.0
3.62 × 10 −4
Example 14
20
100
3.0
1.11 × 10 −4
Example 15
30
100
3.0
2.89 × 10 −4
EXAMPLE 16
Paste Composition Containing Discrete Carbon Nanotubes for Lead-Acid Battery
[0075] The compositions for making an anode paste for a lead acid battery for control 6 and example 16 is shown in Table 4. The expander (Hammond) is a composition of lignin sulfonate, barium sulfate and carbon black in the weight ratio 1:1:0.5, respectively. The expander is added to the dry powder of lead oxide, then water is added and mixed, followed by slow addition and mixing of acid (sulfuric acid, 1.4 specific gravity) while maintaining the temperature below 55° C. In example 16, discrete carbon nanotubes of average length 700 nanometers and oxidation level about 2% and polyvinyl alcohol, PVA, (Sigma Aldridge, average molecular weight 30,000 to 70,000 daltons, 87 to 90% hydrolyzed) are admixed with water and sonicated to give a dispersion of discrete carbon nanotubes of 2.25% by weight and PVA of 3.375% by weight. The discrete carbon nanotube solution is added together with the water to the lead oxide followed by slow addition of the sulfuric acid. The anode material is pasted to a lead grid and assembled into a battery with a lead oxide cathode, followed by standard battery formation as recorded elsewhere, i.e., Lead-Acid Batteries: Science and Technology: Science and Technology, Elsevier 2011. Author: D. Pavlov. The weight % of discrete carbon nanotubes to dry lead oxide in the anode paste is 0.16.
[0076] Relative to Control 6, Example 16 showed a higher charge efficiency of at least 30% at 14.2v charging voltage, an increase rate of charge of at least 200% and at least 50% lower polarization between 14 and 15 volts. Polarization is the difference between the voltage of the battery under equilibrium and that with a current flow.
[0000]
TABLE 4
Control 6
Example 16
Kg
Kg
Lead Oxide
230
230
Fiber flock
0.15
0.15
Expander
1.4
1.4
Discrete carbon nanotubes
0
0.368
Polyvinylalcohol
0
0.552
Water
27
27
Sulfuric acid 1.4 sg
23.1
23.1
|
In various embodiments an improved binder composition, electrolyte composition and a separator film composition using discrete carbon nanotubes. Their methods of production and utility for energy storage and collection devices, like batteries, capacitors and photovoltaics, is described. The binder, electrolyte, or separator composition can further comprise polymers. The discrete carbon nanotubes further comprise at least a portion of the tubes being open ended and/or functionalized. The utility of the binder, electrolyte or separator film composition includes improved capacity, power or durability in energy storage and collection devices. The utility of the electrolyte and or separator film compositions includes improved ion transport in energy storage and collection devices.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to methods and apparatus for production of pyrolysis oils, gaseous matter, charred carbon, zinc, and filler materials from synthetic or natural rubber and rubber vulcanizates, particularly, used old tires (referred to hereinafter as scrap rubber) by traveling fluidized bed distillation. Waste rubber disposal is a critical problem due to the huge amounts generated every year, and the lack of acceptable and economical means to recycle or convert the waste rubber into valuable products. Only a small portion of the waste tires are retreaded, and a very small portion is devulcanized by tedious processes, usually in batches. Some of the scrap tires are buried in landfills or completely burned. Neither method has gained popular acceptance because the waste tires make poor landfill, and they do not readily degrade. Combustion of waste tires is difficult to accomplish without creating environmental pollution problems.
2. Description of Prior Art
A number of processes are known for the production of pyrolysis oils and other products by the thermal decomposition of rubber vulcanizates. These processes differ from each other in the manner of heat supply, heat transfer, use of devulcanizing agents, introduction of oxygen for oxidative distillation, size requirements of feed materials, and methods of feeding and removal of residue. One of the disadvantages in the known processes is the formation of coke, which hinders production. Numerous interruptions are necessary in the process in order to free the apparatus from the coke. These methods are not geared for high production and tend to be less practical as the disposal of waste tires and similar rubber products increases every day. The present invention provides for economical and acceptable environmental means for disposal of waste tires and rubber products, and it also provides for recovery of valuable products.
U.S. Pat. No. 4,030,984 discloses the method and apparatus by which the whole tires are suspended in hot gases, melting the carbonaceous material and converting it into raw material.
U.S. Pat. No. 3,890,141 discloses a method to heat treat scrap tires to produce a fluid material which, in turn, is burned to produce heat energy. The ash in the flue gases is collected by high efficiency air cleaning devices for recovery, and the ash is further processed to recover the zinc and titanium.
U.S. Pat. No. 3,823,223 disclosed the method to produce char from the destructive distillation of scrap synthetic rubber for use in rubber enforcement.
U.S. Pat. No. 3,582,279 discloses a method and apparatus for oxidative distillation of rubber vulcanizate by partial combustion of waste rubber, using air throughout the still or retort.
Bureau of Mines Report of Investigation 7302, "Destructive Distillation of Scrap Rubbers," September, 1969, discloses the gaseous, oil, and carbonaceous materials produced from different waste rubber compositions, and at different distillation temperatures. The study identifies the different compounds produced and their percentages.
SUMMARY OF THE INVENTION
This invention relates to methods and apparatus for production of pyrolysis oils, gaseous matter, charred carbon residue of carbon black, zinc, and other filler materials from waste rubber, by the use of traveling fluidized bed technique and selective combustion. The waste rubber is mixed with aggregate materials (recycled within the system at elevated temperatures), in a distillation column and allowed to move downward into several zones, where thermal and chemical treatment takes place. These zones are: (a) Preheating zone, (b) Distillation zone, (c) Precombustion zone, (d) Combustion zone, (e) Post-Combustion zone, (f) Reduction zone, and (g) Cooling zone. The aggregate materials trap the rubber pieces and prevent the rubber from sticking together and forming one large mass. Further, its weight moves the scrap rubber downward, the space between the different pieces allows the volatile materials to escape, and the rubber pieces remain in dynamic motion until all of the volatile matters are removed. The aggregate materials retain part of the heat energy produced in the column. It also allows the distribution of the heated gases throughout the column and allows the creation of a fluidized bed by the dynamic movement of the smaller parts of aggregate, pieces of rubber and the charred carbon residue.
The volatile matter is drawn at the top and cleaned from suspended particles in high efficiency cyclones. The cleaned volatile matter is subjected to cooling and scrubbing operations to remove gaseous sulfur compounds and condense heavy and light fractions of pyrolysis oils. These oils can be fractionally distilled into oils with variable boiling points. The remaining noncondensables are used for combustion needs and steam generation.
BRIEF DESCRIPTION OF DRAWINGS
The accompanying drawings illustrate apparatus suitable for carrying out the process according to this invention.
FIG. 1 is a schematic representation in elevational view of fragmentary portions of the distillation column into which the rubber and aggregates are charged and processed to yield volatile materials and char, carbon-rich in elemental zinc.
FIG. 2 is a schematic flow diagram for putting into practice the methods of reclaiming volatile materials produced according to this invention.
FIG. 3 is a schematic representation of the experimental column.
DESCRIPTION OF PREFERRED EMBODIMENTS
The pyrolysis-distillation of waste rubber products produces an oily distillate, dark in color, called "pyrolysis oil." This oil contains acids, bases, neutral oils of olefins, aromatics, paraffin, and naphthenes, compounds that are present in the elastomer. The composition of the oil will vary with the pyrolysis-distillation temperature, particle size, and with the residence time at the pyrolysis temperature, which is between 500° C. and 1100° C. The higher the pyrolysis temperatures, the tendency is for the aromatic compounds to increase. Higher aromatic content of pyrolysis oils is desirable for preparation of resins suitable for molding. The noncondensable gases contain small amounts of butadiene and isoprene monomers, products of combustion: nitrogen, carbon dioxide, water vapor, and sulfur dioxide, in addition to combustible gases of hydrogen, methane, ethane, propane, hydrogen sulfide, and other organic vapors. Monomers can be recovered by refrigeration. The remaining gases, with a heating value of 500 BTU to 900 BTU per cubic foot, are used for combustion and steam generation.
This invention relates to a continuous traveling fluidized bed pyrolysis-distillation system for production of pyrolysis oils of variable aromatic contents from scrap rubber vulcanizate, shredded into pieces of small size (up to one inch), and in mixture with aggregate maerials. Waste rubber vulcanizate is prepared by cracking old tires to the required size, and the removal of free tire bead and steel cords. The larger size used in this invention is of advantage because it requires less energy to prepare when compared with other recovery systems that require a ground rubber of less than six millimeters in size. It is the primary object of this invention to provide a process, method, and apparatus that enhance the yield and the composition of the pyrolysis oil produced by pyrolysis-distillation of scrap rubber vulcanizate. Because this invention can be used on a large scale, it provides an economical and acceptable environmental solution to the disposal problems of waste tires.
This invention proposes to utilize fluidized bed mixture of waste rubber vulcanizate and aggregate materials made up of refractory materials and/or steel slag (referred to hereinafter as aggregate). The scrap rubber is made up of ground waste tires, vulcanized, and unvulcanized rubber, in sizes up to one inch, as determined by the size of the distillation column. The aggregate materials are a coarse mixture of high temperature refractory and steel slag in sizes ranging between 3/4 inch to one inch. The aggregate materials are constantly recycled in the distillation column and are introduced at the top with the scrap rubber.
Referring to FIG. 1, the pyrolysis-distillation apparatus is a refractory-lined steel column with insulation 10 between the steel shell 9 and the refractory 11. High temperature dense refractory is needed for the lower half of the column, while light refractory might be used for the upper half. The column is equipped with feeding hoppers for aggregates 1 and scrap rubber 3. Each hopper is equipped with air lock feeding valves 2 and 4, that permit slightly above atmospheric operation in the column. The scrap rubber mixed with aggregate materials are allowed to move downward into several zones, where thermal and chemical tratment takes place. These zones are:
(a) Preheating zone (200° C. to 400° C.), where the scrap rubber is heated by the sensible heats of the aggregate materials and the volatile matter leaving the column.
(b) Heating and the distillation zone (400° C. to 500° C.), where the scrap rubber reaches a temperature high enough to cause distillation and thermal decomposition to take place, the height of this zone is directly related to the particle size of the scrap rubber, and amount or heat applied in the combustion zone and post-composition zone, the pressure maintained inside the column, and the rate of removal of aggregates and volatile matter from the column.
(c) Precombustion zone (500° C. to 900° C.), where pyrolysis takes place because of the relatively high temperature of the gases leaving the combustion zone, and thus the residual rubber is reduced to a carbonaceous residue. The rate of pyrolysis of the residual rubber and production of high yield of aromatics in the pyrolysis oil is controlled by recirculating a side stream of the volatile matter before leaving the column 6, with the aid of recirculation blower 7. The recirculated stream suppresses any combustion in the precombustion zone and maintains suitable pyrolysis temperature.
(d) Combustion zone (800° C. to 1100° C.), where auxiliary gaseous fuel (mixture of natural gas and a portion of the waste gas from the recovery section) is introduced 8 and combusted with excess air under sufficient pressure to fluidize the carbonaceous residue and the small particles of waste rubber present above the combustion zone, and provide the heat energy requirement through combustion of a portion of the carbonaceous residue and combustion of any combustible gases produced below the combustion zone.
(e) Post-combustion zone (900° C. to 1100° C.), where controlled volume of secondary air is introduced to sustain sufficient combustion to provide the needed heat energy for the reduction zone 12.
(f) Reduction zone, where a reducing atmosphere is maintained to reduce the zinc oxide into elemental zinc, the reducing atmosphere is produced by allowing steam in the cooling zone to form blue water gas according to the following equations:
C+H.sub.2 O→CO.sub.2 +H.sub.2 -Heat
C+2H.sub.2 O→CO.sub.2 +2H.sub.2 -Heat
C+H.sub.2 O→CO.sub.2 +H.sub.2 -Heat
C+CO.sub.2 →2CO-Heat.
Thus, the heat produced by the post-combustion zone and the reducing gases produced by the cooling zone provide the conditions needed for the reduction of zinc oxide into elemental zinc.
(g) Cooling zone (350° C. to 500° C.), where small volume of steam is introduced to cool the aggregate and the residue materials 13, sufficient enough to allow their handling outside the column.
The aggregate materials are discharged by an air lock discharge valve 14 to an enclosed conveying and screening mechanism 15. Remaining broken steel cords are magnetically removed within the screen, aggregates are returned to the column after separation of foreign objects such as fused glass and broken pieces 16, and used over 1. The fine residue is separated by oscillating screen into two products--one is a carbonaceous mix, suitable for use as filler material or carbon black 18, and the second product is a coarse mix, high in elemental zinc 17. Zinc can be reclaimed by smelting.
The volatile matter leaves the column from the top 5. Pressure within the column is controlled by a butterfly valve 19.
The use of aggregate and their constant movement in the column, their removal, and their reuse helps to create the following conditions:
1. It creates a fluidized bed of the scrap rubber pieces within the column. Further, it provides for easy passage of the hot gases at low pressure drop, which is needed to conduct a counter current flow, and allows the transfer of heat from the hot gases to the rubber-aggregate mixture.
2. It prevent the rubber pieces from forming a fused mass and causing poor heat and mass transfer in the column.
3. Its weight helps forcing the rubber downward toward the high temperature zone.
4. It retains the heat (sensible heat) and provides the heat transfer medium needed to distribute the heat to the waste rubber in the distillation section.
5. It creates a large surface area for heat transfer throughout the column and the combustion zone.
6. The percentage of rubber to aggregate ratio can be changed to affect the composition of pyrolysis oil and its yield.
7. It prevents the carry-over of carbonaceous materials and other fines with the vapors and gases leaving the column.
Thus, unlike prior art systems, which rely upon indirect heat transfer, or direct pyrolysis in a batch-type retort, this invention provides for direct pyrolysis-distillation of the waste rubber using heated aggregate and hot gases from the combustion zone. Further, the energy needed for this system is provided by combustion of natural gas, portion of the waste gases generated, and by the combustion of carbonaceous materials present with the fillers used for compounding rubber. Another advantage of this invention is its continuous operation, its high capacity, and controlled composition of pyrolysis oil and residue material.
The traveling fluidized bed column shown in FIG. 1 can be designed in any way to allow for large- or small-sized materials charged, the ratio of rubber to aggregate, the heat input to the column in the combustion zone, the amount of carbon allowed to burn in the post-combustion zone, the methods of removing the solid residue, the aggregate reuse system and the zinc-rich residue.
There are many arrangements for recovery of pyrolysis oils produced by this invention, and the flow sheet of FIG. 2 is suggestive of the basic steps needed to collect and recover the products. Additional fractional distillation of oils produced by this invention can be performed to separate the low boiling oils from the high boiling point oils, and the residue can be blended with fuel oils or sold as is for combustion purposes, or as feed stock for cracking operation for manufacturing of petroleum products.
Referring to FIG. 2, the recovery system consists of gas cleaning step to remove suspended particles from volatile matters in a high efficiency cyclone 20, followed by direct cooling and alkaline scrubbing in column 21 for the removal of sulfur dioxide and hydrogen sulfide gases. The effluent from the column is collected in a recirculation tank 23. Heavy oils are separated 26, alkaline make up solution 22 is added to adjust the pH of the solution. The tank is equipped with cooling coils to remove the sensible heat of the effluent stream from the column 24. Also provided is a blowdown 25 to the water treatment. The second column 27 provides for additional cooling and further condensation of heavy oils 26 by scrubbing with the heavy oils collected after removal of their sensible heat. The movement of vapors and gases through the recovery system is accomplished by electric-driven turboblower 28 placed after the first recovery column. The gas-vapor stream leaving the second column is subjected to indirect cooling 29 for recovery of light oil fraction 30. A gas holder 31 is provided to act as a temporary surge and storage of the remaining gases (called hereinafter waste gases). Waste gases 32 are used for combustion needs and steam generation.
The invention is further described in the following example:
EXAMPLE
Experimental apparatus similar to the distillation column of FIG. 1 was used to simulate a traveling fluidized bed of aggregate materials and waste rubber mixture. The apparatus in FIG. 3 was made from three steel sections, joined together to form a column. The upper section is a pipe six feet long and five inches in diameter with a threaded top 33, a middle section which is a cylindrical container eight inches in diameter with a conical top and bottom, each with a 60° slope. The bottom cone has an opening of four inches, the height of the middle section is twenty-four inches 34. The bottom section is a cylindrical container eight inches in diameter and thirty inches high used to collect the aggregate and residue mix 35. The discharge from the middle section is controlled by two gate valves to regulate the rate of discharge of aggregate residue mix 36. The column is fitted with volatile matter take off opening 37, ports for temperature measurement 38, as well as opening for combustion burners 39, ports to allow the addition of steam 40, ports for secondary air 41, and cooling water 42.
A mix of shredded scrap automobile tires and crushed refractory bricks in size range 1/4 inch to 3/8 inch was prepared in different proportions. Each mix was subjected to conditions similar to the conditions described in this invention as follows:
Mix No. 1 was made of eighty pounds of aggregate and twenty-five pounds of scrap tires. Forty pounds of aggregates were charged to the column first in order to reach operating temperature before any aggregate-rubber mix was added. The mix was allowed to reach operating temperature in the precombustion zone of 850° C. Then, the entire contents of the column were allowed to drop at the rate of (approximately) one pound per minute into the container. Small amounts of water were added to cool the charge, and the vapors were vented to the lower section of the column. Volatile matters were collected by condensation using dry ice and waste gases were flaired off. During the experimental secondary combustion, air was introduced only during the second half of the experiment, which caused the the precombustion zone to reach 900° C. After the aggregate and residue mix was completely removed in the collection container, it was allowed to cool, nine pounds of residue was found with the aggregates. The condensate was dark in color, it contained water which was separated, and 10.8 pounds of oil were recovered. No attempt was made to measure the amount of waste gas generated during this example, but it can be accounted for as the difference between the starting weight and the weight of oil and residue collected which is 5.2 pounds. The residue mix contained 6.7 grams of free zinc as fine particles.
Mix No. 2 was made of eighty pounds of fresh aggregates and forty pounds of scrap tires, forty pounds of aggregates were charged to the column first, in order to reach operating temperature before any aggregate rubber mix was added. This example followed similar steps as Mix No. 1. The yield of products was as follows:
Residue: 16.2 pounds
Oil: 15.8 pounds
Waste Gas: 8.0 pounds
Zinc: 10.4 grams.
It is understood that this invention has just been described without limitation of the same and that various modifications can be made without exceeding its scope, in particular, the ratio of aggregates to scrap rubber, the amount of residue allowed to burn to supplement the heat requirements of this invention, the operating temperatures and pressures, the composition of scrap rubber, the composition of aggregates, and the yield and composition of products.
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Method for traveling fluidized bed distillation of coarse ground tire scrap, rubber vulcanizate (also vulcanized rubber), in a mixture with coarse aggregate. The rubber and aggregates are charges to a vertical still equipped with power burners near the bottom to burn a portion of the carbonaceous residue and supply the needed heat for the distillation process. The volatile materials and the pyrolysis oil vapors are drawn at the top for recovery and processing. Fines are recovered and the aggregate still at elevated temperatures are recycled to the top of the column and reused again with additional ground rubber. Noncondensable gases resulting from the "pyrolysis oil" condensation and recovery system contain high heating value and can be used for combustion needs in the still, or for steam generation. Therefore, this invention makes use of the different components of the distillation process by selecting the gases and the carbonaceous components for combustion and heating needs to generate the pyrolysis oils in high yield. Another use of this invention is the production of zinc, as a result of the reducing atmosphere and high temperature present below the combustion zone.
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